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

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 benefits can be expected when utilizing a StaBlox System including:

  • Run the reformer temperature within approximately +/- 2% of the design temperature
  • Reduction of methane slip
  • Extension of catalyst tube life by reducing stress cracking
  • Extension of catalyst life by avoiding carbon fouling
  • Improvement of methane to hydrogen conversion
  • Efficiency improvements result in a better CO2 footprint for specified emitters
  • Increased production due to improved efficiency of conversion 
  • Fast tunnel construction, substantially reduced downtime and overall installation cost
  • Improved structural reliability results in less distortion and cracking
  • Reduced concerns associated with subsequent changes in flow patterns, ultimately resulting in preserved conversion efficiency and prevention of preliminary tube deterioration
  • Elimination of external buttressing enables a smooth exterior tunnel geometry, resulting in improved flow uniformity, reduced pressure drop and lower temperature gradients around the tubes
  • Lower mass 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

Download the Blasch Precision Ceramics and BD Energy Systems brochure.

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
Compare StaBlox flue gas tunnel and a brick wall side by side.
Watch as Blasch engineers easily assemble a 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.
    Reformer Furnace Revamp
  • Learn 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
    Improving Flue Gas Tunnel Reliability

Materials for Flue Gas Reformer Tunnel System: StaBlox™


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.


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