Case Study · Hydrocarbon & Chemical
Ammonia Reformer High Emissivity Coating: 5% More Production at CSBP
| Industry | Hydrocarbon & Chemical |
|---|---|
| Asset | Primary ammonia reformer |
| Customer or location | CSBP, Kwinana, Australia |
| Products used | Emisshield ST-17.2 and DI-1 |
| Headline metric | +5% ammonia production |
| Secondary metric | Bridge wall below alarm setpoint |
| Also measured | ROI 6 to 8 months |
CSBP coated the ceramic fiber, insulating firebrick, and burner blocks of its natural-gas-fired primary ammonia reformer with Emisshield ST-17.2 and DI-1. Bridge-wall temperatures dropped below the alarm setpoint, emergency shutdowns stopped, ammonia production rose 5%, and energy and maintenance costs fell, with a 6 to 8 month return on investment.
01
What was the challenge?
Radiant box temperatures exceeded the alarm setpoint above 800°C, triggering repeated emergency shutdown alarms and raising concern about damage to the process tubes. CSBP needed a way to lower bridge-wall temperatures while improving production and energy efficiency.
02
What was applied?
Emisshield ST-17.2 and DI-1 were applied to the ceramic fiber, IFB, and burner blocks in the reformer's east and west chambers, covering the radiant walls, end walls, roof, transition ducting, and walls up to the top of the convection section. The furnace operates at about 1,000°C, the heat exchanger at about 500°C.
03
What were the results?
| Metric | Before | After |
|---|---|---|
| Bridge-wall temperature | Above alarm setpoint (>800°C) | Below alarm level |
| Emergency shutdowns | Repeated | Prevented |
| Ammonia production | Baseline | +5% |
| Energy and maintenance cost | Baseline | Significantly reduced |
| Ceramic fiber modules | Shrinkage, dusting, joint formation | Longer life, reduced shrinkage |
| Return on investment | 6 to 8 months |
The coating re-radiated heat away from the bridge wall, keeping temperatures below alarm levels, while balanced heat across the radiant box raised ammonia output. Ceramic fiber modules lasted longer with less shrinkage, dusting, and joint formation. CSBP reduced fuel consumption, improved production, and met its environmental sustainability goals.
04
Why did it work?
Raising the emissivity of fiber, IFB, and burner blocks converts the radiant box from a reflector into a re-radiator aimed at the process tubes. More energy reaches the tubes at the same firing, so gas leaves the radiant section cooler (lower bridge-wall temperature) and the plant can either save fuel or raise throughput. See Production Increase and How Emissivity Works.
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