pt q&a
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Q How can refiners increase petroleum coke production? A Al Geraskin, Senior Director, Integrated Global Services (IGS), al.geraskin@integratedglobal.com Increasing petcoke production is often less about expand- ing capacity and more about eliminating operational bottle- necks that reduce coker availability and throughput. Many delayed coker units (DCUs) are constrained by fouling, thermal inefficiencies, or equipment reliability rather than by their design capacity. One common limitation is fouling in the heater convec- tion section. As deposits build up, heat transfer efficiency declines, and operators must increase firing rates to main - tain process temperatures. Higher firing rates can acceler - ate tube coking, decreasing operating cycles and increasing the frequency of decoking shutdowns. Maintaining clean heat transfer surfaces through effective inspection and cleaning strategies can improve thermal efficiency while extending run lengths. Another opportunity lies in improving heat distribution within the radiant section. Uneven heat flux across heater tubes can create local hot spots that promote premature coke formation. Technologies such as engineered high- emissivity coatings can help deliver more uniform heat transfer, reducing tube skin temperatures and extending the time between decoking events. Reliability of downstream equipment is equally impor - tant. Fractionators, scrubbers, and amine systems exposed to corrosive or high-temperature environments can become production constraints if degradation leads to unplanned maintenance. Targeted repairs or on-site alloy upgrades can extend equipment life while improving resistance to corrosion and erosion without requiring complete vessel replacement. Finally, ageing coke drums remain a significant challenge for many refiners. Where replacement is difficult because of cost, logistics, or outage constraints, engineered repair and restoration solutions may provide a practical way to restore structural integrity and maintain reliable operation. Ultimately, increasing petcoke production depends on improving overall unit availability. Small gains in heater efficiency, longer operating cycles, and greater equipment reliability can combine to deliver meaningful increases in annual production without major capital investment. Q How can the industry avoid failures to thermal sys - tems, such as heater faults? A Larry Emch, Furnace Efficiency SME, Integrated Global Services (IGS), larry.emch@integratedglobal.com The industry’s approach to thermal system reliability is shifting from reactive maintenance to condition-based and predictive asset management. A key priority is maintain- ing efficient heat transfer. Fouling in convection sections
reduces thermal efficiency, increases fuel consumption, and raises tube metal temperatures, all of which acceler - ate equipment degradation. Regular assessment of fouling rates and cleaning strategies should be considered part of routine reliability planning rather than simply an outage activity. Understanding heat distribution is equally important. Uneven heat flux within fired heaters can create localised hot spots that promote tube coking, creep, and premature failure. Increasingly, refiners are using advanced modelling, infrared inspections, and surface engineering technologies to better manage heat transfer and reduce thermal stresses across heater components. Many heaters and associated pressure vessels continue to operate beyond their original design life, often under more severe process conditions than originally anticipated. Periodic fitness-for-service assessments and selective materials upgrades can improve resistance to corrosion, erosion, and high-temperature degradation while extend - ing asset life without wholesale replacement. Finally, digital inspection tools and robotics are expand- ing the industry’s ability to inspect and maintain equipment safely and more frequently. Improved access to condition data allows maintenance activities to be prioritised based on asset health rather than fixed schedules, reducing both operational risk and unnecessary downtime. No single technology eliminates heater failures. Instead, the greatest improvements come from combining good operational practices, effective inspection programmes, appropriate materials selection, and targeted maintenance interventions. Together, these measures can improve reli- ability, reduce energy consumption, and extend the safe operating life of thermal systems. Q What advancements to online catalyst monitoring tools benefit refinery operations? A Nattapong Pongboot, Project Leader, R&D Solutions, Avantium, Nattapong.pongboot@avantium.com Previously, refinery operators and engineers manually programmes, appropriate materials selection, and targeted maintenance interventions No single technology eliminates heater failures. Instead, the greatest improvements come from combining good operational practices, effective inspection
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PTQ Q4 2026
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