Hydrocarbon Processing - January 2021 - 56

Heat Transfer
850
825
800
775
750
7.25
700
675
650

Before ceramic coating

After ceramic coating

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based on the lowest thickness
recorded and was 0.28 mm/yr.
* Based on the minimum recorded
thickness for each heater, the
corrosion rate was calculated
to determine the remaining life
of the tubes (TABLE 1). The
corrosion rate was based on
the operating life of 5 yr
(November 2009-August 2014).
Again, preventing oxidation of radiant
tube surfaces eliminates metal loss and
extends tube life (FIG. 4).
operated at higher throughput regardless
of feed variations. The unit load prior to
ceramic coating was 97%-98%, as shown
in FIG. 5. Moreover, when processing highnaphthenic feed, the unit load was reduced
further to 96%. However, post coating, the
unit is being operated at 103%, regardless
of feed composition-even with highnaphthenic feed, desired throughput is
obtained with the same fuel firing.
Controlled steam generation. With

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Date

FIG. 6. Bridgewater wall temperature, °C.

Increased throughput. The unit is being

2019
JANUARY

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TA-17
April 22, 16

March 22, 16

Temperature, °C

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ceramic coating on tubes and refractory,
radiant heat loss has been considerably reduced, increasing the efficiency of the radiant heat transfer and reducing bridge wall
temperatures by an average of 30°C-50°C
(86°F-122°F). Therefore, even when operating at higher loads, the arch temperatures
have relatively reduced, avoiding excessive
steam generation and high heat loads on
the convection steam coils (FIG. 6).

Fuel gas savings. With the commission-

ing of a new refinery, the H2-rich fuel gas
from the aromatics plant is being sent to
the off-gas recovery section, and the heaters are being operated entirely on natural
gas. The amount of fuel burned in MMB-

tu/hr post-coating to maintain a 103%
load is less than the fuel required to maintain 96%-99% load prior to coating.
Cost savings and ROI. The total project cost was approximately $25 MM, with
an expected return on investment (ROI)
within 11 mos of operation, with an internal return rate (IRR) of 111%. However,
considering all factors and a favorable
market, the ROI was achieved within
6 mos of operation.
Advantages. The proprietary ceramic

coating a eliminates oxide scale formation
and increases conductive heat transfer
to the process fluid. The high-emissivity
coating of the refractory increases radiant
heat transfer efficiency, and the increase
in radiant section efficiency allows for
energy (fuel) savings and/or production
increases, while providing uniform heat
distribution in the firebox. Foulant adhesion to the tube surface and refractory
is limited, and bridge wall temperature
and convection section temperatures are
lowered. Tube wall temperature can be
directly inferred from thermography or
infrared measurement.
NOTES
a IGS's Cetek ceramic technologies
JOHANNES POTH is a Cetek
Subject Matter Expert in ceramic
science and engineering. He earned
an engineering degree in ceramics
from the University of Applied
Science in Koblenz, Germany.
Mr. Poth then joined Fosbel as a
Quality and Product Manager, specializing in Cetek
high-emissivity ceramic coatings. Over the years, he
has been responsible for the development, application
and market introduction of Cetek ceramic coatings
globally. Mr. Poth joined Integrated Global Services
(IGS) in 2017, when the Cetek brand was acquired by
IGS, and continues to support fired heater efficiency
optimization projects in Europe and around the globe.

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Hydrocarbon Processing - January 2021

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