Increasing efficiency of catalytic
reformer unit fired heaters
Application of ceramic coating on CRU heater tubing and refractory avoids oxidative
scale formation, significantly lowering fuel consumption and CO2 formation
Diyar Kiliç Mert and Alp Zeren Tüpraş Izmit Refinery
Anton Korobeynikov and Sergei Merchev Integrated Global Services (IGS)
C
atalytic reforming units (CRUs) are one of the high-
est margin but most energy-demanding processes
in oil refining. This flexible technology can produce
high-octane gasoline components and individual aromatic
hydrocarbons (xylene, benzene, toluene), which are raw
materials for the petrochemical industry. The reforming
process involves converting low-octane naphtha into a
reformate at high temperatures and relatively low pressure.
Catalytic reforming is typically carried out in a series of
four reactors. Before entering each reactor, the feedstock
is reheated to a temperature of 520-540°C. This reheating
is achieved using high heat flux fired heaters consuming
sizeable amounts of energy and emitting greenhouse gases
(GHGs).
Radiant coils within the catalytic reforming fired heater
are made of 9%Cr chromium/molybdenum alloy (ASTM
A335P9) and are subject to oxidation scale formation under
firebox conditions. This oxidation scale may reach up to 1-2
mm thicknesses, reducing radiant coil thermal conductiv-
ity, hindering radiant section efficiency, and significantly
impacting the entire plant’s economic performance.
Enhancing radiant efficiency
A CRU with continuous catalyst regeneration (CCR)
experiences a high rate of scale formation, approxi-
mately reaching metal loss levels of 0.15-0.25 mm/year.
The plant team thoroughly tracked the performance and
detected an energy efficiency decrease due to scale for-
mation. Every four years, during a major turnaround, the
plant carried out activities to clean the external tube sur-
faces. Nevertheless, a significant decrease in furnace effi-
ciency was observed by the end of the second year after
the turnaround.
A detailed analysis of furnace operational data revealed
the feasibility of high-emissivity ceramic coatings applica-
tion to the radiant tube and refractory surfaces. The project
was executed during a major turnaround, and the furnace
performance analysis was carried out two months later.
Post-project analysis showed a radiant efficiency gain of
13%, expected to last over the coating’s service life (8-10
years). Achieved radiant efficiency enhancement may
be utilised for reducing fuel consumption along with CO2
emissions or throughput/severity increase under the same
firing rate.
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Scale formation
Refineries seek ways to find energy optimisation solutions
in their processes and prioritises projects that are geared
towards reducing fuel gas consumption and cutting GHG
emissions. These initiatives align with strong commit-
ments to a zero-carbon strategy, sustainability, and opti-
mised energy usage, especially for units like the catalytic
platformer.
While platforming reactions occur in the stacked set
of reactors, scale formation is observed on the external
tube heater’s surfaces due to oxidation, fuel gas impuri-
ties, and high heat flux. Oxidation scale formation results
in the non-uniform heat distribution along the tubes and
hotspots formation. Moreover, the radiant efficiency of the
heater decreases with the corresponding fuel consumption
increase. To prevent oxidation scale formation, the refinery
decided to apply ceramic coatings to the furnace tube and
refractory surfaces on-site during a turnaround.
A detailed analysis of furnace
operational data revealed the
feasibility of high-emissivity
ceramic coatings application to
the radiant tube and refractory
surfaces
This case study pertains to the application of Cetek High
Emissivity Coatings on both radiant tubes and refractory
surfaces within the refinery catalytic reforming heaters.
The primary objective was to enhance radiant efficiency
and facilitate the sustainable operation of the heater for
the next 8-10 years.
Ceramic coatings nowadays are approved materials to
increase the energy efficiency of fired heaters or debot-
tleneck the heaters with various limitations, such as
bridgewall temperature (BWT), firing duty or uneven heat
flux distribution. Initially developed in the 1970s, coatings
have found successful use in all heavy industrial appli-
cations, including metals processing, aerospace, glass
industry, and fertilisers but became especially beneficial in
the oil and gas and petrochemical industries.
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Figure 1 ISO SA 3 sandblasted tubes
High emissivity tube and refractory coatings for
catalytic reforming units
Since, in most cases, tubes in catalytic reforming fired heat-
ers are made of 9%Cr steel, they experience oxidation scale
formation on the external surfaces. Heavy scale creates
poor conductive heat transfer through the tube wall to the
process. This leads to over-firing and high BWTs, eventu-
ally leading to a BWT limitation and reduced production
rate. High emissivity tube coatings can provide the follow-
ing benefits:
The dehydrogenation reactions
within these processes are
endothermic. To initiate these
reactions, the inlet temperatures
of the reactants must be elevated
beyond 500°C, usually 520-540°C
for catalytic reformers
• Reduce fuel consumption or increase capacity under the
same firing
• Increase emissivity of tube surface up to 0.92
• Prevent oxidation scale formation
• Lower BWT and increase radiant efficiency
• Reduce CO2 and NOx emissions.
Additional benefits can be provided by high emissivity
Figure 2 Tubes (on the left) and refractory (on the right) after coating
12 Revamps 2023
ceramic coatings applied to the refractory surfaces, which
improve radiant heat transfer efficiency to the process over
design conditions.
General heater information
Catalytic reforming units are initially designed to pri-
marily generate a high-octane reformate. Nevertheless,
in response to the increasing demand for hydrogen (H2),
these units have gained additional significance as a key
source of hydrogen for hydrotreating and hydrocracking
processes. The reforming processes entail the conversion
of lower- octane heavy naphtha, converting C7-C10 hydro-
carbons into aromatics. This transformation yields high-oc-
tane reformate, hydrogen gas, and a minor proportion of
liquefied petroleum gas (LPG).
The dehydrogenation reactions within these processes
are endothermic. To initiate these reactions, the inlet tem-
peratures of the reactants must be elevated beyond 500°C,
usually 520-540°C for catalytic reformers. This temper-
ature elevation is typically achieved using fired heaters
chosen for their comparatively high efficiency compared to
other alternatives. The substantial heat input requirements
of these heaters also necessitate careful monitoring of the
emissions they generate.
The catalytic reforming unit consists of four cells with
sketches available in the public domain. All cells have dou-
ble firing with burners located on the bottom. Tubes are
made of A335P9 steel, and walls and arch are insulated
with castable refractory. The internal division walls and
floor are made of insulating firebrick.
Pre-application conditions
Before the project, the refinery had searched for a solution
to gain efficiency of its catalytic reformer unit and prevent
any radiant tube oxidation. This oxidation scale acts as a
strong barrier for heat transfer and may decrease radiant
coil thermal conductivity.
In the case of no scale formed on the surfaces, it has been
calculated that there is a potential gain on radiant efficiency
of at least 11.2 % from the initial state throughout the run.
It is worth mentioning that the feed naphthene content,
which has a direct effect on the BWT limit, was expected
to increase by an additional 5 to 10 vol.%. It allows a wider
operational flexibility for the feed selec-
tion choice. Picture 3 shows this change
in naphthene content in the feed.
Application
High emissivity coatings were applied
to all radiant surfaces in all three inter-
heaters during a major turnaround. A
special ceramic coating system has
been selected for each type of surface.
As a first step, tube surfaces have been
prepared to meet ISO SA 3 standards
(SSPC-SP5, NACE No. 1) via blasting to
white metal conditions (see Figure 1).
During tube blasting, the refractory
was protected with tarps to prevent
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 AVERAGE SURFACE TEMPERATURE 716°C (BEFORE)
Figure 3 IR images before (left) and after (right) in interheater #1
damage. After the blowdown of the unit and removal of the
tarps, a high emissivity tube coating (TC) was applied.
After refractory preparation, additional cleaning, and
blowdown, the tubes adjacent to the walls were protected
from overspray. The result after both tube and refractory
application can be found in Figure 2. The application took
only nine days, including all steps and phases.
IR inspection results
To accurately predict the anticipated outcomes following the
application of high emissivity coatings, an infrared inspec-
tion was conducted on all process tubes. This assessment
was coupled with collecting process data related to heater
performance. Post-application, a significant reduction in
tube surface temperatures and BWTs was anticipated for
Figure 4 Uncoated cell (left) vs coated (right)
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AVERAGE SURFACE TEMPERATURE 563°C (AFTER)
all interheaters. This reduction was expected to enhance
radiant efficiency, enabling the potential for fuel savings or
an increase in capacity under the same firing rate.
Figure 3 demonstrates a substantial reduction in tube
surface temperatures (averaging more than 100°C) fol-
lowing the turnaround, particularly in the context of fuel
savings. Furthermore, the temperature distribution along
the length of the tubes became more uniform. The deter-
mination of tube metal temperature via IR thermography is
notably more reliable after coating application, as the oxi-
dation scale is eliminated, and the coating’s emissivity and
temperature gradient are well-defined.
Visual inspection results
Following the completion of the project, a visual inspection
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 45
Data Oct-Nov 2022 TA 2023 Data Mar-Apr 2023
43 890

41

39 ~5 Gcal/hr Firing duty decrease

under the same throughput
37 860

35

33

31 830
21˚C lower weighted
29 average BWT
Fuel firing, Gcal/hr
27
Weighted average BWT, ˚C
25 800
Time (hours)

Figure 5 Weighted average BWT and fuel firing before and after the Cetek application

was carried out. Figure 4 vividly illustrates the noticeable After the application, BWTs were lower than before. These
distinction between the uncoated cell (charge heater) and lower BWTs led to a fuel consumption decrease under the
the coated ones (interheaters). As an additional advantage, same throughput. A weighted average BWT reduction of
the heat distribution along the length of the tubes became 21°C and fuel savings reduction of circa 5.0 Gcal/hr were
more even. Moreover, determining tube metal temperature observed.
through IR thermography became possible, owing to the
well-established ΔT (temperature difference) and a con- Full evaluation results
stant emissivity value attributed to the coating. The initial full data set was collected before the turnaround
and compared with data after application.
Data trends on energy efficiency Process data (see Table 1) shows that the application
Data trends on BWT, excess air, combustion air tempera- has improved radiant efficiencies and debottlenecked the
ture, and fuel consumption were analysed for periods before fired heater limitations. The Cetek coating application has
application and two months after application (see Figure 5). accomplished the objectives of increasing fired heater effi-
ciency and protecting process tubes
from corrosion and oxidation, thereby
Cetek Evaluation Results
prolonging tube service life. Data from
Parameter Oct-Nov 2022 Mar-Apr 2023 a year before the application was
Throughput (hydrotreated naphtha), % of design 100 100 selected as a base case condition due
H2:HC ratio, mole/mole 1.8 1.7 to the established throughput and
Interheaters combined ΔT, °C 211.2 213.8 similar weather conditions with the
Total absorbed duty (interheaters only), Gcal/hr Base case Base case – 0.2
post-application case after the pro-
Fuel consumption (interheaters only), Gcal/hr Base case Base case – 4.7
Apparent radiant efficiency (interheaters only), Δ% Base case Base case + 6.4 ject’s execution..
Achieved fuel savings (interheaters only), % – 13.2 This project has provided an imme-
diate economic benefit and long-term
Table 1 reliability for Tüpraş. It has achieved
13.2% of fuel savings under the same
production or a corresponding pro-
Cetek Ceramic Coating and Independent Modifications Results Comparison
Table 1 duction increase under the same fuel
Parameter Before Turnaround After Turnaround
firing potential. Based on the fuel con-
Throughput (hydrotreated naphtha), % of design 100 100 sumption reduction, the estimated CO2
H2:HC ratio, mole/mole 1.8 1.7 savings are circa 9,600 MTPA accom-
Fresh BFW consumption, vol. flow Base case Base case – 35% panied by thermal NOx emissions
Charge heater inlet temperature, °C 414 444 reduction due to lower radiant box
Charge heater bridgewall temperature, °C 842 647
temperatures.
Fuel consumption (charge heater), Gcal/hr Base case Base case – 5.0
Fuel savings (by ceramic T&R coatings), % – 48.4 The benefit (in Gcal/hr fuel savings)
Fuel savings % – 51.6 is very similar to the benefit after
other independent modifications (see
Table 2 Table 2).

14 Revamps 2023 www.digitalrefining.com

Outcomes
Apart from the benefit of the radiant efficiency increase EII and GHG assessment results
(fuel savings or capacity increase potential), the process
Parameter Value UOM
tubes will be protected from corrosion and oxidation, Δ Fuel consumption 4.7 Gcal/h
thus extending the tube lifetime and achieving reliability Δ Energy equivalent 5.5 MWh
targets. Δ EII equivalent 0.31 EII
It is expected that the rapid scale/oxidation trend that GHG reduction 9,600 MTPA
occurs in heater process tubes after conventional sand- Wood equivalent 25,000 Units

blasting will not be observed during the next two planned

maintenance periods after the application, so it will not Table 3
cause any production (feed rate or RON) bottlenecks.
Moreover, the next planned maintenance is expected to be engineers will undertake IR thermography inspections at
shorter, minimising downtown and turnround costs since regular intervals.
tube abrasive sandblasting is not needed.
With the application of the high emissivity coating on the Platforming is a mark of Honeywell UOP’s proprietary catalytic reform-
interheaters, the environmentally friendly approach of the ing process.
refinery and IGS has also been fulfilled. This approach can
be expressed in the project’s impact on GHG emissions and Diyar Kiliç Mert is Process Technical Leader at Tüpraş Izmit Refinery.
the energy intensity index (EII). Alp Zeren is Senior Engineer at Tüpraş Izmit Refinery.
The project allowed the refinery to decrease fuel con- Anton Korobeynikov is Senior Process Engineer at Integrated Global
sumption by 4.7 Gcal/hr while keeping the same condi- Services (IGS).
tions for the rest of the unit. This change reflected a CO2 Sergei Merchev is Business Development Director at Integrated Global
gas emission drop of 9,600 MTPA. Regarding EII, an Services (IGS).
improvement of 0.31 was reported after the application
(see Table 3). LINKS
Cetek coatings application brought an immediate radiant
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www.digitalrefining.com Revamps 2023 15