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Flue Gas Reformer Tunnel System: StaBlox™

The patented Blasch StaBlox™ flue gas reformer tunnel system is a versatile, mechanically stable system consisting of a series of stackable, interlocking blocks.

The StaBlox system allows for an extremely fast, easy installation as compared to conventional brick and mortar designs, while at the same time offering a much higher level of reliability with customizable blocks and highly engineered, mortar-free expansion joints.

Roof assemblies offer lightweight, structurally stable designs that are engineered to be much more resistant to the effects of high temperature creep than standard designs.

Flue Gas Reformer Tunnel System Advantages

Several advantages can be expected when utilizing a StaBlox System including:

  • Greatly enhanced speed of tunnel construction, substantially reduced downtime and overall installation cost
  • Improved structural reliability resulting in less distortion and cracking which reduces concerns associated with subsequent changes in flow patterns, ultimately resulting in preserved conversion efficiency and prevention of preliminary tube deterioration
  • Elimination of external buttressing which enables a smooth exterior tunnel geometry, resulting in improved flow uniformity, reduced pressure drop and lower temperature gradients around the tubes
  • Lower mass, which means less heat storage and more even cooling

With orifice inserts, BD Energy Systems’ patent-pending TOP™ technology can be implemented to provide near uniform flow along the length of each tunnel, promoting even heating and reducing tube hotspots, discussed further in the July/August 2016 issue of Nitrogen + Syngas.

The same base material and distributed expansion technology behind the StaBlox system has been saving Blasch customers money in various high temperature combustion applications for decades.

Product Videos

Blasch - Stablox_3D Animation-HD
The Blasch Precision Ceramics StaBlox flue gas tunnel system and a traditional brick wall are installed side by side - showing the efficiency that can be realized with this advanced system
Watch as Blasch engineers demonstrate assembly of our StaBlox™ flue gas tunnel system

Product Information Sheets


  • The ability to design and construct tunnels using new highly-engineered refractory shapes is new to the industry and could be the answer to improving flue gas tunnel effectiveness and improving catalyst tube reliability and longevity.
  • Sales Engineer Joe Quintiliani and Applications Engineer William Russell discuss how the reliability of primary reformer flue gas tunnels can be improved through the application of engineering design and improved material selection in the July – August issue of Nitrogen + Syngas

Materials for Flue Gas Reformer Tunnel System: StaBlox™