INCREASING PROCESS EFFICIENCY

VIA THE APPLICATION OF

CERAMIC COATINGS

John Bacon
International Sales Director
Cetek Limited
640 North Rocky River Drive
Berea, Ohio 44017
USA
Phone: 1-440-891-0892
Fax: 1-440-891-0899
Email: John.Bacon@fosbel.com

Donatello Del Latte

Resp. Conservazione Energia
API Raffineria di Ancona s.p.a.
Via Flaminia, 685
Falconara M. ma 60015
Italy
Phone: 39-071-916-7262
Email: d.dellatte@apioil.com

Executive Summary
API Raffineria di Ancona s.p.a. contracted the services of Cetek Limited to apply ceramic
coatings to one heater cell of an SR Reformer in October 2000. Cetek high emissivity ceramic
coatings are applied to refractory and process tube surfaces to improve radiant and conductive
heat transfer efficiency. The aim of this application was to provide a reduction in fired duty of
7%, under normalized production conditions.
In the last 12 months, the average benefit has been 7.32% reduction in fired duty, with other
benefits of lower bridgewall temperature, lower tube surface temperatures and a total elimination
of scale formation. The operational parameters, which have been compared before and after the
intervention, are the flue gas temperature, the radiant efficiency, and the heat released. The
parameters compared pertain to the period from August 2000 to December 26, 2001.

Case Study: Coating Application at API Raffineria di Ancona, Falconara, Italy

Introduction & Evaluation
The subject of this case study is one cell, charge heater 2603, of a semi-regenerative catalytic
reforming unit at API Raffineria di Ancona in Falconara, Italy. The heater is a vertical cylindrical
heater, with typical P22 (2.25% Cr, 1% Mo) process tube configuration. The refractory lining is a
lightweight, insulating castable material.
Management at API chose to have Cetek Limited apply ceramic coatings to the process tubes and
refractory of this heater in an effort to achieve a reduction in fired duty in the heater, with a
payback of less than 18 months. Additional benefits expected include a reduction in flame length,
bridge wall temperature, tube metal temperature and an elimination of scale formation.
Before the decision was made to proceed with the coating application, Cetek performed a
preliminary evaluation of the unit. This evaluation required a detailed analysis of design data and
operating data, as well as a corresponding Infra-Red Thermography inspection, and the results

that API could expect to meet its production and economic requirements through the application
of ceramic coatings.
An Infra-Red Thermography analysis of an area of the tubes in the Charge Heater taken before
coating is shown in Figure 1.
Figure 1. IR Thermography Analysis Before Coating Application

700.0C
700

AR01

650

LI01

Emissivity

0.90

Ambient temperature

700.0C

Label

Value

Line LIO1:
600

550
540.0C

C
700

IR01

LI01 : max

679.5C

LI01 : min

559.3C

LI01 : max-min

120.1C

Area AR01:
AR01 : max

652.1C

AR01 : min

571.1C

AR01 : max-min

80.9C

AR01 : avg

608.5C

680
660
640
620
600
580
560
540

Line
li01

Min
559.3C

Max
679.5C

Cursor
-

From this study of the surface temperature of the tubes, it is clear that there is considerable scale
formation on the tube surfaces, as indicated by an approximate delta T of more than 80oC over
the tube metal temperature (shown as AR01: max-min in Figure 1), indicating more than 2 mm of
surface scale. This leads to a significant insulation of the tube from the process heat, resulting in a

reduction of conductive heat transfer efficiency. The thermal conductivity coefficient would be
reduced under these conditions, to less than 50% of the theoretical clean metal value.
The refractory lining in the charge heater was a lightweight insulating castable material, with an
emissivity of approximately 0.6. It was in good condition.
Ceteks evaluation showed that it would be possible to achieve a reduction of fired duty of at least
7% from an application of coatings to both refractory surfaces and process tube surfaces in the
radiant section.
Application of Coatings
Based on the evaluation, API decided to proceed with the application of both refractory and tube
coatings for this charge heater. The coating application was undertaken during the plant shut
down in October 2000.
The procedure of applying process tube coatings begins with the complete removal of all surface
scale and oxide layers on the tube surface, to a white metal finish. The tube coating is then
applied, which prevents any further oxidation and scale formation. This maintains the thermal
conductivity of the tube wall at 97% of the theoretical clean metal value.
The refractory coatings produce a high emissivity property to the interior surface of the refractory
linings. In gas-fired or gas/oil-fired process heaters, this produces an increase in the radiant heat
flux to the process. The nature of the radiation from the refractory surface is changed to near
black body radiation, which is able to penetrate to the process tubes without being
preferentially absorbed by the atmosphere.
For a full technical explanation of the coatings function, please see Appendix I at the end of this
paper.
The entire coating application took two days, including tube preparation (blasting to a white
metal finish), coating tubes and refractory surfaces and attendant ancillary activities.

Results from the Coating Application

Follow-up inspections showed that the tube coating was performing beyond APIs expectations.
Figures 2 and 3, which illustrate IR Thermography Analyses taken at 9 and 14 months after the
coating application, showed no evidence of surface scaling. Tube surface temperatures were
shown to be lower and more uniform, with no appearance of surface scale, and delta T was
substantially reduced.

Figure 2: IR Thermography Analysis, 9 months After Coating Application

>750.0C

700
AR01

Emissivity

0.90

Ambient temperature

700.0C

Label

Value

Line LI01:
LI01 : max
600
LI01

467.3C
IR01

700

650

600

550

500

450

Line
li01

Min
453.1C

Max
619.4C

LI01 : min

453.1C

LI01 : max-min

166.3C

Area AR01:

500

619.4C

Cursor
-

AR01 : max

537.0C

AR01 : min

510.3C

AR01 : max-min

26.7C

AR01 : avg

522.1C

Figure 3: IR Thermography Analysis, 14 months After Coating Application

652.0C
650

AR01

600

Emissivity

0.90

Ambient temperature

700.0C

Label

Value

Line LI01:

LI01

550

LI01 : max

614.4C

LI01 : min

504.7C

LI01 : max-min

109.6C

500

Area AR01:
456.0C
C

IR01

640
620
600
580
560
540
520
500
480
460
Line
li01

Min
504.7C

Max
614.4C

Cursor
-

AR01 : max

537.8C

AR01 : min

507.5C

AR01 : max-min

30.3C

AR01 : avg

523.3C

During a recent shut down, an opportunity was taken to examine the coating at ambient
temperatures. The tubes remain in excellent condition, with no surface oxidation taking place.
This can be seen in Figure 4, which is a representative photograph of the tube surfaces, taken 18
months after the application. The refractory coating is also in excellent condition.

Figure 4: Photograph of Coated Tubes, 18 Months After Application

Measured fired duty has shown a 7.3% benefit, with no detrimental effects on steam production.
Payback for the project was achieved in 12 months.
API Raffineria data for radiant efficiency improvement, reduction in flue gas temperature and
reduction in fired duty are shown in Figures 5, 6 and 7. Here the data for before coating and after
coating are shown against absorbed duty. The results obtained are compared with typical
applications from worldwide records, in Figure 8.

Figure 5: Bridge Wall Temperature Trend Comparison

The bridge wall temperature has been reduced by up to 95oC, following the ceramic coating
application. This is often a direct measure of the improvement in heat transfer in the radiant
section of the heater.
F-2603 - Bridge Wall Temperature Trend
Before Coating

After Coating

1000

Temperature (C)

900
800
700
600

3.
80
4.
70
5.
10
5.
17
5.
23
5.
43
5.
59
5.
70
5.
75
5.
79
5.
82
5.
88
5.
93
6.
07
6.
17
6.
22
6.
25
6.
32
6.
56

500

Absorbed Duty (Mkcal/h)

Figure 6: Radiant Efficiency Trend Comparison

The radiant efficiency has increased by an average of approximately 7% following the ceramic
coating application.
F-2603 - Radiant EfficiencyTrend
After Coating

70.0
68.0
66.0
64.0
62.0
60.0
58.0
56.0
54.0
52.0
50.0

3.
80
4.
70
5.
10
5.
17
5.
23
5.
43
5.
59
5.
70
5.
75
5.
79
5.
82
5.
88
5.
93
6.
07
6.
17
6.
22
6.
25
6.
32
6.
56

Efficiency (%)

Before Coating

Absorbed Duty (Mkcal/h)

Figure 7: Fired Duty Trend Comparison

The reduction in Fired Duty is shown here and averages 7.34%, following the application of
ceramic coatings to the process tubes and refractory surfaces. This matched the calculated
performance benefits exactly.

F-2603 - Fired Duty Trend

After Coating

11.50
11.00
10.50
10.00
9.50
9.00
8.50
8.00
7.50
7.00
6.50
6.00

3.
80
4.
70
5.
10
5.
17
5.
23
5.
43
5.
59
5.
70
5.
75
5.
79
5.
82
5.
88
5.
93
6.
07
6.
17
6.
22
6.
25
6.
32
6.
56

Fired Duty (Mkcal/h)

Before Coating

Absorbed Duty (Mkcal/h)

Ceteks ceramic coating systems have been applied very successfully to many different process
heaters worldwide. The following table in Figure 8 summarizes the benefits obtained.
Figure 8: Typical Performance Benefits from the Application of Ceramic Coatings
to Process Heaters

Refractory

Tube

Productivity Benefit

Coating

Coating

SR Reformers

6.0 15.0

CCR Reformers

7.0 25.0

Crude Heaters

1.5 5.0

Vacuum Heaters

1.5 5.0

HDS/NHT Heaters

1.5 - 5.0

Other Heaters

Up to 20.0

Hydrogen Reformers

2.0 - 4.5

Ethylene Furnaces

1.5 - 4.0

10

Appendix I: Technical Introduction to Cetek Ceramic Coatings

Cetek Ltd. offers a service of applying coatings to process heaters, which have been shown to
improve the efficiency of radiant and conductive heat transfer to the feed. This is achieved using
two different types of coatings. Both are water-based ceramic coatings and have high
emissivities. One type is applied to clean process tubes to prevent oxidation and scale build-up.
The other type, a high emissivity coating that is applied to the refractory surface, is designed to
improve the radiant heat transfer to the tubes from the refractory.
Process Tube Coating Technology
The rate of heat transfer by conduction through the tube wall is calculated by the following
equation:

k(To-Ti)
Q = 2
2.3log(D0/Di)
T0 and Ti are the outer and inner tube wall temperatures, of internal diameter Di and outer
diameter D0. k is the coefficient of thermal conductivity for the material from which the tube
is formed.
When a tube is clean, the value for k is 29.08 W/moK. When the tube becomes oxidized and
only 1.6mm of scale is formed, the value for k drops to 15.02 W/moK. It is obvious that the rate
of heat transfer by conduction is therefore reduced to a third of the original level. This means that
either too much fuel is being used to push T0 up to allow for the poor conductivity, or the unit
becomes a bottleneck, unable to process sufficient feed.
Ceramic coating, applied to a clean new tube or cleaned old tube, will maintain the value for k
at 28.40 W/moK. The result is an ability to run the process at very close to optimum levels, with
no penalty from excessive fuel use. Alternatively and more interestingly, it is possible to fire the
unit harder and obtain significant increases in throughput.

11

When a new, clean tube is installed, the emissivity of the surface is low; around 0.6. At this level,
it is not an efficient absorber of radiant energy. When the tube becomes oxidized, however, the
emissivity increases to around 0.88. At this level, the surface becomes much more efficient at
absorbing radiant energy, but this is only a short-lived situation, until the oxide layers develop
and produce the insulating effect, described above. Cetek Ceramic Coatings provide a permanent
emissivity of 0.92, thus significantly improving the radiant heat absorption of a clean tube, or
maintaining the absorption levels of an oxidized surface without the attendant problems from
oxidation.
High Emissivity Refractory Coating
In a process heater, thermal energy developed by burning a fuel/air mixture is transferred to the
feed by three processes; conduction, convection and radiation. All three are employed
successfully, but above 600C, the radiant heat transfer mechanism is dominant.
In the radiant section of a process heater, much of the radiant energy is transferred from the
burners to the process tubes via the refractory surface. The surface receives the radiant energy
and transmits it back to the tubes. The efficiency with which it achieves this is related to the
emissivity of the refractory surface. The quantity of heat absorbed and re-emitted from a surface
is calculated from the following equation:

Q = Ae
T4
A is the surface area, e is the emissivity, is the Stefan Boltzman Constant and T is the
temperature. A perfect radiator, or black body has an emissivity equal to 1. In a steady state, the
amount of heat absorbed by a surface is also related to the emissivity; a perfect radiator will
absorb all radiation striking it.

12

The emissivity of different types of refractory surfaces varies greatly, as can be seen in Figure 9.
Figure 9 Emissivity Values of Various Refractory Surfaces

Typical Emissivity of Refractory Linings at 1000C

0.20

0.45

0.40

0.60

0.60

0.65

Emissivity

0.80

0.92

1.00

0.00
Cetek
Refractory
Coating

Castable

Insulating Fire Ceramic Fiber

Brick

At process heater operating temperatures, new ceramic fiber linings, for example, have emissivity
values of around 0.4. Insulating fire brick (IFB) materials have emissivity values around 0.6.
These materials have been designed with structural considerations and insulating efficiency as the
primary requirements. Cetek Ceramic Coatings, however, with emissivity values of above 0.9
were designed to have permanent high emissivity that does not decrease with temperature over
the range shown in figure 9.
The emissivity property of a surface can greatly affect the efficiency of heat transfer. There are
two factors that 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.
All materials absorb and re-radiate energy differently. In the visible spectrum this is readily
understandable as differences in color. In the infrared, the effects are the same, but not so
immediately apparent. The chart shown in Figure 10 shows energy spectra for two major
components of the combustion products of methane, water vapor and carbon dioxide. They are
compared with the spectrum of a perfect radiator, or black body, at the same temperature.
13

Figure 10 Energy Spectra of H2O and CO2 as Compared to a Black Body

Spectral distribution of radiation emitted

by a black body at temperature 1353K

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.
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 gases, resulting in wasted energy lost to the stack.

14

In typical process heaters, refractories with emissivity values from 0.45 to 0.60 are typically used.
The emissivity values are brought up to over 0.9 with the application of Cetek Ceramic Coatings,
which improves the radiant efficiencies significantly. Additionally, there are other benefits from
the use of the Cetek Coating systems, which include improving the surface durability of the
refractory, especially with IFB and more so with ceramic fiber. This serves to prevent fiber loss
through hot gas abrasion from the flame and there will be no resulting deposition in convection
sections or loss through the stack to the environment.
Environmental Improvements: NOx Emissions Reduced
Environmental considerations are also becoming increasingly important. Cetek Ceramic Coatings
have been proven to have a very beneficial effect on NOx emissions, through the reduction in
Fuel NOx and Thermal NOx. Because the radiant energy is not so easily absorbed by the
heater atmosphere, the super-heating effect found with lower emissivity linings is virtually
eliminated. Independent measurements of NOx emissions after the application of coatings have
shown reductions from 20% to 50%.
The result after the coating is applied allows the best insulation materials with optimum
construction properties to additionally provide exceptional radiative heat transfer characteristics.

15