Catalytic Reformer Units (CRU)

Improving Radiant and Convection Section Efficiency

IGS Catalytic Reformer Unit Solutions deliver:

Our Solutions

 

catalytic_reformer_descaling

Addressing Oxidation and Carburization Issues on the External Surfaces of Fired Heater Radiant Tubes

High-Emissivity Ceramic Coatings for Process Tubes and Refractory

Cetek Ceramic Coatings provide a durable, protective, thin-film layer on the outer surfaces of process tubes, which prevents oxidation, corrosion, and carburization of the metal and maintains the tube thermal conductivity coefficient close to new tube conditions. Tube coating can be applied in conjunction with a refractory coating, increasing the benefit and encapsulating the refractory.

Corrosion and carburization result in metal loss and reduced service life.

The Problem

Radiant Tube Oxidation

Radiant tubes in Catalytic Reformer applications in oil refineries are typically steel alloy, ASTM A335 P22, P5, or P9 which contain 2.25%, 5% and 9% Cr respectively. Radiant tubes oxidize at operating temperatures and scale will grow continuously on the surface, often reaching 2mm in thickness in higher temperature / high heat flux units.

The layers of oxide scale are highly insulating and represent a significant barrier to conductive heat transfer to the process fluids. During fired heater operation, to overcome the insulating effects of the oxide and scale layers, it is necessary to increase the firing rate, to maintain the heat flux through to the process feed inside the tubes.

Tube scale results in:

  • Increased costs associated with increased firing rate
  • increased bridgewall temperature and stack temperature
  • Increased rate of oxidation
  • Tube wall thinning
  • Unplanned shutdowns
The Solution

Cetek’s High Emissivity Ceramic Coating system ensures maximum conductive heat transfer for the process.

Layers of fouling and scale prevent accurate determination of tube metal temperature, reducing the reliability of those measurements. Cetek applies a thin layer of ceramic coating which provides a consistent temperature differential between the outside surface and the metal tube. This results in a significant improvement in the reliability of tube metal temperature determination.

The Benefits

  • Typical productivity benefits of 4% to 10%
  • Fuel Savings
  • Production Increases
  • Decreased BWT
  • Increased Tube Life / Reliability
  • Rapid payback on investment

Available Applications:

  • In-situ
  • Tubes already installed in heaters
  • New tubes

Tube Tech

Engineered Convection Section Cleaning

Tube Tech’s Catalytic Reformer convection section cleaning service is recognised by world-leading refining and petrochemical companies as the most effective technology to achieve OEM performance clean fired heaters.

90+% clean guarantee even on the most fouled assets

The Problem

Fouling

Catalytic Reformer fouling is a costly problem for refineries around the world. Heater intake collects 1 ppm airborne particulate while in service, which results in deposits of 2.5 tonnes over 12 months either landing in or traveling through the heater.

Fouling results in:

  • More Fuel Consumed
  • Increased Emissions
  • Higher Stack Temperature
  • Heat Stress on Tubes, uneven expansion, and heat distribution
  • More Running Costs
  • Potential Tube Failure

 The Solution

Tube Tech’s Catalytic Reformer convection section cleaning service is recognized by world-leading refining and petrochemical companies as the most effective technology to achieve OEM performance clean Catalytic Reformers.

Traditional cleaning methods are only able to clean 30-45% of the total fouled area. Tube Tech, backed by multi-million-dollar European funding, has developed a Rover system that penetrates deep between tube rows to remove even the most stubborn fouling.

The Benefits

  • Removes 95%+ of Fouling
  • No Refractory Damage
  • Safety – No Man Entry
  • Reinstates Thermal Efficiency and Reduces CO2 Emissions
  • Extends Asset Life due to Reduced Stack Temperature
catalytic_reformer_efficiency

Hot-tek™ Services for Catalytic Reformers

Online Maintenance & Emergency Services (During the Heater’s Normal Operation)

Hot-tek™ is the industry leader in online maintenance, repair, and cleaning of fired heaters during operation, while the unit continues to produce product. IGS holds multiple patents on the approach, methods, and tools used to carry out these services. The approach is customized for every client’s needs. Often, multiple Hot-tek™ Services are employed simultaneously during an application to achieve the best results.

Hot-tek™ Services: