Careers Convection Section Fouling Removal
A Smart Fouling Removal Service to Restore Fired Heater Efficiency
If your facility is experiencing an increase in stack temperature or reduced performance or output, it could be a sign of furnace convection section fouling. When fouling occurs, it limits the thermal efficiency of the fired heater which results in an increase in fuel consumption as the heater must work harder to achieve the required results.
TubeTech™’s fired heater convection section fouling removal service is a proven turnkey solution which guarantees to remove 90%+ fouling, restoring fired heater performance and reducing CO2 emissions and fuel consumption.
- 90%+ fouling removed guarantee
- 2-5% increase in thermal efficiency*
- Up to 15% reduction in CO2 emissions*
- ROI within 2 months
- Average* results reported by TubeTech™ clients
Technical Information
As a result of a comprehensive research and development programme, TubeTech™ has developed a patented robotic fouling removal system which is used by major petrochemical and refining plants around the world. On average, our clients report a 3-5% increase in thermal efficiency and up to 15% reduction in CO2 emissions.
The robotic system can access even the most difficult-to-reach convection banks. It is remotely controlled by an experienced technician and the engineered lance penetrates deep between each tube row to remove the toughest fouling.
Understanding Convection Section Fouling in Fired Heaters
Below are answers to common questions from fired heater operators and reliability engineers about convection section fouling and heater performance.
Does staying below maximum stack temperature mean our heater is operating efficiently?
Not always.
Operating below Tₘₐₓ confirms safe operation, but it does not guarantee optimal heater performance. Stack temperature alone is only one indicator and can remain stable even as fouling increases elsewhere.
In many cases, performance improvements manifest as:
- Reduced fuel consumption
- Improved heat transfer across coils
- Stabilised process temperatures
- Lower emissions
A fired heater performance evaluation helps identify these gains and quantify losses that are not immediately visible from stack temperature alone.
Is water washing effective for convection section fouling?
Traditional water washing / water jetting can be effective for small heaters or limited tube banks.
For larger or more complex convection sections, access and coverage become limiting factors. Water jetting typically cleans from the top or from restricted entry points, leaving fouling deep between rows untouched.
TubeTech ROV cleaning:
- Reaches every level of the convection section
- Cleans between every tube and fin
- Delivers consistent results across the entire bundle
A key question is longevity; if fouling returns quickly and fuel consumption rises again, the cleaning method may not be fully effective.
Why consider ROV convection section cleaning instead of chemical cleaning?
Chemical cleaning is commonly used to maintain baseline performance, particularly during turnarounds. However, in convection sections, many deposits are already inert due to prolonged high temperatures.
Chemical cleaning can:
- Create sludge rather than fully remove deposits
- Increase waste handling and disposal complexity
- Gradually weaken refractory bonding agents over time, causing crumbling
TubeTech cleaning uses a controlled, water-based mechanical process that removes fouling from all tubes, rows, and fin spaces, restoring surface area and extending the time between cleaning cycles.
TubeTech™ Fired Heater Fouling Removal Case Studies
Thermal Efficiency Increased by 3% at Turkey Refinery
The refinery had been experiencing reduced performance due to fouling on convection bank tubes within a steam methane reformer.
- Hydrogen production cost decrease resulted in ROI in less than 60 days
- Flue gas temperature decreased by 3%
- Steam production increased by 20%
Robot Restores Stack Temperatures in Holland
The convection section of the fertiliser production plant’s Primary Reformer Furnace was heavily fouled as it had never been cleaned before and fouling build-up was affecting efficiency.
TubeTech™ was able to deploy its patented robotic fouling removal system to penetrate and clean deep between each tube row whilst protecting the asset from refractory damage.
- 95% of the asset surface area was accessed
- Stack temperatures were restored
- 90%+ of fouling was removed
Free Whitepaper: How to Cut Emissions & Fuel + Increase Capacity in Fired Heaters
Key features include:
Smart digital sensors
Automatically adjusts water pressure to deliver fouling removal results whilst protecting asset materials. The robot also adjusts to warped tubes.
Adjustable lance and track
The robot can access every row of a convection bank regardless of size. As it is remotely mounted, there is no need for man entry so fouling removal can be completed safely.
Pre-programmable
The robot is pre-programmed with asset information prior to arrival on-site, saving valuable time and ensuring that fouling removal is precise and thorough.
Records images and videos
An HD camera records footage of the fouling removal taking place and identifies any blockages or areas of concern. These can be used for reporting purposes and future fired heater maintenance planning.
What do our customers say?
“The service they provide, in my opinion, is second to none. Technically and technologically TubeTech™’s knowledge surpasses any company I have personally met that supplies this kind of service.”
Process Engineer, Major European Refinery
Contact a Fired Heater Furnace Expert Today
If you are experiencing a drop in stack temperature, thermal efficiency or output, our team can help identify and solve the issue.