2020 Virtual AIChE Annual Meeting

(517k) Engro’s Innovative Approach for Sustained Plant Operation with 25+ Years Life of Reformer Radiant Tubes

Authors

Asif, U. - Presenter, Engro Fertilizers
Jameel, K., Engro Fertilizers Limited
Being the energy intensive unit, primary reforming furnace is the host for massive heat generation needed to cater the heat requirement of endothermic reforming reaction for the production of syn gas. With being among the high temperature zone, the reliability of furnace equipment is imperative to sustained plant operation as the upset not only is a risk to business sustainability but the failure of furnace equipment poses catastrophic risk to the safety of assets and personnel. The reliable operation of furnace equipment becomes more challenging as the plant ages.

This paper describes the challenges faced in sustaining plant operation where the furnace tubes surpassed double the recommended life. The double terrace induced draft furnace designed by foster wheeler is a primary reforming unit at a vintage ammonia plant commissioned 1967. The furnace radiant tubes were last replaced in 1992 and have seen a life of two hundred thousand operating hours against the recommended life of one hundred thousand hours.

The secret of double the recommended useful life lies in the stringent inspection regimes and best operating practices. The efforts to ensure the tubes in operable conditions range from apt temperature monitoring regimes to tubes inspection in terms of creep measurement and diametric growth. The paper describes in detail the reliability measurements along with the challenges faced to sustain extended life of reformer tubes spanning over 28 years.