High Emissivity Ceramic Coating of

Furnace Walls in Tubular Reformers

Theory and practice

The furnace walls in a tubular reformer are lined with refractory, bricks and fiber materials having a
relative low emissivity. By applying a “High Emissivity Coating” on the surface of the furnace walls, it is
possible to increase the emissivity and thereby improve the thermal efficiency of the furnace box
significantly.

The enhanced efficiency of the furnace box can be utilised to alleviate excessive temperatures in the
convection section, increase the capacity of the reformer or prolong the lifetime of the catalyst tubes. The
lifetime of the catalyst tubes in side wall fired tubular reformers may be further prolonged if the heat
release of the bottom row burners can be reduced to half the heat release of the upper row burners. In
addition, several other secondary benefits are obtained by sealing the furnace walls with the coating
material.

High emissivity coating of the furnace walls have been applied in several tubular reformers with
satisfactory results. Industrial feed-back from two plants and two case histories are presented.

Peter Bruun Jensen

Haldor Topsøe A/S
Copenhagen, Denmark

Venkat Pattabathula and Stephen Maule

Incitec Pivot Ltd,
Brisbane, Australia

John Bacon
Cetek Limited
Brook Park, OH, USA

Darius Pasaribu
Kaltim Pasifik Amoniak
Bontang, Indonesia

2011 53 AMMONIA TECHNICAL MANUAL

 Introduction
C
atalytic steam reforming of hydrocarbons
in tubular reformers is the most common
process for production of synthesis gas.
The reforming reactions are highly endothermic
and the heat is provided by combustion of fuel gas
in a furnace box and transferred to the catalyst
tubes mainly by radiation. The thermal efficiency
of the furnace box is typically 45-60% and
additional 35-50% of the heat is recovered from
the flue gas in the reformer convection section.
The recovered heat is used for preheating of
reformer feed, process air, steam superheating and
preheating of boiler feed water or combustion air.
The thermal efficiency of the furnace box can be
increased by applying a high emissivity ceramic
coating on the furnace walls which enhance the
radiative heat transfer contribution from the hot
furnace walls to the catalyst tubes. However, the
efficiency improvement depends on the reformer
design and the actual conditions in the reformer.
Tubular steam reformers are divided into four
categories depending on the location of burners
and the arrangement of the catalyst tubes in the
furnace box. Please see Figure 1.
Figure 1. Reformer furnace configurations
Top fired and bottom fired reformers have the
catalyst tubes arranged in several parallel rows
with the burners located between the tube rows
AMMONIA TECHNICAL MANUAL
either in the top or the bottom of the furnace box.
The area and angled view of the surrounding
furnace walls relative to the catalyst tube plane
limits the radiative heat transfer contribution from
the hot furnace walls to the catalyst tubes except
for the outermost tubes near to the furnace walls.
Attempts of enhancing the radiation efficiency of
the furnace walls may impair the heat distribution
in the furnace box as the tubes near the furnace
walls will receive relatively more radiation than
the other tubes in the furnace box. This however
can be mitigated by installing lower duty burners
in the outside rows and next the end walls.
Side wall fired and terrace wall fired reformers
have the tubes arranged in single rows between
two opposing furnace walls on which the burners
are located either in typical 6-7 horizontal rows or
in two horizontal terraces. The area and direct
view of the surrounding furnace walls relative to
the catalyst tube plane results in a significantly
higher and more uniform radiative heat transfer
from the hot furnace walls to the catalyst tubes
than obtained in top and bottom fired reformers.
The radiative heat transfer from the hot furnace
walls to the catalyst tubes amounts typically to 20-
30% of the total heat transfer in a side wall fired
reformer.
The more uniform and higher radiative heat
transfer contribution from the furnace walls makes
the side wall fired and the terrace wall fired
reformers superior with respect to utilisation of
enhanced radiation from the furnace walls. In fact,
as explained later, the degree and flexibility of
utilising the enhanced radiation of the furnace
walls depends on the applied firing profile and the
flexibility to change it. The Topsoe side wall fired
reformer is ideally suited for this optimisation as
the firing profile can be changed by individual
adjustment of the heat release in the horizontal
burner rows.
54 2011
 Cetek’s Proprietary High
Emissivity Coating Technology
The use of high emissivity ceramic coatings,
applied to the refractory surfaces in radiant
sections of fired heaters and tubular reformers,
was pioneered by Cetek and has now become an
accepted means of improving the efficiency of
radiant heat transfer, leading to energy savings as
well as environmental and reliability benefits. A
range of ceramic coatings have been developed
and used reliably for many years, for different
substrate types, operating environments and
targeted application benefits.
In fired heaters and tubular reformers, the
necessary thermal energy to drive the endothermic
processes is provided by burning a fuel/air
mixture and transferred to the process by three
heat transfer mechanisms: radiation, convection
and conduction. The primary means of heat
transfer is by radiation.
Why High Emissivity?
In the radiant section, of tubular reformer, much
of the radiant energy from the flame/flue gas is
transferred directly to the process/catalyst tubes;
however, a significant proportion interacts with
the refractory surfaces. The mechanism of this
interaction has an appreciable effect on the overall
efficiency of radiant heat transfer. A major factor
in determining the radiant efficiency is the
emissivity of the refractory surface.
At process heater operating temperatures, new
ceramic fiber linings, for example, have
emissivity values of around 0.4. Insulating fire
brick (IFB) and castable materials have emissivity
values around 0.6. These materials have been
designed with structural considerations and
insulating efficiency as the primary requirements.
They tend not to handle radiation in the most
efficient way. Cetek Ceramic Coatings, however,
with emissivity values of above 0.9, have been
2011
designed specifically to supplement the radiation
characteristics of the refractory surfaces.
It is important to understand how the emissivity
property of a surface can affect the efficiency of
heat transfer. There are two factors which need to
be taken into account. The first is the spectral
distribution of the radiation absorbed/emitted
from a particular surface and the second is the
value of the emissivity of that surface. The
amount of heat, Q, radiated from a surface (area,
A; temperature, T; emissivity, ε) is given by the
following, well-known Stephan Boltzman
equation:
Q = AεσT4
Where σ is the Stephan Boltzman constant.
Lobo & Evans (1) and others extended the
calculation with reference to fired heaters and a
simplified equation would appear as:
QR = Aσ(T14-T24)/F
Where F = 1/ε1+{A1/A2}{(1/ε2)-1} for tubes of
area A2, surface temperature T2 and emissivity ε2
are inside an enclosure, area A1, with surface
temperature T1 and emissivity ε1. The effects of
maximizing the emissivity ε1 of the enclosure are
obvious; there is a significant increase in radiant
heat transfer to the tubes. As stated earlier, much
of the radiant heat to the tubes travels directly
from the flame/flue gas, but the emissive property
of the refractory surface has a profound effect.
The chart in Figure 2 shows the energy spectra for
two major components of the combustion
products of natural gas; water vapour and carbon
dioxide. They are compared with the spectrum of
a perfect radiator, or black body, at the same
temperature.
The combustion products will radiate and absorb
energy in the narrow wave bands shown, whereas
a black body will radiate and absorb energy over a
much wider wavelength range.
55 AMMONIA TECHNICAL MANUAL

Figure 2. Energy Spectra of Combustion Products of Natural Gas
Products of Natural Gas
High emissivity surfaces are able to radiate energy
across a broad wavelength band lessening the
interference of the CO2 and H2O in the flue gas.
When the radiation from a flame strikes a perfect
radiator, all of the energy is absorbed, but most
importantly, it is transformed into “black body
radiation”, as the wide waveband form. As the
energy is re-emitted from the surface, it is able to
penetrate the atmosphere in the furnace, composed
of the combustion products, with little being re-
absorbed and taken to the stack by the draft.
Therefore it is more readily available to heat the
load in the furnace.
If the surface were a poor radiator, or one having a
very low emissivity value, the energy striking the
surface would be reflected back from the surface
still in its untransformed state, therefore more
readily absorbed by the furnace atmosphere. The
effect is to “super-heat” the furnace atmosphere,
or flue gas, resulting in wasted energy lost to the
stack.
AMMONIA TECHNICAL MANUAL
Spectral distribution of radiation emitted by a black body at
temperature 1350 K.
The improvement in radiant heat transfer
efficiency naturally leads to a reduction in flue gas
temperature. This has consequences in the
convective heat transfer in both the radiant and
convection sections of the fired heater. In the
convection section, heat in the flue gas is used to
produce steam and preheating of combustion air
and often process fluids. The heat
transfer/absorbed duty balance should be
examined closely to ensure that the balance is not
adversely affected. There is also a contribution,
though minor, from convective heat transfer in the
radiant section, which may be characterized by the
following equation:
Qc = hcA2(T1 – T2)
Where hc, the film heat transfer coefficient, is an
empirically derived factor related to the design of
the radiant section and the tube configuration.
Cetek’s Evaluation Process
Cetek’s high emissivity ceramic coatings applied
to the refractory surfaces provide a significant
effect, which varies for different types and designs
of fired heaters, or tubular reformers. In order to
56 2011
 derive the most benefit, it is important that a
complete technical analysis/evaluation of the
effects of the application is completed beforehand.
The benefit in the radiant section and the effects
on the convection section are studied and
reported, before any commitment is made by
client, or Cetek. Typical approved applications in
steam methane reformers show productivity
benefits (as energy savings, or production
increase) ranging from 2.5% to 5.0%.
The life of the coating system applied to refractory
surfaces is related to the temperature to which it is
subjected and the local environment. Typically in
steam methane reformers the coatings will
gradually lose emissivity, declining from over 0.9
to around 0.8, after approximately 6 to 8 years.
This is still substantially higher than the original,
uncoated refractory. At this stage it is
recommended to touch-up the coatings to boost
the emissivity to the original level and restore
performance. The deterioration is caused by high
temperature, solid state diffusion of the elements
in the coating which provide the high emissivity
property. The rate of deterioration may be
increased by localized flame impingement.
Environmental Benefits from Cetek’s High
Emissivity Coatings
The reduction in flue gas temperature leads to a
significant reduction in thermal NOx emissions.
The typical reduction in NOx emissions in steam
methane reformers is 20% to 30%, irrespective of
burner type.
CO2 emissions are reduced proportionately with
the productivity benefits.
Cetek’s ceramic coatings (high emissivity or
neutral emissivity) provide a real encapsulation of
ceramic fiber (blanket, modules, or panel)
insulation. There is no loss of friable fiber from
radiant sections and therefore no fouling of radiant
section tubes/catalyst tubes, convection section
tubes, screens of SCR (Selective Catalytic
2011
Reduction) units or loss to the environment,
through the stack. Entry to radiant sections during
shut downs is less hazardous since negligible
contamination results.
Haldor Topsoe reformer simulation
for evaluation of high emissivity
coating
Tubular reformers and the associated convection
sections are complex units operating close to the
mechanical design limits. Balancing the reactivity
in the catalyst tubes and heat flux along the tubes
is obviously essential, but also a correct heat
balance between the radiant furnace box and
convection section is important to obtain
maximum utilisation of the reformer capacity
without compromising the mechanical design
limits of the unit.
Application of high emissivity coating of the
furnace walls will increase the radiative heat
transfer from the furnace walls to the catalyst
tubes and thereby change both the heat flux in the
radiant furnace box and heat balance between
furnace box and convection section. In-depth
analysis of these changes is recommended to
determine and optimise the impact on the reformer
and plant performance prior to application.
Advanced process modelling of the tubular
reformer and associated convection section, based
on detailed equipment information and actual
operating data, is required to accomplish a reliable
impact study.
In Topsoe, we use our in-house developed
proprietary programs for process simulation. A
reformer impact study will typically include
process modelling by use of following programs:
GHEMB – a general heat and mass balance
program to reconcile the operating data and
evaluate the overall impact, by changing operating
parameters, on the entire process plant.
57 AMMONIA TECHNICAL MANUAL
 CROSSHEX – a detailed heat exchanger program
to simulate the series of coils in the reformer
convection section.
REFRAD – a detailed reactor and furnace
modelling program to simulate the complex
interactions of heat transfer and coupled chemical
reactions in the tubular reformer furnace box. The
furnace model (2) is based on a multi-zone
radiation model and divides the furnace chamber
into a number of gas, burner, furnace wall and
tube wall zones and calculates the radiative heat
transfer between them. The flue gas radiation is
modelled by a one clear + three grey gas radiation
model in order to allow the radiation from the
furnace wall to the tube wall in the clear window
and weight the ratio of the two radiating
components (H2O and CO2) in the flue gas. The
clear window is obviously important to account
for the increase in radiative heat transfer from the
furnace wall to the tube wall when the furnace
wall emissivity increases after application of the
high emissivity coating. The furnace model is
combined with the catalyst tube model by
converging the heat flux profiles in the two
models.
Figure 3. Modelling of reformer furnace chamber
The first step in the impact study will be a detailed
simulation of the actual reformer operation to
verify the process model and identify the
operational constraints in the reforming unit. Next
step includes process simulation with increased
AMMONIA TECHNICAL MANUAL
emissivity of the furnace walls, after application
of the high emissivity coating, and finally various
operating scenarios are investigated to find the
optimum solution for the plant. If deemed
necessary, the threshold condition for re-coating
can also be calculated as the coating efficiency
will decline over time.
Primary benefits obtained by coating
The operating constraint in tubular reformers is
normally imposed by one or more of the following
parameters:
 Maximum temperature of the flue gas
outlet from the radiant box
 Maximum or minimum temperatures of
process stream outlet from the convection
section coils
 Maximum metal temperature of catalyst
tubes (TMT)
 Maximum heat release of the burners
Increasing the furnace wall emissivity will
increase the thermal efficiency of the furnace box
and result in lower temperature of the flue gas
outlet from the radiant box and also lower fuel gas
consumption if the outlet process gas temperature
is maintained. Simulations of side wall fired
tubular reformers before and after coating, with
the expected changes in furnace wall emissivity,
show a flue gas temperature drop of 25-50oC (45-
90oF) outlet the radiant box and a corresponding
drop in fuel gas consumption, after coating. The
degree of temperature drop depends on the furnace
geometry, applied firing profile and change in
furnace wall emissivity. Similar drop in flue gas
temperature has been observed in industrial side
wall fired tubular reformers after coating. In case
the firing profile remains unchanged after coating,
in order to benefit from the lower flue gas
temperature and lower fuel consumption, the
calculated decrease in maximum tube metal
temperature (TMT) will be less than 2oC (3.6oF).
58 2011
 However, many reformers in ammonia plants have
to maintain a constant flue gas temperature at the
inlet to the convection section, or at least inlet to
the steam superheating coil in order to keep the
temperature of the superheated high pressure
steam unchanged. These plants will have to
increase the firing in the upper part of the furnace
box, which decreases the firing in the lower part
of the furnace box as the total heat input to the
reformer remains unchanged to maintain the outlet
process gas temperature constant. Reformer
simulations with change in firing profile i.e.
increased firing in the top row of burners and
decreased firing in the remaining burners after
refractory coating shows typically a drop in the
maximum TMT of 2-5oC (3.6-9 oF).
If all burners in the lower part of the furnace box
operate at the same heat release, the TMT will
increase all the way down to the bottom of the
furnace box. In case the flue gas temperature
outlet from the furnace box, after coating, is
increased by decreasing the heat release of the
bottom row of burners, and maintaining the outlet
process gas temperature constant, the maximum
TMT will decrease significantly and the location
of the maximum TMT will move upwards from
the bottom of the furnace box. Reformer
simulations show that the maximum TMT will
decrease by 5-10oC (9-18oF) and move a few
meters upwards in the furnace box if the heat
release in the bottom row of burners is decreased
significantly to increase the flue gas temperature
outlet from the furnace box. Furthermore, the
TMT in the bottom of the furnace box, where the
creep damage of the tubes is most pronounced,
will decrease by 10-15oC (18-27oF).
The above mentioned reduction in maximum
TMT of the catalyst tubes is small but still
significant considering the rule of thumb, derived
from the Figure 4, that operating the catalyst tubes
15-20oC (27-36oF) below the design temperature
will double the tube lifetime.
2011
Figure 4. Tube lifetime for various materials
In case the tubular reformer is operating at its
capacity limit due to the above mentioned
constraints, there is a potential for production gain
by improving the furnace wall radiation and
optimising the firing profile in the furnace.
Simulation of side fired tubular reformers aiming
at the same maximum TMT, outlet temperatures
of flue gas and process gas, respectively, before
and after coating indicate that the production of
synthesis gas can be increased by 2-4% after
coating.
Secondary benefits obtained by coating
In addition to the benefits derived from the
enhanced furnace wall emissivity, refractory
coating may also provide secondary benefits like:
 Preservation of the lining material around
burners, which otherwise is slowly
degraded/eroded due to exposure to the
flue gas being at high temperature and
high velocity when it leaves the
combustion zone.
 Elimination of refractory dust from
erosion, which otherwise may deposit on
the tube surface and decrease the tube wall
emissivity resulting in lower thermal
efficiency of the furnace box and
convection section.
59 AMMONIA TECHNICAL MANUAL
  Absence of refractory dust on the tubes to complete energy efficiency projects. IPL
makes the TMT measurement less identified the potential to install the reformer
scattered and more reliable due to higher coating through networking with other Ammonia
certainty about the tube wall emissivity. producers, and this project fitted in with the IPL
strategy to improve energy efficiency.
 The lower flue gas temperature will result
in lower NOx emission. In 2008 IPL provided baseline information to
Cetek to evaluate the potential benefit of applying
Furthermore, coating of fiber materials will make the coating in the radiant section. The initial
the material less unhealthy as the fibers will be potential benefit, as modelled by Cetek, was a fuel
encapsulated in the coating. saving of 3.75% to 5% in the radiant section, and
a reduction in bridge wall temperature
(temperature exit of the radiant section prior to the
Case history 1 transition area) of 42oC (75oF) for the same
production rate. Alternatively, a similar gain in
Incitec Pivot (IPL) operates an Ammonia plant
production was predicted for a constant fuel gas
designed by J.F Pritchard, commissioned in 1969,
rate. At the IPL plant, the bottleneck for
that produces around 890 MTPD of Ammonia.
production is normally in the back end of the
The Reformer is a single cell Foster Wheeler
plant, meaning the target for the project would be
design with a straight row of 108 catalyst tubes
in pursuing energy savings not additional
heated on each side by two decks of 24 up–firing
production.
burners. Downstream of the radiant section, is a
mixed steam and natural gas (mixed feed) coil in
The other predicted benefit of the coating was a
the transition area before the convection section.
more even split between the top and bottom
In the convection section there is auxiliary firing
burner rows. IPL had been running the reformer
for steam generation, and for superheated steam.
with significantly more firing on the bottom row
Two induced draft blowers draw air locally
of burners; so that the top row of burners could be
through the radiant section burners, and
turned down in order keep the outlet temperature
convection section burners. The reformer radiant
of the downstream mixed feed coil under its alarm
section is a mixture of approximately ¾ castable
temperature.
brick and ¼ ceramic fiber. Typical furnace draft is
-0.1in W.G at the arch and stack exit temperature
IPL investigated the impact of the reduced
of 193oC (380 oF).
temperature from the flue gas on the convection
section in more detail to determine if there would
Background
be any adverse effect on plant operation. This
study determined that the existing superheat coil
In Australia a requirement exists for large energy
was significantly underperforming. Replacement
using companies to identify opportunities to
of this coil and installation of new brickwork
improve energy efficiency under the Energy
(corbel bricks) would mean the current high rate
Efficiency Opportunities Act. The number of
of auxiliary firing would not be needed and the
opportunities that have been identified, and the
reduced temperature of the flue gas would not
status of these opportunities, have to be reported
impact superheat temperatures.
to the public and to the government each year.
However, there is no requirement to implement
IPL was planning on doing significant
the opportunities identified. This legislation
maintenance work on the reformer in the 2011
encourages companies to identify and improve
shutdown, and this was the next available
energy efficiency and provides additional impetus

AMMONIA TECHNICAL MANUAL 60 2011

 opportunity to implement the coating. In order to
gain more understanding of the practical impacts
of the coating, three engineers travelled to
Indonesia in 2010 to review two other plants that
had also implemented the coating. The feedback
from the other plants was positive and as a result
of this trip, the project was added to the shut-
down scope.

Implementation
The coating was installed by a staff of 6 after all
the other work had been completed in the radiant
section. The installation of the coating was not on
Figure 6. Ceramic fiber coated. Castable brick
the critical path for re-commissioning, as other
uncoated
work was still progressing in the convection
section. Initially, the reformer was cleaned by
wire brushing the castable brick and flattening the
ceramic fiber with a nylon brush.

Figure 5. Cleaned castable brick and flattened

ceramic fiber

The dust generated from this activity was blown

down from the reformer with air. Long plastic
sheeting was installed to protect the reformer
tubes from any overspray.
Figure 7. Coated and uncoated wall during job
The ceramic fiber was applied with a rigidizer as a
base layer and top coated with R371. The castable
brick was then coated with a base layer (R360)
and a top coat (R371). As the project was not on
the critical path, only day work hours were
required and the whole process of cleaning the
final coat took 3 days.

2011 61 AMMONIA TECHNICAL MANUAL

 radiant section due to Cetek coating. The bridge
wall temperature before the mixed feed coil had
also reduced by approximately 50oC (90oF)
compared to previous operation.

Case history 2
P.T. Kaltim Pasifik Amoniak (KPA) operates a
2000 MTPD ammonia plant located within the
Kaltim site in Bontang, Indonesia. The process
design for the plant was by Haldor Topsoe. At the
time of its commissioning and acceptance in May,
Figure 8. Finished castable brickwork 2000 it was the largest single train ammonia plant
in the world.
Results
The Primary Reformer is a side-fired Topsoe
After the plant was restarted, a reduction in
design with draft fans located at the top of the
natural fuel gas was noticed to the reformer for the
convection section. Sidewalls and roof are
same production rate.
insulated with ceramic fiber insulation.
This was due to a combination of not having to
From the beginning of operations it was evident
fire auxiliary burners in the convection section;
that the Primary Reformer operated with high
due to the super heater coil replacement, and also
bridgewall temperatures at the top of the radiant
a reduction in radiant section firing due to the
section. These high bridgewall temperatures
Cetek coating. In the radiant section the balance
resulted in high process temperatures from some
between top and bottom decks was adjusted to
of the lower convection section coils. Since some
increase firing on the top deck, while reducing the
of these convection coils were operated close to
firing pressure on the bottom deck. Importantly
design temperatures, various means were
this increase did not result in higher outlet
investigated to bring down the bridgewall
temperatures of the downstream mixed feed coil,
temperatures and Cetek’s proprietary high
which typically runs close to its alarm
emissivity coating technology was an obvious
temperature.
candidate.
Comparing a long baseline period before and after
Both KPA and Cetek carried out evaluations of
the changes were made showed that the overall
the benefits of the technology and the decision
measured improvement was approximately 600
was made by KPA to proceed. The coating was
GJ/day for the same production rate. The super
carried out on a turnaround in November of 2007.
heater replacement was typically contributing 250
The work was done by Cetek technicians in four
GJ/day, and the Cetek coating 350 GJ/day which
days and had no impact on the overall duration of
is approximately 4% saving in fuel gas for the
the turnaround.
radiant section. The steam generation in the
convection section had reduced from 120 klb/hr to
Figure 8 and 9 below show the condition of the
100 klb/hr. This was due to a combination of
refractory coating before box-up in 2007.
reduction in auxiliary firing of superheat burners
(which in addition to superheating also raised
steam), and reduced flue gas temperature from the

AMMONIA TECHNICAL MANUAL 62 2011

 Figure 9. Ceramic coating condition on ceramic
fiber end wall
On plant start up following the installation of
the Cetek coating, bridge wall temperatures
were noticeably lower. Both indicated
temperatures and calculations by Topsoe
showed that bridgewall temperatures were
reduced by 40 to 50oC for the same operating
rate. Fuel gas efficiency for the reformer was
improved by over 2%, and process outlet
temperatures were easily achieved without
overheating the bridgewall.
Figure 11. Thermal deterioration of ceramic coating
2011
Figure 10. Ceramic coating condition on brick
side wall
Some (not all) of the top row reformer burners
which have not been in operation before were
then able to be lit. Plant throughput capability
was also raised by an estimated 2%.
Because the impact of this coating on plant
operations was so marked it was decided to re-
apply the coating to furnace walls in 2011 as the
thermal coating effect deteriorated over time as
shown below.
63 AMMONIA TECHNICAL MANUAL
 Other industrial feed-back after
coating
Topsoe have received feed-back from two other
HTAS licensed ammonia plants, PT Kaltim Parna
Industri’s 1500 MTPD ammonia plant in
Indonesia (KPI) and Profertil’s 2050 MTPD
ammonia in Argentina (PFT), after coating of the
furnace walls in their side wall fired tubular
reformer. Both plants were coated by Cetek in
year 2008, with the primary objectives to increase
the thermal efficiency of the furnace box and
utilisation of excess firing capacity in the top row
burners.
KPI observed a drop in flue gas temperature outlet
from the furnace box of 27oC after coating.
Shortly after start-up, the firing profile was
optimised by igniting several burners in the top
burner row which reduced the heat release in the
lower burner rows. The change in firing profile
increased the flue gas temperature outlet of the
furnace box by 10oC but reduced the measured
maximum TMT of the catalyst tubes
approximately 2oC. Subsequently, the plant load
was increased by 2.5%, which resulted in
additional 10oC temperature rise in the flue gas
outlet from the furnace box.
prolong lifetime of the furnace wall lining and
catalyst tubes or gain synthesis gas production
depending on the operating constraints in the
reformer or it can be included as an integral part
of a more comprehensive optimisation of the
reformer unit.
The expected benefits from coating have been
obtained in many tubular reformers but the effect
will decline over time due to deterioration of the
coating material. The thermal lifetime of the
coating is typically 4-8 years depending on the
coating work and the environment in the furnace
box. The declining rate should be followed closely
in order to identify the right time to reapply the
coating and fit the work into the normal turn-
around period.
References
(1) Lobo, W. E. and Evans J.E. (1939) Trans
AIChE, 35-743.
(2) Rostrup-Nielsen, and Christiansen, L.J in
“Concepts in Syngas Manufacture”
Catalytic Science Series – Vol.10, 2011,
Imperial College Press, London

PFT experienced a substantial drop in flue gas

temperature outlet from the furnace box after
coating and adjusted immediately the firing profile
after start-up by igniting all burners in the upper
burner row, which had previously been switched
off to avoid excessive temperatures in the
convection section. Although the firing profile
was changed significantly after coating a
temperature drop of 25oC was observed in flue gas
temperature outlet the furnace box.

Conclusion
The benefits obtained after applying high
emissivity coating of the furnace walls in side
fired reformers, can either be utilised as stand-
alone benefits to save energy, lower emissions,

AMMONIA TECHNICAL MANUAL 64 2011