Cetek Ceramic Technologies have been applied at more than 200 refining/ chemical processing sites around the world. Cetek has been developed by pioneers in the ceramic coating industry to improve and sustain the efficiency of heat transfer in fired heaters.
Facilities that choose to apply Cetek can expect long-term performance and significant ROI.
As an integral and unique part of IGS’ Cetek Ceramic Coating service, a complimentary technical evaluation is performed on all fired heaters before a proposal is provided.
Data is collected by IGS technicians from the plant. It comprises an IR Thermography inspection completed by IGS with operating data corresponding to the precise time and date of the IR inspection.
To determine how close current operating conditions are to design, complete design specifications are required, together with general arrangement drawings of the fired heater.
The evaluation can also project further, more reaching benefits in flexibility of operation, such as C5 + RONC Octane increase at current production/firing rates and potential for leaner feedstock flexibility, or lower cost naphtha.
Cetek Ceramic Coatings will prevent process tube oxidation and carburization and maintain heat transfer to the process. High Emissivity Cetek Coatings for refractory surfaces will increase radiant absorbed duty and encapsulate fiber surfaces.
The application of Cetek Coatings will maximize radiant absorbed duty and optimize heater operation alleviating bottlenecks and decreasing fuel usage and CO2 & NOx emissions.
By improving radiant section heat transfer efficiency, more of the available heat generated by the burners is absorbed by the process. This means that the flue gas temperature leaving the radiant section (BWT – Bridgewall Temperature) will be lower. If your fired heater is limited by BWT, Cetek’s high emissivity ceramic coatings are a simple, cost-effective fix.
More efficient heat transfer in the radiant section will overcome any firing duty limitation – a solution readily available from an application of Cetek’s high emissivity ceramic coatings.
Is your fired heater limited by bridge wall temperature, tube metal temperature or firing duty?
Cetek’s Tube-Coat service addresses excessive fouling/scale formation on the radiant tubes, bringing the tubes back to an as-new condition, while the High Emissivity Ceramic Coatings ensure that the tubes remain in this clean state for an extended period.
Cetek Ceramic Coatings provide a durable, protective, thin-film layer on the outer surfaces of process tubes to and maintain the tube thermal conductivity coefficient close to new tube conditions.
Cetek’s high emissivity ceramic coatings applied to the process tubes and refractory surfaces provide a significant improvement in radiant section heat transfer efficiency, which varies for different types and designs of fired heaters, or tubular reformers. To derive the most benefit, it is important that a complete technical analysis/evaluation of the effects of the application is completed beforehand.
The benefit in the radiant section and the effects on the convection section are studied and reported before any commitment is made by the client or Cetek.
Typical high emissivity ceramic coating applications to the tube and refractory surfaces show heat transfer efficiency benefits ranging from 5% to 15%, depending on service and heater configuration.
Reducing emissions while ensuring adequate supply of hydrocarbon derivatives is a complex issue for the refinery operators and chemical producers. At a company level, Environmental, Social, and Corporate Governance (ESG) initiatives have been put in place to provide practical solutions to these emissions issues, while continuing daily operations.
Many industries and economies rely on hydrocarbon derived products. Our everyday products, including medicine, clothing, toothpaste, and even solar panels start their lifecycle as unrefined petroleum. Demand for most of these items is not expected to drop with our growing population, while initiatives focusing on production from plant-based materials are still in their infancy.
Cetek’s Dual Emissivity Coating System effectively shields the tube surfaces in high heat flux areas but increases heat absorption in lower heat flux areas. This prevents rapid coke formation while at the same time eliminating uneven scale formation, thus allowing accurate tube metal temperature measurements.