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Fired Heater Design and Simulation - IJETT-V4I2P215
Fired Heater Design and Simulation - IJETT-V4I2P215
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I. Introduction
A fired heater is a direct-fired heat exchanger that uses the hot
gases of combustion to raise the temperature of a feed flowing
through coils of tubes aligned throughout the heater.
Depending on the use, these are also called furnaces or
process heaters. Some heaters simply deliver the feed at a
predetermined temperature to the next stage of the reaction
process; others perform reactions on the feed while it travels
through the tubes.
Fired heaters are used throughout hydrocarbon and chemical
processing industries such as refineries, gas plants,
petrochemicals, chemicals and synthetics, olefins, ammonia
and fertilizer plants. Most of the unit operations require one or
more fired heaters as start-up heater, fired reboiler, cracking
furnace, process heater, process heater vaporizer, crude oil
heater or reformer furnace.
Heater fuels include light ends (e.g. refinery gas) from the
crude units and reformers as well as waste gases blended with
natural gas. Residual fuels such as tar, pitch, and Bunker C
(heavy oil) are also used. Combustion air flow is regulated by
positioning the stack damper. Fuel to the burners is regulated
from exit feed temperature and firing rate is determined by the
level of production desired.
A typical fired heater will have following four sections: (1)
Radiant section, (2) Shield section, (3) Convection section,
and (4) Breeching and stack. A fired heater may be a box
ISSN: 2231-5381
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)(
= 0.023( )
)+
15,000,
= 0.021( )
Where,
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Where,
Overall heat transfer coefficient, Btu/hr-ft2-F
Total outside thermal resistance, hr-ft2-F/Btu
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10,000,
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Page 160
1
= 0.35 + 0.65
1
+
( + )
an inline pattern,
= 0.20 + 0.65
Where,
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Fin height, in
Fin spacing, in
Where,
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+ 460
)
+ 460
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iv. Mass Velocity,
= 0.25
an inline pattern,
= 0.35 + 0.50
:
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Net Free Area,
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Where,
Reynolds number
Geometry correction,
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Fin height, ft
Outside diameter of tube, ft
Transverse tube pitch, ft
fin thickness, ft
number of fins, fins/ft
(1
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(1
)+
(2
+2
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Gas Temperature, F
Tube Wall Temperature, F
1
+ 0.2)
+ 0.4
2 0.4
+ 0.2)
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PROPERTY
Tube
And then,
=
= (0.45 ln
Where,
Combustion
Firebox
Process fluid
= (0.7 + 0.3 )
And,
tanh (
)
Flue gas
Where,
=
(Radiant)
(Shield)
Acp (Radiant)
Acp (Shield)
Acp (Radiant)
Acp (Shield)
(Acp)r+(Acp)s
AR/
((Acp)r+(Acp)s)
+( )
2
=(
ISSN: 2231-5381
(
(
1
+
2
)
)
Partial pressure
Mean beam length
P*l
Emissivity
Exchange factor
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DETAIL
OD, in (do)
thickness, in (tw)
No of tubes (Nt)
(Radiant)
No of tubes (Nt)
(Shield)
Effective length, ft
(Le) (Radiant)
Effective length, ft
(Le) (Shield)
Tube spacing, in (CC)
(Radiant)
No of tubes per row
(Nt/r) (Shield)
Transverse pitch, in
(Pt) (Shield)
Fraction excess air
Diameter, ft (D)
Mean wall
temperature, (Tt), R
Flue gas temperature
(Tg), R
(-)
Assumed (-)
ft2
ft2
ft2
ft2
ft2
AT, ft2
Area of Shield
Section, ft2 (As)
AR, ft2
AR/
((Acp)r+(Acp)s)
atm (P)
ft
atm-ft
E
F
AMOUNT
8.626
0.05118
40
12
35.07
18.31
16
4
16
0.15
19.98
1097.95
2077.1
0.9086
1
1870.52
97.64
1699.51
97.64
1797.15
2103.81
97.64
306.66
0.17
0.256
13.32
3.406
0.5087
0.5129
Page 162
Btu/hr
MM Kcal/hr
3.37*10^7
8.488
PROPERTY
Fin
Tube
Process Fluid
Flue Gas
ISSN: 2231-5381
DETAIL
Height, in (lf)
Thickness, in (tf)
No of fins, fins/ft (nf)
Ther. Cond., Btu/hr-ftF (kf)
OD, in (do)
Thickness, in (tw)
No of rows (Nr)
No of tubes per row
(Nw)
Effective tube length,
ft (Le)
Pitch, in (Pt)
Wall temp, F (Tw)
Wall Ther. Cond.,
Btu/hr-ft-F (kw)
Inlet temp, F (t1)
Outlet temp, F (t2)
Ther. Cond., (Liq),
Btu/hr-ft-F (kl)
Ther. Cond. (Vap),
Btu/hr-ft-F (kv)
Sp. Heat (Liq), Btu/lbF (cp,l)
Sp. Heat (Vap),
Btu/lb-F (cp,v)
Viscosity (Liq), lb/hrft (l)
Viscosity (Vap), lb/hrft (v)
Mass flow rate, lb/hr
Wt fraction (Liq) (Wl)
Wt fraction (Vap)
(Wv)
Fouling factor,hr-ft2F/Btu (Rfi)
Inlet temp, F (t1)
Outlet temp, F (t2)
Mass flow rate, lb/hr
(Wg)
Ther. Cond., Btu/hr-ftF (kg)
Sp. Heat, Btu/lb-F
(cp,g)
Viscosity, lb/hr-ft (g)
hi, Btu/hr-ft2-F
AMOUNT
1
0.05118
60
21.292
Gn, lb/hr-ft2
1017.79
8.626
0.5
5
4
Gas
Colburn HT Factor
Outside Film HT coefficient
Average Outside HT
co-efficient
Fin Efficiency
Effective Outside HT
co-efficient
Overall HT coefficient
LMTD
HT Area
Convection Heat
Transfer
j
hc, Btu/hr-ft2-F
0.00543
2.0291
ho, Btu/hr-ft2-F
2.599
E
he, Btu/hr-ft2-F
0.9838
2.5595
Uo, Btu/hr-ft2-F
1.9348
F
ft2
Btu/hr
MM Kcal/hr
430.28
10102.93
8.4*10^6
2.119
18.307
Table 3 Heat Balance
16
959
12.83
609.8
621.1
0.04939
0.11995
0.694
0.8985
0.31448
PROPERTY
Assumed amount of
Radiant HT
Assumed amount of
Convection HT
Thermal Efficiency
Total Heat Input (Qfuel)
Total Heat Transferred
(Qht)
Radiant HT (Qr)
Convection HT (Qc)
Heat Loss (Qloss)
Heat out from HT area to
stack (Qstack)
DETAIL
AMOUNT
80
20
% (given)
MM Kcal/hr
MM Kcal/hr
(given)
MM Kcal/hr
MM Kcal/hr
MM Kcal/hr (2.5%
of Qfuel)
MM Kcal/hr
(=Qfuel-Qht-Qloss)
90.7
11.70
10.61
8.488
2.122
0.2924
0.7955
0.0508
V. HTRI Introduction
1054905.3
0.7
0.3
0.00391
1472
788
42620.545
0.0353
0.3087
0.0883
461.16
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VII.
References
[1]
[2]
[3]
[4]
[5]
Conclusion
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