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.
Tube Tech’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.
As a result of a comprehensive research and development programme, Tube Tech 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.
The refinery had been experiencing reduced performance due to fouling on convection bank tubes within a steam methane reformer.
The petrochemical facility had noticed cold spots on certain radiant tube legs of its box heater with Arbor Radiant Coil, possibly caused by fouling, leading to the client having concerns with differential tube temperatures and the potential for expansion cracks around the cold spots.
Tube Tech’s bespoke solution was able to identify the location and severity of fouling and remove more than 90% of the deposits, restoring tube temperatures and minimising the risk of expansion cracks and equipment failure.
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.
Tube Tech 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.
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.
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.
“The service they provide, in my opinion, is second to none. Technically and technologically Tube Tech’s knowledge surpasses any company I have personally met that supplies this kind of service.”