Steam Methane Reformers (SMR)

Cut Steam Methane Refomer CO2 and NOx Emissions with IGS Solutions

Fired Heaters, including Steam Methane Reformers, have the greatest running cost on your site. If any one of these heaters is 1 or 2% inefficient it can consume an additional $1m in fuel over a year or result in $millions in lost revenue.  

IGS Steam Methane Reformer (SMR) Solutions deliver: 

  • CO2 and NOx emission reduction 
  • Increased capacity 
  • Fuel savings 
  • Elimination of operational limitations (excess flue gas temperature, firing duty, draft) 
  • Refractory particle encapsulation

Our Solutions

Cetek Efficiency Coatings 

Tube Tech

Environmental Services for Steam Methane Reformers:

Hot-tek Services:

  • Hot Refractory Repair
  • Hot Convection Cleaning
  • Hot Inspection Service
  • Hot Vacuum Service
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Cetek Efficiency Coatings

High-Emissivity Ceramic Coatings for Refractory 

Cetek has seen a distinct benefit in treating refractory surfaces with a high emissivity ceramic coating, increasing the radiant heat transfer inside Steam Methane Reformers over design. The coating increases refractory emissivity which results in a significant increase in hydrogen production at the same process parameters.

The problem 

Steam Methane Reformers are operated at a high process outlet and flue gas temperature, so radiant tubes (or catalyst tubes) are not manufactured from steel alloys found in refinery fired heaters, but from 25% Cr; 20% Ni, or high Ni steels, such as HL40. These metallurgies form an oxide layer when subjected to high temperatures, but unlike regular steel alloys, this layer inhibits further oxidation of the tube and further scale growth is prevented.

The Solution 

Cetek’s High Emissivity Ceramic Coating system increases the radiant heat transfer inside Steam Methane Reformers, delivering optimum performance and reducing CO2 and NOx emissions.  

The Benefits 

  • CO2 and NOx emission reduction 
  • Increased capacity 
  • Fuel savings 
  • Elimination of operational limitations (excess flue gas temperature, firing duty, draft) 
  • Refractory particle encapsulation

Tube Tech

Engineered Convection Section Cleaning 

Tube Tech’s Steam Methane 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.  

95% clean guarantee even on the most fouled assets. 

The Problem

Fouling 

Steam Methane Reformer fouling is a costly problem for refineries around the world. Heater intake collects 1 ppm airborne particulate whilst in service, which results in deposits of 2.5 tonnes over 12 months either landing in or travelling 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 Steam Methane Reformer (SMR) convection section cleaning service is recognised by world-leading refining and petrochemical companies as the most effective technology to achieve OEM performance clean SMRs. 

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 

Environmental Services for Steam Methane Reformers

Selective Catalytic Reduction (SCR) Screens

The Solution 

IGS Base Filtration Screen Technology is designed to catch refractory and insulation fibers before they reach the catalyst. Key features of this solution include: 

  • Perforated plate design assists in self-cleaning 
  • Designed to allow particles to collect at the lower edge of the screen and trap them there for permanent removal during a planned outage 
  • Built with standard interchangeable panels 

The Benefits 

  • Eliminates build-up-related forced outages, system derates, and excessive pressure drops 
  • Extends catalyst life 
  • Improves NOx removal 
  • Reduces ammonia usage 
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Mixer Plates  

The IGS patent-pending flow mixing system is designed to maximize ammonia mixing prior to the catalyst to reduce ammonia usage and ensure an even ammonia concentration distribution through the catalyst, which improves DeNOx and preserves the catalyst reactivity. This can be installed in conjunction with the filtration screen or even as a standalone improvement. 

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Air Cannons

The Problem 

Industrial Air Cannons have been used for years to solve blockage and build-up issues within steam methane reformers and other critical process assets. Clinker, snowman, Christmas trees, and rhino horns can be easily shifted with a sudden blast of air. The design for releasing this powerful blast has remained virtually unchanged since its introduction in the early 1970s. 

The Solution 

Introducing IGS Big Blue Air Cannons 

The IGS Big Blue Air Cannons have become the new norm with fit-for-purpose innovative designs addressing the needs for better cleaning solutions by effectively removing blockage and build-up. 

Benefits 

  • Elimate workplace safety hazards 
  • Clean faster and more effectively 
  • Standardised parts for easy maintenance 

Hot-tek™ Services for Steam Methane Reformers

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

Hot-tek™ is the industry leader in hot maintenance and online Steam Methane Reformer repair and cleaning techniques and 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.