Ceramic coating "A" is a unique disruptive technology for refining, chemical, and petrochemical critical applications, a game-changer for the industry to reduce OPEX and CAPEX. This Innovative and customized silica-based inert coating technology provides anti-fouling, anti-corrosion, and anti-coking properties for the harsh environments and extreme temperatures (700°C/1300°F) applications, making the ceramic coating "A" useful in almost all refineries and petrochemical applications, focusing on delayed cokers, visbreakers, cracking, vacuum distillation unit furnaces and similar units.
In most refining conversion units such as delayed coker and others, unscheduled shutdowns, high maintenance, higher fuel consumption, and throughput reduction due to furnace tube coking, fouling and corrosion is widespread problem. Ceramic coating technology minimizes formation, deposition, and plugging due to coke/carbon in addition to the reduction in fouling, corrosion, and fuel usage. The use of the ceramic coating technology in these applications leads to longer runs, the incremental life cycle for equipment, reliable operations, reduced fuel consumptions, and hence significant savings in OPEX and CAPEX.
This presentation covers the properties and advantages of resistance of ceramic coated tubes to various forms of coking, corrosion, fouling, scaling, and the expected cost savings. Results and case studies from various commercial field trials and runs with major US, European, and Asian refineries and further developments and new applications are also covered in this presentation.
The formation of carbon deposits and fouling of tubes is one of the most common operational issues regarding the operability and lifetime of materials at an industrial scale. Several billion dollars are spent worldwide on annual basis to upgrade/change materials apart from revenue loss on account of production halt and additional costs incurred in maintenances. Particularly, the carbon deposition in the refining process is an evitable and undesired factor. Most refineries worldwide have vacuum distillation, delayed cokers, visbreakers, or thermal cracking units where coke formation occurs faster due to high temperatures used in the process. Therefore, unscheduled shutdowns are required, or throughput is reduced due to tube de-coking. From an economic point of view, stainless steel is the most frequently used material, but sometimes more expensive metals are required. The coating of the internal surface with a ceramic layer is useful for preventing the formation of deposits and extending the lifetime of the tubes. This innovative solution not only helps fight fouling, erosion, and corrosion but also helps in an overall reduction of cost, reliable plant operations with improved energy efficiency.