investigation of heat lost and hotspot on module no.2 reformer burners in khouzestan steel company (ksc)

Annual maintenance of reformer module.2 in khouzestan steel company involved replacing floor tile refractories, but thermography scans detected radiation-type thermal leaks from the floor, burner bodies, and connections, with leaks likely originating under reformer headers. initial assessment confirmed the design's theoretical adequacy but recommended rearranging refractory layers. instead of replacing hot air line compensators, replacing all connections is advised to prevent convective heat transfer and raise reformer floor temperature. another solution involves altering burner geometry and optimizing refractory layer application to address leaks and enhance efficiency. additionally, the absence of suitable tools for vibrating poured refractory cement from the bottom part can lead to defects. simulations revealed changes in gas flow capacity enhancement, causing hot spots due to proximity of high-pressure fluid points with insulation defects. burner geometry complicates lower part insulation but facilitates heat transfer, prompting a change to a two-piece design to ensure refractory quality.