Que: As India strengthens its position as a global refining hub, what are the most critical efficiency and asset-reliability challenges Indian refiners are facing today?

Ans: Indian refiners are operating some of the most complex and highly utilised assets in the world. Today’s key challenges focus on managing energy efficiency losses in fired heaters, controlling high tube metal temperatures and extending the life of ageing infrastructure while maintaining high throughput.

Many heaters were originally designed for lighter feeds and lower operating severity. Today, they are handling heavier crudes, working at higher utilisation, and operating under stricter safety and emissions expectations. This combination places significant stress on fired heaters, where even small inefficiencies can quickly lead to higher fuel consumption, increased emissions and growing reliability risk.

Que: IGS recently delivered up to 10 percent productivity gains and over USD 4 million in annual energy savings for a major Indian refinery. What were the key issues identified, and how did IGS address them?

Ans: The refinery was experiencing a gradual loss of heater efficiency, driven by poor radiant heat transfer, rising stack temperatures, and localised high tube metal temperatures. Together, these issues pushed the operators to run more conservatively and increase fuel firing to maintain performance.

Rather than replacing the equipment, IGS focused on restoring heat-transfer effectiveness and stabilising tube temperatures. By addressing surface conditions and balancing heat-flux distribution, the heaters were able to transfer the same duty with lower firing rates and more uniform temperatures. The result was clear and measurable gains in fuel efficiency, improved throughput capability and a more stable operating window.

Que: How did solutions such as Cetek® high-emissivity coatings and Hot-tek™ online repairs improve fired heater performance while minimising operational downtime?

Ans: Both solutions are designed to fit the realities of refinery operations by improving performance without the need for extended outages.

Cetek® high-emissivity coatings enhance radiant heat absorption, allowing heaters to achieve the required duty at a lower and more uniform tube metal temperatures. This reduces hot spots, slows coke formation, and improves overall heater efficiency.

Hot-tek™ online repair technology allows localised damage or thinning to be addressed in situ, avoiding full shutdowns or tube replacements. Together, these solutions help refiners recover performance, reduce operational risk, and extend run length while keeping units online.

Que: The project achieved a sub-six-month payback period. How important is clear ROI in accelerating the adoption of advanced surface protection technologies in India?

Ans: In India, a clear return on investment is essential. Whether it is a PSU operator or a private refiner, any technology must demonstrate tangible benefits.

Adoption accelerates generally when two things are true: refiners see impacts clearly, whether it's fuel savings, avoided downtime, or deferred capital replacement, and when those benefits translate into a payback measured in months rather than years. In many cases, the decision is less about innovation and more about risk management and controlling costs. Strong ROI simplifies that decision.

Que: With ageing infrastructure and rising energy costs, how do IGS technologies help refiners extend asset life while improving energy efficiency and sustainability?

Ans: The two objectives go hand in hand. Lower and more uniform tube metal temperatures directly reduce creep damage and extend tube life, while improved heat transfer lowers fuel consumption and emissions.

By protecting surfaces, restoring efficiency, and addressing damage early, refiners can safely operate assets beyond their original design life without compromising reliability. This approach reduces capital spend, lowers energy intensity, and supports sustainability targets, all without major modifications to existing equipment.

Que: Looking ahead, how do you see advanced surface engineering and asset-optimisation technologies shaping the future of India’s refining and petrochemical sector?

Ans: As assets age and operating severity continues to increase, surface engineering will become a core part of refinery strategy, and it will no longer be just a maintenance solution.

Refiners will increasingly rely on technologies that extend equipment life, improve energy efficiency, and reduce unplanned outages. Combined with stronger monitoring and data-driven maintenance, it will help Indian refineries remain competitive, reliable, and energy-efficient as global standards continue to rise.