For more information or to receive a quote, please fill out our contact form or contact the market manager directly:

Tim Connors: +1-518-436-1263 Ext. 105

StaBlox™ Flue Gas Reformer Tunnel System

stablox flue gas reformer tunnel systemThe patented Blasch StaBlox™ reformer flue gas tunnel system is a versatile, mechanically stable system consisting of a series of stackable, interlocking blocks. Unlike traditional flue gas reformer tunnels, which rely on mortar for mechanical integrity, and typically fail as a result of multiple thermal cycles and poorly performing expansion joints, the StaBlox system is designed to fit together in a mortar-free assembly that can easily and accurately accommodate for any thermal growth. 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. All StaBlox components are fully customizable allowing for any situation or unit.


Mechanical Stability

The unique geometry and advanced mating features of the blocks in the base, walls, tie-rods, and structural lid of the StaBlox Tunnel System allows for the assembly of complete tunnels in hours instead of the days required to fabricate a tunnel using traditional brick and mortar techniques. The highly engineered design also reduces overall mass by 60% while maintaining structural integrity.

Other mechanical advantages include, but are not limited to:

  • Prefired components/no mortar required/no cure-out
  • Expansion joints designed into every block
  • Improved structural reliability results in less distortion and cracking
  • Lower mass means less heat storage and more even cooling
  • Elimination of buttresses means tunnels may be wider

Process Improvement

With orifice inserts, BD Energy Systems’ patented TOP™ technology may be implemented to provide near-uniform flow along the length of each tunnel, promoting even heating and reducing tube hotspots.

Other process improvements that your plant can expect to achieve include, but are not limited to:

  • Reduction of methane slip of 2%-3% provides options for plant operations.
  • –   Improved efficiency in methane conversion can provide significant savings in feedstock costs
  • –   In situations where the plant is bottlenecked, the reduction in methane slip can result in a significant increase in plant capacity.
  • Improved uniformity results in more uniform tube life, improved reliability of high-temperature components.
  • Improved uniformity results in less need for individual burner adjustment to address high TMTs.
  • Reduced pressure drop across the tunnel system
  • –   Greater allowable interior tunnel width
  • Increased tube reliability – Increased tunnel reliability
  • –   Fewer emergency shutdowns – process safety improvement
  • Improved SNCR NOx reduction performance

Download the Blasch Precision Ceramics and BD Energy Systems brochure.

The same base material and distributed expansion technology behind the StaBlox system have been saving Blasch customers money in various high-temperature combustion applications for decades. Tighter temperature control leads to greater conversion efficiency, and that means more product for the same amount of fuel or less fuel for the same amount of product, and less fuel means lower carbon emissions. Reduce natural gas consumption by reducing methane slip between 1%-3%, creating more uniform temperature distribution. The reduction in natural gas consumption results in substantial savings per year, not including equivalent or larger savings in carbon tax reductions or credits.

Watch this short video to see how Blasch’s fully engineered and stackable StaBlox parts can be installed orders of magnitude faster than traditional brick and mortar tunnels. The installation of a Blasch StaBlox flue gas reformer tunnel system includes:

– Lightweight bricks interlocking together with built-in expansion gaps
– Hollow, but strong engineered lids locking into the sidewall, providing the necessary protection from impact and cracking.
– Complete moisture less design, requiring no drying or curing.


In this recorded presentation, learn about the mechanical and reliability features of Blasch’s StaBloxTM, and the process improvements of BD Energy’s TOPTM technology, including:

– Reduction of methane slip of 2%-3% provides options for plant operations.
– Increased tube reliability
– Potential to incorporate an in-tunnel SNCR NOx reduction system


Blasch - Stablox_3D Animation-HD thumbnail

In this short video, take a look at how quickly the StaBloxTM Flue Gas Reformer Tunnel system can be put together in comparison to a traditional brick-n-mortar tunnel.



The overall influence of tunnels on the flue gas flow in a steam methane reformer has been modeled and documented, and the concept that running a reformer without tunnels can decrease overall efficiency is well understood in the industry. In this 30-minute webinar, learn about the Blasch modeling methods and findings that show the significant efficiency and improved financial impacts.



In this on-demand webinar, presented with, Senior Global Director Uday Parekh discusses how ceramic solutions like Blasch VectorWallTM and StaBloxTM boost the reliability and performance of your hydrogen production and sulfur recovery plants with benefits including:

– Higher plant reliability and much longer run-lengths
– 60-90% faster installation times
– Annual energy savings of several hundred thousand dollars for SRUs, and lower emissions


In this video, watch and see how easy it is to stack the StaBlox interlocking blocks into place to build the tunnel system.




U.S. Patent #10,605,456

Product Information Sheets

Materials for StaBlox™ Flue Gas Reformer Tunnel System


Contact Us

Thank you for your interest in Blasch Precision Ceramics. For more detailed information concerning your specific application, please give us a call or complete the form below. One of our technical representatives will respond as quickly as possible.

Contact Us

Thank you for your interest in Blasch Precision Ceramics. Please complete the form below and we will respond as quickly as possible.


This website uses cookies

We use cookies to personalize content and ads and to analyze our traffic. We also share information about your use of our site with our advertising and analytics partners who may combine it with other information that you’ve provided to them or that they’ve collected from your use of their services. You consent to our cookies if you continue to use our website.

Show Details OK
Cookie Declaration
About Cookies
Necessary (2)
Preferences (1)
Statistics (3)
Marketing (2)
Unclassified (2)

Necessary cookies help make a website usable by enabling basic functions like page navigation and access to secure areas of the website. The website cannot function properly without these cookies.

PHPSESSIDblaschceramics.comPreserves user session state across page requests.SessionHTTP, app-ab16.marketo.comUsed to distribute traffic to the website on several servers in order to optimise response times.SessionHTTP

Preference cookies enable a website to remember information that changes the way the website behaves or looks, like your preferred language or the region that you are in.

_mkto_trkBlasch CeramicsTrack website statistics and email marketing2 yearsHTTP

Statistic cookies help website owners to understand how visitors interact with websites by collecting and reporting information anonymously.

_gablaschceramics.comRegisters a unique ID that is used to generate statistical data on how the visitor uses the website2 yearsHTTP
_gatblaschceramics.comUsed by Google Analytics to throttle request rateSessionHTTP
_gidblaschceramics.comRegisters a unique ID that is used to generate statistical data on how the visitor uses the website.SessionHTTP

Marketing cookies are used to track visitors across websites. The intention is to display ads that are relevant and engaging for the individual user and thereby more valuable for publishers and third party advertisers.

_hjIncludedInSampleblaschceramics.comDetermines if the user's navigation should be registered in a certain statistical place holder.SessionHTTP
ads/ga-audiencesgoogle.comUsed by Google AdWords to re-engage visitors that are likely to convert to customers based on the visitor's online behaviour across websites.SessionPixel

Unclassified cookies are cookies that we are in the process of classifying, together with the providers of individual cookies.

_conv_datablaschceramics.comUnclassified1 yearHTTP
_orig_datablaschceramics.comUnclassified1 yearHTTP

Cookies are small text files that can be used by websites to make a user’s experience more efficient.

This site uses different types of cookies. Some cookies are placed by third party services that appear on our pages.

You can adjust your browser settings to disable cookies and to block tracking of your browsing data. By continuing to browse our website with cookies and tracking enabled, you indicate your consent to the use of those cookies and tracking software.

Learn more about who we are, how you can contact us and how we process personal data in our Privacy Policy. To change your cookie permissions, view our Cookie Declaration page.

Your consent applies to the following domains:,,,

Cookie declaration last updated on 5/30/2018