Source:

https://cokebusters.com/comparing-decoking-methods/

Decoking is the process of removing coke/scale build

up from the process tubes of fired heaters and boilers.
Internal cleaning of heater tubes can be done in
several ways; chemical cleaning, steam-air decoking,
in-line spalling and mechanical pigging are the most
common. The effectiveness of each method varies.

Steam-air or thermal decoking is widely recognised as the traditional

decoking method. A mixture of steam, air and heat is used to cause
shrinkage and cracking of the coke deposits inside the tubes. The
steam and air mixture is passed through the coke deposits inside the
tube walls whilst they are heated externally. It works best for radiant
tubes, but it is not always guaranteed to remove coke thoroughly. When
this is the case, it may be necessary to dismantle tubing which is an
expensive and destructive method of cleaning. Only trained,
experienced personnel should carry out this process, as incorrect
procedures could lead to overheating the tubes and cause serious
damage to the heater. Another disadvantage is that the chemical
reactions of hot coke, steam and air produce CO, CO2 and H2 which
are vented to the atmosphere and are bad for the environment.

In-line Spalling offers the advantage of being the only decoking

operation that can be carried out whilst the furnace is in service. One
furnace at a time can be treated whilst the others remain in operation.
The process involves using high velocity steam, which is alternately
heated and cooled, delivering thermal shocks to the coils in order to
create a contracting and expanding effect, to spall coke off the tube
wall. It has less environmental issues than steam-air decoking,
however, other decoking methods may still be required as it is not
considered to be a full decoke, and it has very little effect in convection
areas of the furnace. The other disadvantage of this method is that the
coils are susceptible to damage due to contraction and expansion
during the spalling process.

Chemical cleaning consists of circulating a chemical cleaner, usually an

acid, through the process tubes until the coke build-up has been
softened and removed. The tubes are then flushed through with water to
remove all deposits from the coil. It is important to pay close attention to
the chloride content of the water used for flushing in order to avoid
corrosion damage of the tube walls. The use of chemicals for decoking
are not environmentally friendly so need to be disposed of carefully
which can increase costs.

Mechanical decoking or Pigging has been proven as the most effective

method of removing internal fouling, coke and scale from the inner
surface of fired heater and boiler process tubes. When mechanical
decoking using scraper pigs was introduced in the early 1990’s, many
refineries were quick to benefit from the clear advantages of this new
process. Mobile pumping units are used to propel studded pigs through
the process tubes bi-directionally to remove coke deposits in a wire
brush-like method. Latest developments mean that the pigs can
navigate plug headers easily without any modifications to the pipe.
Mechanical decoking can potentially reduce damage to the tubes as
with other techniques like steam-air and chemical cleaning. Not only
useful for the cleaning of tubes, pigs can also be used as an inspection
tool.
When comparing decoking methods, it is clear to see why mechanical
decoking has become the preferred choice. Mechanical pigging
eliminates the problems associated with steam-air decoking and on-line
spalling, such as venting of waste gases to the atmosphere and the
vulnerability of coils to rupturing due to high-temperature operation.
Pigging removes almost all the coke from the coils and it is a faster
cleaning process and comparatively longer run lengths are achieved
with respect to the other cleaning processes.