Efficiency and Reliability Audio Case Studies

This episode discusses an ethylene furnace's declining fuel efficiency and increased emissions over six years due to fouling, with limited options for cleaning.

This audio case study highlights the importance of treating vacuum heater systems as a single unit to optimize refinery operations, addressing the impact of phase separation and tube coking on efficiency and safety.

The copper smelter’s waste heat boilers, used to recapture heat, faced significant issues with corrosion, erosion, and accretion due to SO2 and other contaminants. The previous coatings, while somewhat protective, exhibited cracking and spalling, necessitating an effective solution to mitigate these problems and reduce maintenance costs.

Discover how a petrochemical plant struggled with persistent erosion and frequent costly shutdowns, leading to significant production losses and safety issues, and how they turned to IGS for a custom solution to tackle these challenges.

Chief Technical Officer Iain Hall discusses how IGS's technology addresses energy companies' biggest challenges around reliability, efficiency, and reducing fuel consumption.

In this audio case study, Nugen Energy faced a significant challenge when their facilities began experiencing refractory failures, requiring extensive downtime for repairs. This downtime not only halted production but also led to substantial financial losses, nearly $6.59 million per incident.

Integrated Global Services (IGS) deployed Tube Tech’s engineered VCFE cleaning solution to remove fouling from 2688 tubes across two Texas Towers. 100% of tubes were cleaned to a production standard and 10% of tubes received enhanced cleaning for IRIS inspection.

This episode explores the issue of oxidation scale formation on steel tubes in fired heaters. This problem disrupts heat transfer, causing over-firing, high bridgewall temperatures, and reduced production rates.

Today, we'll delve into a case study surrounding the challenges faced by a plant due to erosion and corrosion in their waste heat recovery system, and how they tackled this issue without compromising plant availability or production.

This audio case study is about fouling challenges faced by a petrochemical company. There is a crucial need to restore heater efficiency and operational reliability, leveraging advanced robotic technology in alignment with the company's commitment to sustainability, this process generated minimal waste.