3M Nextel™ Ceramic Fiber for High-Temperature Insulation

Solving Extreme Heat Challenges in Propane Dehydrogenation Heaters with 3M Nextel™ Ceramic Fiber

KLAY EnerSol successfully executed a high-temperature insulation retrofit at a Propane Dehydrogenation (PDH) plant in Malaysia, tackling persistent secondary cracking within a critical process heater. The project leveraged a fully prefabricated insulation system designed to withstand extreme radiant heat and conform to complex furnace tube geometries, delivering superior performance and rapid installation.

The Challenge

PDH units operate under severe thermal conditions where heater uptime directly impacts profitability and catalyst efficiency. The plant faced multiple constraints:

Intensified Secondary Cracking reducing yield and heat distribution efficiency.
Aging Heater Tubes prohibiting welding or hot work, eliminating conventional installation methods.
Complex Tube Geometry with protrusions and thermocouples requiring high conformability.
Critical Downtime Pressure as traditional insulation methods demanded 3–4 weeks of shutdown—unacceptable for a high-value production unit.

High-Temperature Insulation for Propane Heater with 3M Nextel™

Solving Extreme Heat Challenges in Propane Dehydrogenation Heaters with 3M Nextel™ Ceramic Fiber

The Challenge

Download the case study here