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Hot-tek Online Fired Heater Cleaning Services

IGS’s Hot-tek services in Malaysia facilitate maintenance, inspection and cleaning of the fired heater while it is in operation. Holding multiple patents on the approach, methods, and tools used to carry out these services.

Features of Hot-tek Online Fired Heater Cleaning Services

In the last four decades, IGS’s Hot-tek has developed and introduced a wide range of online services (while the heater is operating), targeted at high-temperature production furnaces and heaters. Each project is approached with the utmost safety in mind, ensuring that none of our people or equipment are compromised during the execution of the Hot-tek Services. Evaluation and engineering phases of each Hot-tek project determine the best operational approach and parameters will be set to achieve an optimal outcome, typically with no downtime.

Applications of Hot-tek Online Cleaning

1. Hot Convection Cleaning

Removing Convection Section Fouling & Scale During Furnace Operation

The Hot-tek Hot Convection Cleaning process removes convection section tube fouling & scale during furnace operation. The tube cleaning process uses consumable abrasive media projected through specially designed application lances to blast away years of accumulation, while the heater is in service.

In some applications the Hot-tek’s LancescopeTM system is used to see hard to reach areas. In addition, we have capability to safely create engineered access ports to facilitate the hot convection section cleaning process and for future access.

Hot-tek online convection tube cleaning is efficient, environmentally friendly, and safe for the removal of years of fouling and scale without interruption to production.

2. Hot Tube Descaling

The Hot Tube Descaling Process removes radiant section process tube fireside soot, scale & fouling during furnace operation. The process uses unique water-cooled lances. We ensure continuous scale removal and maximum cleaning of the tubes while the heater continues to function normally. The process utilizes consumable abrasive media resulting in no increase in emissions.

In some applications, we use Hot-tek’s Lancescope™ system to see hard to reach areas. We also have the capability to safely create engineered access ports. These ports can be used to facilitate the hot tube defouling process.

Typical results of the hot tube descaling process include bridgewall temperature reduction of 50°F (10°C) to 100°F (38°C).

3. Hot Vacuum Service

On-Line Cleaning of SCR Screens

The online SCR catalyst cleaning service removes pluggage and fowling from SCR screens, immediately improving catalyst reduction system efficiency.

Hot-tek removes the surface debris online with no interruption impact on production or environmental emissions. Existing access points may be used upstream of the catalyst for the insertion of Hot-tek’s equipment. If necessary, reusable access ports can be created online with Hot-tek’s hot access creation service.

A vacuum lance with a non-damaging low friction tip is inserted into the ducting. The nozzle is placed against the surface of the catalyst and the Lance is manipulated by a technician with no damage to the fragile catalysts. Observation of the vacuuming is maintained with line of sight or through the Hot-tek’s Lancescope™ viewing system. Vacuuming progresses from port to port across the length of the catalyst wall. Each access point is closed before moving to the next location.

Without fouling obstructing the gas flow syngas production can be returned to normal and ID fan usage can be reduced.

Hot Vacuum Service returns SCR Catalyst Bank operation to maximum efficiency by restoring the pressure differential across the catalyst to an “as-new” condition. Decreasing pressure drop, hot SCR screen cleaning eliminates wasted energy consumption and strain on the ID fan motor. Furthermore, it ousts the potential curtailment of production due to gas flow blockage or excessive NOx production. Increased DeNOx potential and mercury oxidation return SCR efficiency.

The online vacuum service is possible with any catalyst configuration, vertical, or horizontal flue gas flow direction. In some applications, we use Hot-tek’s Lancescope™ system to inspect hard to reach areas before online cleaning.

In-situ online catalyst cleaning maximizes catalyst efficiency and lifetime, increases plant uptime and reliability.

4. Hot Inspection Service

Hot-tek’s Lancescope™ system provides real-time, close-up or wide-angle views of virtually any area inside a fired heater, or other high-temperature equipment while it is still operating. The hot inspection system uses a state-of-the-art digital camera system, which provides clear, detailed images of problem areas up to 3000°F (1650°C). The furnace inspection system can be inserted into openings as small as 2.75” (7cm) and reach up to 30ft (10m). In applications below 1000°F (540°C), the heater inspection system provides illumination via a high-temperature light source for optimum clarity.

The Lancescope™ technology is supplemented by a complete infrared thermography analysis, temperature tests, and emissivity measurements.
Infrared Thermography – we employ infrared technology to inspect furnace process tube surfaces to primarily identify the degree of oxidation and scale formation.

Hot-tek Online Services Benefits

Benefits of the Hot Convection Cleaning:

  • Improved fired heater efficiency by removal of fouling on convection section tubes
  • Reduced stack temperature
  • Increased process pre-heat and steam production
  • Improved draft

Benefits of Hot Tube Descaling Service:

  • Improving fired heater efficiency by removal of insulating scale
  • Reduced tube surface temperature
  • Reduced bridge wall temperature
  • Especially effective in catalytic reforming units

Benefits of the Hot Vacuum Service:

  • Restoring differential pressure to optimum level
  • Reducing electricity consumption of ID fan
  • Extending life of ID fan motor

Case Studies

Case Studies
Increasing Furnace Efficiency With Hot Convection Cleaning
Hot Convection Cleaning Reduces Stack Temperature
Hot Vacuuming Prevents Emergency Shutdown