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Fired Heater Design12345
Fired Heater Design12345
HEATER DESIGN
FIRED HEATER
DESIGN
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FIRED
HEATER DESIGN
PROCESS CONSIDERATIONS:
Maintain hydraulic symmetry:-Pipe
lengths, fittings shall be same for all
passes.
Vaporizing Fluids
Min.no. of passes.
With APH=2.5%
Arch pressure:
Normal Value
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-2.5 MMWG
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15%
5%
10%
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STACK DESIGN
Stack is designed to maintain -2.5 MMWG pressure at minimum
120% of design heat release with design excess air & max. ambient
temp.
Draft Analysis:
Draft = 0.1203 * Pa * ( ( Mwa / Ta ) - ( MWf / Tf ) ) * ( Z2-Z1 )
Where,
Pa = Ambient air pressure @ grade level (KPa)
Ta, Tf = Ambient air & Flue gas temp respectively ( K)
Mwa , MWf = Mol. Wt. of air & flue gas respectively ( Kg/Kg mol )
Z2, Z1 = Elevation of point 1 & 2 respectively (M)
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BURNERS
Types of Burners:
(A) Gas Firing
(B) Oil Firing
(C) Combination Firing
No. of burners required for a given heat release shall
be optimized based on following criteria:
(A) In normal cases, max heat release per burner shall
not exceed 3.0
MMKCal/Hr.
(B) Turndown requirements
(C) Flame dimension: ( Flame impingement on tubes,
refractory & adjacent burners shall be avoided )
(D) Heat distribution requirements
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BURNERS (cont.)
Component of Burner:
Main Gas/Oil tips , Pilot tip , Main flame scanner ( IR / UV ) ,
Pilot flame scanner ( Ionization rod ) , Igniter , Sight ports.
No. of Burners Max./Nor. Heat Release
<5 1.25
6-7 1.20
>8 1.15
Min Pilot heat release 20000 Kcal/Hr
Type of Oil atomization:
(A) Pressure atomization = min oil pr. ~ 10 Kg/Cm2g
(B) Steam atomization = steam/oil ~ 0.3 Kg/Kg & Delta P
~2.1 Kg/Cm2
For Oil fired burners, max. viscosity is 43 CSt.
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BURNERS (cont.)
Generation of pollutants from Burner:
(A) SOx : Sox (SO2 & SO3 ) generation chiefly depends on the
sulfur content of the fuel.
(B) NOx : NOx (NO & NO2 ) is generated thermally by the
reaction occurring above 700-800 deg C. Methods of NOx
reduction are:
Splitting fuel within burner
Splitting combustion air within burner
Diluting air-fuel mixture by flue gas mixing.
Normal limit is 50-125 ppmv for gas firing & 200-250 ppmv for
oil firing.
(C) Unburnt hydrocarbon: Result of improper mixing of fuel
with air.
(D) SPM: Soot, ash etc. Refraction method is used to monitor
the SPM content in flue gas.
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BURNERS (cont.)
Min parameters required for burner selection:
(A) Heat release : Min / Nor / Max
(B) Type of burner : Natural draft, Forced Draft, Low Nox,
Combination.
(C) Fuel details : Composition, LHV, Pressure,
Temperature
(D) Combustion air details: Temperature, Pressure,
Relative humidity
(E) Nos. of burners, Ignition details.
(F) Emission requirements: SOx, NOx, UHC, SPM, CO etc.
(G) Noise limitation: 85 dBA A 1M from burner.
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AIR PREHEATER
Advantages of APH :
(A) Enhance efficiency ( up 92-93 %).
(B) To enhance air-fuel mixing ( High air velocity ).
(C) Reduce oil burner fouling
(D) More complete combustion of difficult fuels.
Disadvantages of APH:
(A) Increases potential of SO3 & NOx generation as
adiabatic flame temperature is high.
(B) Reduces the stack temp., so either ID fan or
taller stack will be required.
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SOOTBLOWERS
Soot is generated as a result of improper combustion in burners.
Soot has to be removed to maintain heat transfer coefficient.
Type of soot blowers:
(A) Retractable type:
Mostly use for high temperature & dirtier fuel
application. It is more costly but has better cleaning characteristics.
Normally it is used in fully automatic sequential mode.
(B) Fixed Rotary type: It is cheaper than Retractable type but can not be used in
high temperature or dirty fuel services.
(C) Vibration type: Ultrasound waves are used in this type to create vibration to
disengage the soot from the coils. Very limited experience is available for this type.
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DAMPERS
Type of Dampers:
(A) Control damper: It controls the draft in the heater. It can be
either manual or automatic in operation. It always has some
leakage ( ~3%). It can be single blade ( like butterfly damper ) or
multiple blade ( like louver damper ). Multiple blade damper can
have parallel blade opening or opposed blade opening ( better
control but complex in operation).
No. of Blades ~ inside area of the duct or stack (M2) / 1.2
Control damper is normally use in stack, FD/ID fan and
combustion air bypass around the APH.
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DAMPERS (cont.)
(B) Shut off damper:It is used to prevent the flow
through a duct. It can be operable manually by
chain & pulley arrangement ( as in Guillotine blind )
or by an electric motor ( as in swing gate ). It is
designed for a very high sealing efficiency
( 99.9%).
(C) Diverter damper: It is used to divert the flow of
air or flue gas from one duct to another duct.
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INSTRUMENTATIONS
Applicable code is OISD 111.
Following instruments are normally provided:
Draft gauge for radiant, convection, stack.
High / low arch pressure ( trip / alarm ).
High arch temperature ( alarm ).
Oxygen / CO analyzer in arch ( Alarm ).
Convection outlet temperature / pressure.
Stack outlet temperature / pressure.
SPM / NOx / SOx analyzers.
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INSTRUMENTATIONS (cont.)
Nozzles for pollution monitoring.
Tube skin temperatures in coil / APH.
Process fluid inlet & outlet temperature / pressure.
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REFRACTORIES
Type of refractories:
(A) High Density Fire Bricks(HDFB): These are normally placed on
the floor to protect the mechanically weak castables / bricks. They
have excellent mechanical strength but very poor thermal insulation
properties.They are laid loose on the floor. Exp. AC30 etc.
(B) Insulating Fire Bricks(IFB): These are normally placed on
radiant floor (below HDFB), radiant wall and sometimes in vertical flue
gas ducts. They are lighter than HDFB and hence mechanically poor.
Application of IFB requires more time than castables / ceramic fibres.
They are laid with mortar and expansion gaps are provided to
accommodate the thermal expansion of the bricks. Exp. JM 23, JM 26
etc.
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REFRACTORIES (cont.)
(C) Castables: Castable are placed in all parts of fired heater. They
can be mechanically very strong ( as Insulyte 15Li ) or thermally
very superior ( like Firelite 124). They are applied on the surface by
pouring or gunning. Anchors (CS or SS-304, depending on the tip
temperature) are used to hold the castable with the casing.
Normally V, Y or chain link type anchors are used.
Castable can be applied in dual layer also. In dual layer
construction, a mechanically superior castable is used on hot face &
thermally superior castable on cold surface.
Sometimes ceramic blocks are used in place of castables. Exp.
Cerablok-800 etc.
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REFRACTORIES (cont.)
(D) Ceramic Fibres: These refractory materials are very light
weight, thermally superior but mechanically poor material. They
are used as loose fibres for filling gaps, blankets or module for
application on casing plates. They can not be used where the flue
gas velocity is 40fps ( for blankets) or 80fps( for modules).
Further, they can not be applied where the total metal content
exceeds 100 ppm. They are fixed to the casing by studs & nuts.
Application is very fast. Due to their low weight, they can
potentially reduce the structural cost. Normally a vapour barrier
(0.1 mm SS-304 foil) and an anticorrosive paint are used to avert
the flue gas condensation on the casing plate. Exp: Cerablanket
1260, Cerablanket 1450 etc.
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METALLURGY
Process affects the material selection:
(A) Oxidation at high temperature.
(B) Vanadium & sodium attack in presence of
sulfur.
(C) Attack by H2S.
(D) Attack by Polythionic acid.
(E) Attack by Chlorine.
(F) Attack by H2.
(G) Carburisation.
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METALLURGY (cont.)
Following tube materials are normally used:
Carbon Steel
- 525 deg C
Low alloy steel (P11,P22)
- 525 deg C
High alloy steel ( P5, P9)
-600 deg C
Austenitic Stainless Steel
( SS304 / 310 / 321 / 347)
-820 deg C
Following support materials are normally used:
CS : 427oC, 25Cr-20Ni : 871oC, 50Cr-50Ni-Cb : 982oC
Heater casing is always made of carbon steel.
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METALLURGY (cont.)
Typical tube material for various services:
Crude
P5
Vacuum
P9
Delayed coker / Visbreaker
P9
Hydrotreater
SS 321 / SS 347
Hot Oil Heater
CS
Reboilers
CS
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