StaBlox™ Compromised Tunnel Replacement for Top-Fired Steam Methane Reformer Flue Gas Tunnels
Patented Blasch StaBlox are a superior alternative to traditional fireclay bricks when replacing a collapsed or compromised flue gas tunnel, offering several key advantages including:
• Mortar-free assembly for easier, more accurate thermal growth accommodation
• Faster assembly compared to traditional bricks
• Common sizes available for immediate delivery
Unlike conventional brick tunnels that rely on mortar and often fail due to thermal cycles and poor expansion joints, the StaBlox system fits together without mortar. Its lightweight, structurally stable roof assemblies are highly resistant to high-temperature creep, making them ideal for applications in steam reforming furnaces and ammonia reformers.
U.S. Patent #10,605,456
StaBlox™ offers a quick-install, mortar-free solution for traditional brick tunnels, enhancing thermal resistance and reducing maintenance.
Experience faster recovery from failures and minimize losses.
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MINIMIZING DOWNTIME NOW
Quick Assembly: The interlocking design of StaBlox blocks allows for rapid and easy assembly, enabling reformer tunnels to be built in hours instead of days. This process doesn’t require skilled masonry work, which minimizes downtime and quickly gets your top-fired reformer operational.
Pre-Fired Components: StaBlox system components are pre-fired and ready for immediate use upon installation. The interlocking design eliminates the need for mortar and additional curing, significantly reducing the critical path of your foundry work, especially for furnace tunnels and flue gas collection systems.
In Stock: StaBlox blocks and various common sizes of lids and bases are available for immediate shipment. This ensures quick responses to unexpected situations and avoids the delays associated with traditional brick lead times.
LESS DOWNTIME IN THE FUTURE
Mortar-Free Assembly: Traditional flue gas tunnels often fail due to mortar cracking and deteriorating under thermal stress. The StaBlox system eliminates this issue with a mortar-free assembly of interlocking blocks, increasing tunnel longevity and reducing maintenance.
Integrated Expansion Joints: StaBlox blocks have built-in expansion joints that accommodate thermal growth, reducing structural distortion and cracking. This ensures the tunnels remain stable and operational for longer periods, minimizing maintenance frequency and extent.
Reduced Overall Mass: The StaBlox system cuts tunnel mass by up to 60%, leading to more even cooling and enhanced thermal efficiency. This reduction decreases thermal stress on components, mitigating wear and tear and the need for maintenance in steam methane reforming operations.
If you have a full rebuild in the future, the Blasch StaBlox reformer flue gas tunnel system is a fully customizable system, with all the mechanical benefits discussed above, plus the process improvements from BD Energy Systems’ patented TOP technology. Installing a tunnel now is an investment, eliminating the need for replacement during a full rebuild. Learn more about the improvements you can expect from the full StaBlox system here.
Product Information Sheet
RELATED RESOURCES
Webpage: StaBlox™ Flue Gas Reformer Tunnel System for Top-Fired Steam Methane Reformer Flue Gas Tunnels
Enhanced efficiency and performance with the Blasch StaBlox Flue Gas Reformer Tunnel System, in collaboration with BD Energy Systems' patented TOP™ technology. Engineered orifice inserts ensure near-uniform flow along each reformer tunnel, promoting even heating and reducing tube hotspots. Benefits include a 2-3% reduction in methane slip, lower pressure drop, more uniform tube life, and fewer emergency shutdowns. This revolutionary solution optimizes full tunnel sets, delivering significant process improvements for steam methane reforming and enhancing overall syngas production.
Presentation: New Steam Methane Reformer Technology for Improved Performance
In this presentation, Jeff Bolebruch, Vice President of Global Strategic Business Development at Blasch discusses the mechanical design and reliability features of the Blasch StaBlox™ Flue Gas Reformer Tunnel System. Taken from the paper presented at the 2020 Nitrogen + Syngas Conference at The Hague, this presentation also incorporates the process improvements thanks to BD Energy Systems, LL Tunnel Optimal Performance (TOP™) Technology.
Video: StaBlox Drop Test
In this video, Blasch engineers replicate this phenomenon by dropping large chunks of refractory on our engineered StaBlox™ lids. Our lids are extremely lightweight but structurally engineered to provide impact resistance and stability.
Video: Understanding the Financial Impact of a Collapsed Flue Gas Tunnel in a Top Fired Steam Methane Reformer
In this webinar, learn about Blasch's innovative modeling methods and findings on the significant efficiency and financial impacts of using tunnels in a steam methane reformer. The webinar demonstrates how the presence of reformer tunnels enhances flue gas flow, improving overall efficiency. It provides insights into how running a reformer without tunnels can decrease efficiency, underscoring the importance of proper tunnel design for optimizing syngas production.
Video: StaBlox Build Demonstration
In this video, watch and see how easy it is to stack the StaBlox interlocking blocks into place to build the reformer tunnel system. The demonstration showcases the efficiency of the StaBlox design, making installation quicker and more reliable compared to traditional brick-and-mortar tunnels.
Presentation: Understanding the Operating Impact of a Collapsed Flue Gas Tunnel in a Top Fired Steam Methane Reformer
This presentation focuses on the effects of operating a reformer after removing just a single tunnel, leaving the rest in place. The resultant flue gas flow field is analyzed, looking at temperature profiles, residence time distribution, areas of re-circulation, and predictive conversion effectiveness in the context of steam methane reforming.
