01
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
Why It Worked
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.
04
Summary of 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.