High Performance Insulation for Delayed Coker Units

Pyrogel® HPS Insulation Can Help Increase Value Throughout the Coking Process

Delayed coker units (DCUs) are the unsung heroes of refineries, transforming low-value residual oil feed into profitable heavy coker gas oil (HGCO). Maintaining optimum temperatures throughout the coking process is key, and conventional insulations are not cut out for the job. These insulations often fail, self-removing due to high temperatures and asset movement during the cyclical process.

Pyrogel® HPS was engineered for a delayed coker’s harsh environment. Whether using a panel system or birdcage design, Pyrogel conforms to the drum, helping achieve target outlet temperatures and maximizing liquid yield.


  • Maximize Liquid Yield While Minimizing Recycle Rates

    Pyrogel HPS supports maximum HCGO recovery by reducing post-quench heat loss in the vapor line and lower section of the coker fractionator.

  • Lower Maintenance Costs

    Pyrogel can be removed and reinstalled during routine inspections and maintenance events, eliminating the cost of replacing material each time.

  • Decrease Operating Costs

    Insulating the feedline with Pyrogel HPS reduces heat loss, and limits general wear to the furnace.

  • Maintain Process Stability

    Insulating overhead lines prevents unwanted heat loss and process instability during inclement weather conditions.

  • Optimize Infrastructure

    Achieve superior thermal performance in less space, which opens the possibility of super-insulating for higher liquid yield. 2” (50 mm) of Pyrogel HPS can provide the same level of heat conservation as 6” (150 mm) of mineral wool.

Project Profiles

Reinsulation of Delayed Coker Feedlines Reduces Maintenance

A Midwest refinery was experiencing premature coking in their feedline. This came just two years after insulating the feedline with calcium silicate. An inspection determined the incumbent insulation had failed, causing cold spots in the feedline. If left unchecked, the line would require pigging every few weeks. The plant engineer elected to replace the degraded calcium silicate insulation with Pyrogel HPS.

The Result – Decreased the pigging frequency required for the feedline, saving an estimated $600,000 per year in maintenance costs!


Insulating Overhead Line Improves Process Stability at Midwest Refinery

The overhead lines at a Midwest refinery were historically left uninsulated because of its requirement for rapid heat loss. However, this led to performance issues when there was strong wind, rain, or snow. The decision was made to insulate the overhead lines during its turnaround, so the speed of installation was a top priority. The facility selected Pyrogel HPS because of its proven success in other areas of the facility as well as how quickly it could be installed.

The Result – 20mm of Pyrogel HPS was used to insulate 150ft of overhead lines with 24in diameter in only 3 days!


Discover How Pyrogel HPS Helps You Avoid 5 Mistakes When Optimizing Your Delayed Coker’s Performance.