Improving efficiency and longevity in syngas operations
Published by Kristian Ilasko,
Digital Content Coordinator
Hydrocarbon Engineering,
The syngas industry plays a crucial role in the production of essential chemicals, including ammonia, methanol, hydrogen, and synthetic fuels. However, it operates under extreme conditions e.g. high temperatures, pressures, and corrosive media, that take a heavy toll on critical equipment such as steam methane reformers (SMRs), heat exchangers, and CO2 absorption towers. Addressing these challenges is not only key to operational reliability but also to meeting increasingly strict energy and emissions regulations.
A new white paper from Integrated Global Services (IGS) outlines proven strategies to reduce energy consumption by up to 15%, extend equipment life, and avoid costly shutdowns. It draws on decades of experience and showcases successful implementations of advanced materials and technologies across global syngas facilities.
Restoring convection section efficiency
One of the most common problems in SMRs is fouling in the convection section, which reduces heat transfer and increases fuel consumption. IGS’s TubeTech™ ROV cleaning system uses robotic lancing to restore fouled areas to near-design efficiency. In one fertilizer plant, this system helped lower stack temperatures by 30°C and cut CO2 emissions, delivering significant performance and environmental benefits.
Enhancing radiant heat transfer
The radiant section’s efficiency can also decline over time, impacting burner performance and emissions. Applying Cetek® high-emissivity ceramic coatings to refractory surfaces boosts radiant heat transfer to catalyst tubes. In a twin-cell side-fired reformer, this technology increased feed throughput and ammonia production by over 3%, while reducing bridgewall temperatures by 33°C and fuel usage by 3.2%. The coatings also help prevent refractory fibre loss, which can foul downstream equipment.
Preventing de-rates and shutdowns
Selective catalytic reduction (SCR) units are vulnerable to fouling from refractory debris and ambient dust, leading to pressure drops, de-rates, and even shutdowns. IGS offers a multi-pronged solution combining online hot vacuuming, particulate filtration, and Cetek encapsulation coatings. One hydrogen plant avoided a US$3 million shutdown and achieved full return on investment (ROI) in 90 days by deploying these integrated measures.
Safe, online repairs of hot spots
Delayed turnarounds can force facilities to continue operating with hot spots on reformer shells, risking safety and performance. The Hot-Tek solution enables live refractory repairs without shutting down operations. In one case, a European fertilizer plant used this method to fix a critical hot spot in just three days while running at full load.
Corrosion protection for amine and carbonate vessels
Corrosion in amine systems is a widespread problem. Traditional weld overlays are costly and time-consuming. High Velocity Thermal Spray (HVTS®) offers a faster, no-heat-treatment alternative, creating a robust corrosion barrier. A chemical ammonia plant coated 76 m² of internal vessel surface in just 4.5 days, with no further corrosion reported after follow-up inspections.
Long-term value for autothermal reformers
In autothermal reforming (ATR) processes, metal dusting is a critical concern. A leading GTL producer has standardised the use of HVTS to protect against this form of degradation. Over a 13-year period, the cladding has consistently provided durable performance under aggressive conditions.
These case studies demonstrate that by adopting targeted, engineered solutions, syngas producers can significantly enhance their thermal efficiency, reduce emissions, and extend the service life of key assets, all while minimising operational disruptions. As decarbonisation pressures mount, these best practices are becoming indispensable for staying competitive and sustainable.
Read the article online at: https://www.hydrocarbonengineering.com/special-reports/01092025/improving-efficiency-and-longevity-in-syngas-operations/
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