IGS launches Rovex, a next-generation robotic cleaning technology for fired heater efficiency
IGS, a provider of asset integrity and energy efficiency solutions for energy, power and heavy industry, has launched Rovex™, its next-generation robotic cleaning technology for fired heater convection sections.
Developed through extensive in-house research and field deployment, Rovex is a compact remotely operated vehicle (ROV) designed to improve access to complex tube geometries and remove heavy fouling with precision, helping to restore efficiency to design conditions.
At a time when the industry is under significant cost pressures, the technology can drive significant savings, given just 1% inefficiency in a steam cracker can cost a petrochemical plant several million dollars per year. In large crackers, the impact can exceed $10 million annually when yield, energy, and lost production are included.
Rovex’s fully remote operation eliminates the need for confined-space entry, improving safety, while capturing high-definition visual data during cleaning to enhance operational precision. Integrating robotic mobility, patented lance technology, and digital performance verification, the system supports measurable improvements in efficiency, reliability, and emissions reduction through effective cleaning of stubborn deposits on furnaces and fired heaters.
“Rovex reflects our continued focus on combining engineering and robotics to improve maintenance outcomes,” said Eric Duvekot, VP Engineering at IGS. “It provides a practical way for operators to address fouling safely, before it leads to lost revenue, while achieving consistent and measurable performance improvements.”
Compared to traditional water jetting or manual techniques, which typically access 20-30% of fouled surfaces and can risk asset damage, Rovex enables consistent cleaning coverage reaching over 90% of the surface area.
Each Rovex deployment is supported by a thermal performance evaluation, enabling IGS engineers to quantify efficiency losses and target cleaning activity. This approach allows performance improvements to be measured and verified.
Recent field applications have demonstrated the system’s impact. At Oman Methanol Company, Rovex restored convection section performance, reducing stack temperature by 93.2°F / 34°C and improving fuel efficiency by 1.8%, enabling a return to full production capacity while reducing fuel consumption and associated emissions.
Rovex supports broader industry priorities around decarbonization and digitalization by improving heat transfer efficiency, reducing fuel demand and associated CO₂ emissions, and enabling more data-driven maintenance strategies.
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