I-Cover™ for Reformer Tubes

During shutdowns and maintenance, furnaces cool down, causing reformer tubes that normally protrude above the furnace roof to retract just below the furnace surface. Conventional insulation methods cannot be applied during this phase due to the lack of exposed surfaces.

Once operations resume, the tubes expand and become exposed to extreme temperatures exceeding 400°C, leading to significant heat loss and increased ambient temperatures in the furnace roof area, creating an unsafe working environment.

Furthermore, conventional insulation methods are rigid, wear off quickly, and are difficult to remove for inspection, making maintenance cumbersome.

KLAY EnerSol’s I-Cover™  insulation solution is specifically designed to improve heat uniformity, prevent hot spots, and extend the lifespan of reformer tubes in industries such as Ammonia, Methanol, Fertilizer, and Hydrogen production. By optimizing thermal distribution and reducing heat loss, the I-Cover™  ensures higher efficiency, lower maintenance costs, and improved operational reliability.

I-Cover™  provides a complete insulation solution for reformer tubes, including inlet tubes, hairpin sections, bottom outlets, and other critical areas. Engineered to withstand extreme operating conditions, I-Cover™  reduces heat loss, minimizes thermal stress, and extends reformer tube life by ensuring uniform heat distribution.

Unlike conventional insulation, which can be rigid and difficult to remove, I-Cover™  is designed for flexibility, allowing easy removal for maintenance and inspection without compromising performance. Additionally, we offer bespoke insulation solutions for specific components, such as small elbows, tube bends, and high-heat exposure points, ensuring targeted protection without the need for full tube coverage.