1 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car

Giampiero Caronno
Sales Manager, Equipment Division
Foster Wheeler Italiana Spa
RRTC 22 & 23 September 2005
Fired Heaters
Enhancing Refinery Profitability
2 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Contents
How a fired heater works
Fired heater design basis the importance
of the heart of the unit
Parameters influencing fired heater operation
Maximization of process unit profitability
Improper operation
Example of revamping case studies
3 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
How a fired heater works
Balanced (forced) draft
Natural draft
S
t
a
c
k
C
o
n
v
e
c
t
i
o
n
R
a
d
i
a
n
t

s
e
c
t
i
o
n
s
e
c
t
i
o
n
Damper
Stack exit loss
Stack effect in
stack
Stack
effect in
convection
section
Burners
0.05
0.1 W.G.
draft.
Draft at
radiant
section
outlet, R
0
Negative pressure
0.05 0.1 W.G.
at top of radiant
section
Stack effect in
radiant section
Negative pressure Positive pressure
0
4 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Design Basis
Tailored design to meet design requirements
Main design parameters: efficiency and heat flux
Optimization between efficiency and cost
How many fired heaters have a proper design basis ?
How many fired heaters work in line with the design basis ?
5 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Parameters influencing fired heater operation
EFFICIENCY REDUCTION
EFFICIENCY REDUCTION
=
=
Heat Load
Heat Load
+
+
Excess Air
Excess Air
+
+
Fouling
Fouling
+
+
6 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Parameters influencing fired heater operation (*)
Higher heat flux
Reduced tube
life time
Reduced
efficiency
Heat load
(*) Based on: (*) Based on:
Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil LHV= 9500 Kcal/Kg
Fuel Oil Cost= 0.2 /Kg Fuel Oil Cost= 0.2 /Kg
430 400 C Stack temperature
62 (+20%) 52 Gcal/h Fired heater duty
77.2
67.36
75.5
82.12
% Fired heater
Efficiency
Gcal/h Heat fired
7 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Parameters influencing fired heater operation (*)
Excess Air
52 52 Gcal/h Fired heater duty
259,200
65.82
400
20
67.36
400
40
Yearly saving
Gcal/h Heat fired
C Stack temperature
% Excess air
33000 Extra Yearly
Cost
21 Kg/h Extra Fuel
2100 Kg/h Extra Air
(*) Based on: (*) Based on:
Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil LHV= 9500 Kcal/Kg
Fuel Oil Cost= 0.2 /Kg Fuel Oil Cost= 0.2 /Kg
8 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Parameters influencing fired heater operation (*)
Clean condition
Internal fouling
External fouling
52 Gcal/h Fired heater duty
/year Incremental fuel cost
/h Incremental fuel cost
7090 Kg/h Fuel fired
100,000 Hrs Tubelife
448 C Metal temperature
435 C Peak film temperature
400 C Stack temperature
77.2 % Heater efficiency
Clean
condition
52
464,000
58
7380
20,000
524
438
450
74.2
Internal
fouling
52
944,000
118
7680
100,000
456
441
500
71.3
External
Fouling
Fouling of
exchange surface
9 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Maximization of process unit profitability
Reduce utility Reduce utility
consumption consumption
Maximization
unit profitability
Minimize Minimize
operating operating
cost cost
Optimize Optimize
fired heaters fired heaters
performance performance
Reduce Reduce
emissions emissions
Increase Increase
capacity capacity
Maximize Maximize
on on- -stream time stream time
10 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Maximization of process unit profitability
Optimize Optimize
fired heaters fired heaters
performance performance Uniform conditions Uniform conditions
Optimize firing Optimize firing
Reduce Reduce
emissions emissions
Reduce firing rate Reduce firing rate
Replace burners Replace burners
Increase Increase
capacity capacity
Limited firing capacity Limited firing capacity
Limited heat transfer surface Limited heat transfer surface
Draft shortage Draft shortage
Flame impingement Flame impingement
High tube metal temperature High tube metal temperature
Firing control difficulties Firing control difficulties
Coke formation inside tubes Coke formation inside tubes
Reduce utility Reduce utility
consumption consumption
Add extra surface Add extra surface
APH installation APH installation
Cleaning surfaces Cleaning surfaces
Maximize Maximize
on on- -stream time stream time
Proper operation Proper operation
Maintenance schedule Maintenance schedule
Fired Heater components Fired Heater components
Minimize Minimize
operating operating
cost cost
Internal tube cleaning Internal tube cleaning
Fire cheap fuels Fire cheap fuels
Automatic devices Automatic devices
Instrumentation improvement Instrumentation improvement
11 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Maximization of process unit profitability (*)
Higher efficiency
Milder conditions at constant load
Possible increased fired heater load
Increase Increase
capacity capacity
Reduce utility Reduce utility
consumption consumption
24,400 28,000 Kcal/h m
2
Heat flux
83 70 % Fired heater efficiency
N.A.
393
33
46,000
1,243,000
387
33
46,000
/year Saving
C Peak film temperature
Gcal/h Fired heater duty
BPSD Topping capacity
Increase of convection surface
(*) Based on: (*) Based on:
Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil LHV= 9500 Kcal/Kg
Fuel Oil Cost= 0.2 /Kg Fuel Oil Cost= 0.2 /Kg
30,900
81
387
43
60,000
Increase of radiant surface
12 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Maximization of process unit profitability (*)
Installation of air preheating system
6,080 7,090 Kg/h Fuel fired
70,000 70,000 BPSD Topping capacity
90 77 % Fired heater efficiency
N.A.
40
52
1,620,000
20
52
/year Saving
% Excess air
Gcal/h Fired heater duty
Increase Increase
capacity capacity
Reduce utility Reduce utility
consumption consumption
(*) Based on: (*) Based on:
Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil LHV= 9500 Kcal/Kg
Fuel Oil Cost= 0.2 /Kg Fuel Oil Cost= 0.2 /Kg
Higher efficiency
Short payout period
13 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Maximization of process unit profitability
Reduce Reduce
emissions emissions
184 t on/y No
x
outlet (**)
250 mg/Nm
3
No
x
emissions (**)
442 t on/y No
x
outlet (*)
600 mg/Nm
3
No
x
emissions (*)
40 % Excess air
77.2 % Heater efficiency
H.I.
burners
low eff.
54
75
252
350
20
79
Low No
x
burners
56
90
253
400
20
90
Low
No
x
w/APH
(*) Fuel oil firing
(**) Fuel gas firing
Emission reductions
14 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Improper fired heater operation
Original
fired heater
design
Current
fired heater
conditions
Damper design
Low velocity
inside tubes
Old type
burners
Positive pressure
Uneven flow
distribution
Fouling on
heat transfer
surfaces
Air infiltration
High excess air
15 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Case 1 Atmospheric distillation fired heater
Installation of a fix type air preheating system (APH) on a twenty-
five year crude heater
APH Installation was carried out during scheduled turnaround
Forced and induced draft system installed
Fired heater control was upgraded
Fired heater duty, Gcal/h 52 52
Net efficiency, % 72 90
Heat fired, Gcal/h 72.2 57.8
Fuel oil saving, Kg/h 1,520
Annual saving, Euros (*) 1,216,000
(*) Euros equivalent / F.O.
Cost : 0.1 / Kg equivalent
16 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Case 2 Refinery fired heaters
Firing optimization and emission reduction program for most of
refinery process heaters
Burners of significant fired heaters were replaced during phased
turnarounds; minor modifications on fired heater floors required
Refinery fuel balance re-arranged to have most effective
FO / FG ratio
Refinery global flue gas emissions were reduced to 65%
Overall fired heaters duty, Gcal/h 1,039.4
Ave. NOx emissions, mg/Nm
3
455.5 296.3
Total NOx outlet, Kg/h 425.6 276.8
17 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Case 3 Vacuum Distillation fired heater
Improved operating conditions of vacuum distillation fired heater
Replaced burners with state-of-the-art type to solve tube bending due
to flame impingement problems and to reduce flue gas emissions
Convection section and stack were modified and replaced
Fired heater duty, Gcal/h 20 20
Net efficiency, % 74 80
Heat fired, Gcal/h 27 25
Fuel oil saving, Kg/h 214
Annual fuel saving, Euros(*) 342,000
(*) Not considering improvement in operating conditions
18 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Case 4 Atmospheric Distillation fired heater
Increase unit capacity from 30,000 to 42,000 BPSD
Improved fired heater efficiency (+40% capacity with only 11%
additional heat fired)
Added radiant surface in available space
Replaced bare tubes with finned tubes in convection section
Unit capacity, BPSD 30 42
Fired heater duty, Gcal/h 25 35
Net efficiency, % 65 82
Heat fired, Gcal/h 38.5 42.7
Heat flux, Kcal/h m
2
27,000 28,500
19 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
Case 5 Steam reformer revamping in a middle east refinery
Identified a need of additional hydrogen production capacity of
12000 Nm
3
/h
Revamped an existing steam reformer; the upgrading project
included the catalyst tubes replacement with new ones with new
material (lower thickness)
The increased catalyst volume, the higher catalyst performances
and the convection review allowed to target a production increase
of 20%
Hydrogen capacity, Nm
3
/h 60,000 72,000
Fuel+feed consumption, Gcal/h 247 298
Overall steam production, t/h 120 158
Export steam, t/h 63 93
20 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Fired Heaters Enhancing Refinery Profitability
The importance of the fired heater specialist
360 vision on fired heaters
Dampers & stack Dampers & stack
Fans and Fans and
blowers blowers
Pressure profile Pressure profile
Heat recovery Heat recovery
section section
Pressure parts Pressure parts
Tube supports & tube Tube supports & tube
sheets sheets
Burners operation Burners operation
Emission Emission
reductions reductions
Mechanical Mechanical
Re Re- -rating rating
Process Process
21 w:\dept\d151\a\graphics\depts\279\Russian Refining Conf Sept05\giampero_car
Giampiero Caronno
Sales Manager, Equipment Division
Foster Wheeler Italiana Spa
refining@fwc.com www.fwc.com
Thank you