2). Ceramic coating was applied to 4747.1 m² of process tubes and 4,837.76 m² of castable refractory, ceramic fibre, and castable brick surfaces. The Cetek high-emissivity thin-film coating system is specifically engineered to prevent oxidation and scale formation that typically hinder conductive heat transfer. By forming a durable layer on the outer tube surfaces, it maintains thermal conductivity close to as-new conditions and significantly extends tube life. This technology also provides crucial
operational reliability by enabling more accurate determination of tube metal temperatures. The thin, uniform coating creates a consistent temperature gradient, reducing measurement discrepancies typically caused by fouling layers. As a result, operators benefit from more reliable IR thermography and improved process control. Table 1 summarises the results of this project. They highlight not only the effectiveness of the coating technologies but also the benefits of coordinated planning and execution.
Summary of 2024 fired heater coating project
protection against carburisation, a risk that increases under low excess oxygen firing conditions, which are common in fuel- saving strategies. Ceramic coatings counter this effect and have demonstrated longevity of up to 10 years in global refinery applications. Additionally, the coating enhances
Parameter
Details
Project duration
January 19 to February 3, 2024 274 tubes (360° coverage)
Process tubes coated
Tube OD range
114.3-141.3 mm
Tube surface area coated Refractory surface area treated Average coating thickness
4,747.1 m²
4,837.76 m² (castable, ceramic fibre, brick) 2.61 mils (with minimal efflorescence)
Fuel savings achieved
9.8% average
Energy savings
24.81 Gcal/hr (~$4.2 million/year) 46,370 metric tonnes/year 11.3% (apparent, normalised)
CO₂ emissions reduction
Radiant efficiency improvement Peak tube skin temperature drop
Up to 17°C
Table 1
improved thermal efficiency by 3%, decreased flue gas temperature by 58°C, and raised steam production by 20%. • Primary ammonia reformer (global location) : Cetek coatings led to 3.5% fuel savings, 21% NOx reduction, and ROI within four months. • Ammonia reformer in compliance with government mandates : Application of refractory coatings achieved a 4% fuel savings and a 50°C reduction in bridgewall temperature. These examples validate the replicability of results across geographies and environments. Holistic strategy for fired heater optimisation Optimising fired heater performance represents a high-leverage opportunity for facilities seeking to balance productivity, sustainability, and asset longevity. The case study from India
exemplifies how a phased and integrated strategy, involving hot work, ceramic coatings, and thermal inspections, can yield tangible improvements in energy efficiency, emissions reduction, and operational resilience. Rather than relying on a single intervention, the most successful outcomes arise from combining multiple, complementary technologies tailored to site-specific challenges. As energy markets evolve and environmental regulations become more stringent, such holistic approaches will enable refineries and petrochemical plants to operate smarter, cleaner, and more sustainably. CCR Platforming is a trademark of Honeywell UOP.
Larry Emch info@integratedglobal.com
Refining India
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