Mar-2025

Increase process efficiency and service life of syngas process equipment

The syngas industry plays a crucial role in producing essential materials like ammonia, methanol, hydrogen, and synthetic fuels. However, it faces significant operational challenges that impact efficiency, safety, and profitability.

Larry Emch, Sergei Merchev, John Bacon, Anton Korobeynikov
Integrated Global Services

Article Summary

These challenges arise from extreme operating conditions, high temperatures, high pressures, and exposure to corrosive materials, which accelerate wear and tear on critical equipment including, but not limited to, steam methane reformers (SMRs), heat exchangers, and CO₂ absorption towers.

As global regulations push for decarbonisation and stricter environmental compliance, syngas producers must find new ways to enhance energy efficiency and reliability while minimising their environmental footprint.

By implementing the best practices in this paper, syngas producers can reduce their energy consumption by 10-15%, significantly extend the life of their equipment, and avoid unplanned shutdowns that can cost millions of dollars.

The syngas industry continues to experience robust growth, with the global syngas market projected to expand significantly due to increasing demand for methanol, ammonia, and other downstream products. According to a report by Grand View Research, the global syngas market demand was estimated at 230.05 million Nm³/hr in 2023 and is expected to grow at a compound annual growth rate (CAGR) of 11.3% from 2024 to 2030.

Rising demand for cleaner alternatives fuels is expected to drive market growth, coupled with growing government support for clean energy initiatives, including tax credits and renewable portfolio standards, incentivises investments in syngas technologies.

In addition, stringent environmental regulations, such as the Clean Air Act and carbon emission reduction targets are driving demand for cleaner alternatives in various industries. Syngas technology’s ability to utilise diverse feedstocks – including natural gas, biomass, and even captured CO₂, positions it as a key enabler of both industrial sustainability and economic growth.

This white paper presents field-proven best practices that have delivered measurable improvements in cost savings, reliability, and environmental performance for syngas producers worldwide. Drawing from decades of experience in corrosion management and energy efficiency optimisation, these solutions combine advanced alloy upgrade techniques with the latest efficiency measures, demonstrating success in autothermal reforming (ATR) and steam methane reforming (SMR) systems. By leveraging these solutions, syngas plants can reduce downtime, extend equipment life, and significantly lower energy costs, positioning themselves for sustained competitiveness in a rapidly evolving industry.

Each best practice in this guide is based on the collaboration between the client and Integrated Global Services (IGS®), with key findings and achieved results. Engineering recommendations are based on technologies developed and delivered by IGS as the sole applicator for these technologies and services.

Thermal efficiency in syngas technologies
Inefficiencies in heat recovery can significantly impact operational costs, increasing energy expenses by 10-15% – amounting to millions of dollars annually for larger operations. Modern heat recovery solutions, including refractory encapsulation in radiant zones and comprehensive cleaning of convective zones, can address these challenges while simultaneously reducing carbon emissions.

Through a detailed thermal efficiency audit, IGS evaluates fired equipment and delivers a comprehensive analysis including benefits, pricing, payback periods, scope, timeline, and optional maintenance considerations. This analysis is provided before any commitment from either the client or IGS. To ensure accountability and validate solution performance, IGS conducts thorough post-project analyses as a fundamental part of its client relationships.

In addition to creating a select line of solutions, IGS has also assembled and trained employee-based crews capable of installing these technologies anywhere in the world. IGS operations teams have completed more than 5,000 projects in more than 70 countries meeting both the rigorous safety standards and timely execution required by turnaround-based project work. This suite of global references points to decades of experience and validated technology.

Best Practice 1: Convection section efficiency: Improve throughput by restoring convection section efficiency
The IGS Tube Tech Convection Section ROV is a proven system for heavily fouled convection sections in Steam Methane Reformers (SMRs). Unlike traditional methods like water pressure lances or chemical cleaning, which often fall short in fully removing heavy fouling, this technology restores efficiency to near design levels with unmatched precision, safety, and reliability.

The IGS business model includes a review of design specifications, general arrangement drawings and current process data as part of a site visit to inspect the unit. This comprehensive approach creates the opportunity to consider the implications of utilising multiple technologies to regain optimal performance. In many cases, our recommendation provides affordable options compared to securing cap-ex funding for revamp options.

After a comprehensive review and detailed discussions with the client, the IGS thermal efficiency team recommend a scope and calculate a payback for the project. The combination of a meaningful payback and short project duration are typical for convection section applications. In the following case study, the optimal scope of the project was largely comprised of utilising the Tube Tech ROV fouling removal system.

Case Study 1: Tube Tech ROV restores efficiency at fertiliser plant
A fertiliser production plant was suffering from heavy fouling in the convection section of its primary reformer furnace. The efficiency had dropped well below design, negatively impacting operating parameters and throughput. Restoring the asset to near design efficiency during the upcoming turnaround was vital.

IGS implemented its Tube Tech ROV fouling removal system to deep clean between each row and throughout the bundles to dislodge excessive fouling. Even the fouling material deeply embedded in the coils was readily removed as confirmed by a Lancescope™ camera inspection before and after the work.

The patented rover equipped with a power lance was preprogrammed with the dimensional data of the tube bank ensuring maximum access to the surface area. IGS crews were able to access ~95% of the surface area, ensuring no collateral damage to refractory fiber side walls. The crew safely completed the scope within the quoted 48 hours.

Prior to the project the outlet stack temperature was running at 170°C, 30 degrees above the original design stack temperature. The client supplied post project operational data confirmed that the stack temperature was restored to 90% of design. CO₂ emissions were also reduced as less fuel is consumed to produce the same results.

Other best practices for keeping the convection section clean will be improving combustion air filtration and protecting ceramic fiber refractory with refractory encapsulation coatings.