Careers Hot Convection Cleaning for Fired Heaters
Removing Convection Section Fouling & Scale During Furnace Operation
Is the convection section in your fired heater experiencing reduced performance and declining efficiency? Symptoms such as low steam production, inadequate process pre-heat, and elevated stack temperatures are often clear indicators of fouled or scaled convection section tubes. Over time, accumulated deposits restrict heat transfer, increase fuel consumption, and negatively impact overall heater performance.
Hot-tek™ Hot Convection Cleaning is an online cleaning solution for fired heaters, sometimes alternatively referred to as online furnace cleaning, designed to remove years of fouling and scale from convection section tubes while the heater remains in service. Executed safely under full-load operating conditions, this process restores heat transfer efficiency without requiring a shutdown or interruption to production.
Hot Convection Cleaning Process
The Hot Convection Cleaning process uses high-velocity, consumable abrasive media projected through specially engineered application lances to effectively blast away stubborn deposits from tube surfaces. This proven method safely removes buildup from finned and bare tubes without damaging the tube metallurgy, allowing operators to recover lost performance and extend run length.
Hot-tek online convection tube cleaning is an efficient and proven form of online furnace cleaning for fired heaters. HCC is an environmentally responsible and safe solution that delivers measurable results, often within hours, while the heater stays fully operational. By removing years of fouling and scale without production loss, this patented process helps restore productivity, improve asset reliability, and reduce operating costs.
Typical Results of the Hot Convection Cleaning Process
Facilities utilizing Hot-tek Hot Convection Cleaning commonly experience the following benefits:
- Increased heat transfer efficiency in the convection section
- Increased steam production
- Improved process pre-heat and heat recovery
- Lower stack temperatures and improved thermal efficiency
Before Hot-tek Hot Convection Cleaning
Severe fouling and deposit buildup within the convection section of a Continuous Catalytic Reforming (CCR) unit, restricting heat transfer, increasing stack temperature, and reducing overall furnace efficiency.
After Hot-tek Hot Convection Cleaning
Convection section tubes restored to a clean condition following Hot-tek™ online cleaning, improving heat transfer efficiency, lowering stack temperature, and reinstating furnace performance without shutdown.
Hot-tek’s Lancescope™
For applications involving limited access or complex convection section geometry, Hot-tek’s Lancescope™ system can be integrated to provide real-time visibility and targeted cleaning of hard-to-reach areas. In addition, Hot-tek has the capability to safely design and install engineered access ports, facilitating both the current hot convection cleaning operation and future maintenance activities
WATCH VIDEO: How Long Does Hot Convection Cleaning Take?
IGS Subject Matter Expert Larry Emch explains how Hot Convection Cleaning uses dry ice and precision lances to safely remove fouling and restore heat transfer while the heater remains in operation.
Hot Convection Cleaning FAQ
Efficient Online Cleaning for Fired Heaters
At IGS, our Hot-tek® services are designed to keep fired heaters and process units operating safely and efficiently, all without the need for costly shutdowns. Below, our experts answer the most frequently asked questions, drawing on decades of real-world experience across refineries, petrochemical plants, and power facilities worldwide.
What range of improvement in the stack temperature can be delivered by hot convection cleaning?
Results vary depending on fouling and access, but clients typically see a noticeable reduction in stack temperature and improved heat transfer efficiency, directly lowering fuel consumption.
Do you need to reduce the heater duty for Hot Convection Cleaning?
Hot Convection Cleaning can be completed safely online, without impacting production for heaters operating under negative pressure.
How does IGS online clean between the rows within the convection section bundle?
We can only clean the top and bottom rows on standard tube bundles. If there is enough space between the individual rows of tubes, we can clean them. For a more thorough cleaning, we recommend TubeTech’s Robotic Convection Cleaning during scheduled turnarounds.
What kind of material is used for the hot convection cleaning?
Our Hot Convection Cleaning uses CO₂ pellets, no fluids or chemicals are introduced.
Where does the debris go during cleaning?
The light-weight debris goes out of the filters/stack, and the heavier material falls to the floor.
Can IGS perform this service if the customer has concerns about expelling used chemicals into the atmosphere?
The method uses only CO₂, which sublimates without leaving residues or harmful emissions.
What is the root cause of convection fouling and do you work with this?
Common causes include friable refractory, fuel contaminants, and external pollutants (such as dust in desert or coastal environments). IGS mitigates fouling caused by refractory degradation using Cetek Refractory Encapsulation coating.
Would it cause any problems with the detection systems for contaminants after the online cleaning?
In decades of online cleaning operations, we have never experienced any issues with the detection systems.
Trusted Online Maintenance Without Shutdowns
IGS Hot Convection Cleaning offers an effective, environmentally responsible way to improve heater efficiency while staying online.
Explore Hot Convection Cleaning or learn about advanced options like TubeTech Robotic Defouling for your next turnaround.
Other Hot-tek Services
Free consultation with an IGS Subject Matter Expert
IGS is here to provide information, answer questions and create an effective solution for your needs.