2008 Coking.com Safety Seminar29 Sep - 2 Oct, 2008 Köln, Germany

Cetek Dual Emissivity Ceramic Coating System for Coker Heaters

Target: Fired Heaters

• Essential – Majority of Processes are Endothermic

• However, an Often Neglected Necessity

• Energy Wasted

• Capacity Limited

Cetek Ceramic Coating Technology

• Fired Heater Applications

– Refractories (high emissivity coatings)• Radiant Heat Transfer Improvement• NOx Emission Reduction (up to 35%)• Ceramic Fiber Encapsulation

– Process Tubes• Elimination of oxidation, scaling & fouling• Conductive Heat Transfer Improvement

– Heat Flux Manipulation (Dual Emissivity Coating System)• Applications in Coking Sensitive Units• Productivity Improvements• Conductive Heat Transfer Control• Run Length Increases

Cetek Dual Emissivity Coating System- Coker Heaters

• Manipulation of heat flux distribution in single fired heaters.

• Ceramic Coating System application based on coking pattern of the fire box.

Cetek Dual Emissivity Coating System (US Patent # 6,626,663B1)

• Differential Emissivity Tube Coatings– Increase, or Decrease Absorbed Heat Flux– Protects Tubes in High Flux Zones– Reduces Maximum Skin Temperatures

• Reduction of Peak/Average Heat Flux Ratio in Single – Fired Heaters– Use of Coatings on Both Refractory and Tubes– Reduces Heat Flux on Fired Side of Tubes– Increases Heat Flux on Back Side of Tubes– Increases Useable Tube Surface Area

• Overall Improvement in Heat Transfer Efficiency – Productivity Improvements

Cetek Matrix Coating System Cetek Matrix Coating System ––Heat Flux manipulationHeat Flux manipulation

High Emissivity CoatingHigh Emissivity CoatingOn RefractoryOn Refractory

Matrix Coating SystemMatrix Coating SystemOn TubesOn Tubes

Matrix Coating System

IR Thermography Inspection Comparison, MiRO

500.0

900.0 °C

550

600

650

700

750

800

850

FLIR Systems

600.0

800.0 °C

650

700

750

FLIR Systems

Before Coating After Coating

Tube Skin Temperatures After Coating, MiRO

F-001: TMTs after ceramic coating was applied (adjusted for furnace duty)

540

550

560

570

580

590

600

610

620

630

640

24/3/06 13/4/06 3/5/06 23/5/06 12/6/06 2/7/06 22/7/06 11/8/06 31/8/06

TMT Increase Rate: 0.35°C/dayTMT Increase Rate: 0.86oF/day Before CoatingTMT Increase Rate: 0.63oF/day After Coating

Flue Gas & Bridge Wall Temperature, MiRO

Delayed Coker FurnaceBWT and Flue Gas Temp (adjusted to constant furnace duty)

350

375

400

425

450

475

500

3/4/2004 6/12/2004 9/20/2004 12/29/2004 4/8/2005 7/17/2005 10/25/2005 2/2/2006 5/13/2006 8/21/2006 11/29/2006

Flue

Gas

Tem

pera

ture

625

650

675

700

725

750

775

BW

T

Flue-Gas-TemperatureBWTStart of Typical Run Start of Run After Ceramic Coating

Project, April, 2007

Coker #2 Heater

Type:

Cabin, 2 Cell, 4 passesTotal 36 coils (26 radiant + 10 convection)

Design Duty:

77.74 MMBTU/hr

Limitation:

At full capacity, high BWT duringwarm-up & switch-in phases

Project, April, 2007

• New process tubes installed• Preparation for coating before installation

in heaters• Ceramic coating application in situ• Minimizes time & interference during t/a

Project, April, 2007

• Process Tube Surface Preparation– Erection of 2 climate controlled enclosures– Chemical cleaning of tubes– Blasting surface to White Metal spec.– Protecting tubes with plastic wrapping– Storage in low humidity enclosure until

required for installation in heaters

Blasting Tubes

Blasted to “White Metal” Spec.

Tubes Wrapped to Preserve “White Metal” Blast

Project, April, 2007

• Ceramic Coating Application– Climate control in heater cells– Dual emissivity tube coating system

application– High emissivity refractory coating system

application– Climate control until heater start-up

Wrapped Tubes Installed in Heaters

Matrix Coating System

Project, April, 2007

• Results

400.0

900.0 °C

450

500

550

600

650

700

750

800

850

FLIR Systems

Uniform Tube Surface Temperatures

No Oxidation

No Scale/Fouling

Lower Flue gas Temperature

Project, April, 2007

Note: The first 30 days are not representative because capacity was limited by other refinery contingencies

Bridgewall Temperature

0.40

0.45

0.50

0.55

31-50 51-90 91-110

days

°C B

rdgw

ll ce

ll A+

B /

Flow

rate

post coatpre coat

Project, April, 2007

Note: The first 30 days are not representative because capacity was limited by other refinery contingencies

Throughput

2500

2700

2900

3100

3300

3500

31-50 51-90 91-110

days

tpd post coat

pre coat

Project, April, 2007

• Summary of Results

– No BWT Limitation Under Higher Charge Rate– Over 6% Charge Rate Increase– Fuel Saving of 0.5%– Run Length Increase approx. 20%– Pay-back less than 3 months– Improved Heater Reliabilty

• Accurate identification of Coking, real tube skin temperature measurement by IR