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Fired Heaters Design PDF
Fired Heaters Design PDF
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Mar 2014
Since
Fired Heaters Training 1 - 3 days 1976 38
Introduction (100 slides) - 6 ~ 8 hours
Design (40 slides) - 3 hours + 4 hours in Worksheet
Operations (45 slides) - 2 ~ 4 hours
Introduction Design
Process Fired Heaters
Firebox Heat Transfer - A Primer
Plant energy flow; Fired heaters - Source of high temperature heat
Vertical Cylindrical, Box, Cabin, Multi-cell
Radiant Section Sizing
Fired Reactors Convection Section Sizing
Ethylene Cracker; Steam Hydrocarbon Reformer; EDC Cracker; Coil Design
Visbreaker; Delayed Coker
Other Types Stack
All Convection; Water Bath Burners
Firing
Single or double sided; Floor up-fired, End or Side wall fired; Multi-
Refractory System
level fired and Roof or Down-fired
Burners Operations
Gas or Oil or Combination; Low NOx Safety Alerts
Draft
Firebox Explosion
Natural, Forced, Induced and Balanced
Components Excess Air Control
Tube & Tube Supports; Soot blowers, Stack, Refractory Draft Control
Waste Heat Recovery:
Fuel & Firing Control
Steam Generation; BFW Heating, Air Pre-heater, Gas Turbine
Exhaust WHRU Heater Control
Coking & Hot Spots
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Contents
Firebox Heat Transfer - A Primer
Radiant Section Sizing
Convection Section Sizing
Coil Design
Stack
Burner, Fuel Systems
Refractory System
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Gas Radiation - H2O + CO2 The link ed image cannot be display ed. The file may hav e been mov ed, renamed, or deleted. Verify that the link points to the correct
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0.35
0.30 H2
Partial Pressure or
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Refractory
Heat Exchange between gas components
70% heat in non-radiating O2 and N2. Exchange
heat by convection with CO2 and H2O that radiate
In firebox - all 3 modes of heat transfer active
Radiation from gas cloud; convection between
gases, to tube and refractory; tube and heated fluid. Gas cloud remains at
Conduction thru scale and tube wall residual or equilibrium
firebox temperature,
receives heat from
flame and radiates it to
Bulk of heat transfer in radiant section is by convection between gases tubes and refractory
0.8
Reflection boosts radiation transfer. Effectiveness: Total = Direct +
Reflected
Fraction absorbed α
Direct 75%; Once reflected 68%; Twice 61%; Thrice 54% 0.6
Refractory
D
Take 100 rays from a single point 0.4 Direct
S Direct 40 rays x 0.75 = 30 units
Once reflected 30 rays x 0.68 = 20.4 0.2
Twice reflected 15 rays x 0.61 = 9.2 0.0
Thrice reflected 15 rays x 0.54 = 8.1 1 2 3 4
Spacing S in terms of tube dia d, S/D
Total 67.7 units
Refractory re-radiation enhances gas emissivity + S
heats tube backside
Refractory
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Cgr
Cgt
Firebox - Refractory’s Role
Rgt Rrt CCRra
Rgr
3 Zones:
Refractory
adds 25% more area. Also abandoned efforts X
on polished reflecting surface on refractory
X
60°
Gradient in Tube and Gas Temperature based on: Single sided firing
Size and shape of firebox
Squat firebox: Less gas temperature gradient
Long cylinder more gradient
Double sided firing
Proportion of tube covered wall area
Flow of fluid w.r.t flue gas flow
Tube to tube spacing Impact of T4 relationship:
Tube to wall spacing and if T2 < ½T1, flux gradients
Type of firing & firing density impacting recirculation minor. Take a Crude Oil
Heater. Tin = 300°C Tout =
Single sided firing: Max front or fireside 180°flux 370 Tav = 335 Tt = 370 Tg =
50% higher than average flux on 2D spacing; front 870°, Tt4 is about 10% of
60° is 80% more - 45% more on 3D Tg4. 10% variation in Tt has
Double sided firing - 25% more on front 60° little impact on Tg. Some
correlations ignore Tt.
Larger tube spacing evens out maximum flux rate
Inlet : Outlet flux = 1.05:1.0
Example: Peak film temp- 2D = 450°C 3D = 433°C
In case of fired reactors T1
and T2 are close
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Cgr
Cgt
Summary
Rgt Rrt CCRra
Rgr
Emissivity, ε and Absorptivity, α depend on temperature/
wavelength. Higher the temperature, lower in metals; exception
non-metals like refractory
Polished and clean metal surfaces - low ε; oxidized and rough metal
surfaces - high ε. Usual tube ε = 0.9
Simple heat transfer analysis - stirred tank or single zone.
Computerized methods - multiple small zones
Temperature gradients expected in wall firing tall and narrow fired reactors
Conduction and convection decided by temperature difference or
∆t. Radiation decided by temperature level. WB = σT4. Higher
sensitivity to temperature
Net exchange between two surfaces:
q12 A1F σ(T14 - T24)/(1/ε1 - 1/ε2 -1) + convection part, hc Ao(T1 - T2)
Multiple sources + multiple receptors @ temperature gradients in
different firebox zones - can be solved by a network analysis as in an
electrical circuit with differing potential
Qr = Radiant duty
Qin = Heat input into firebox
Literature φoverall = Overall exchange factor
C = Empirical coefft based on Tg
Se = Equivalent effective area
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S S
Literature L
D
Acp
S = 12/6.625 = 1.81
Literature “bookish” correlations S = 8/4.5 = 1.77, say 1.8 D
require Ao ≈ 2αAcp
Firebox layout to find Tg; as if equations
hc = 10 W/~, kCal/~ , 2
are good for rating only Btu/~ units based on Ao.
Not true. One can assume a radiant duty
Based on αAcp
split / duty, lay out firebox and tubes, Taking εeffective = 0.57,
calculate Ar, αAcp, Tg, and check duty 10*2/0.57 = 35 W/~, kCal/~
, 7 Btu/~ units,
Which tube area?
Projected area, At = DL
Projected cold plane, Acp = SL = 1.8DL
Flux specified on tube OD area, Ao = πDL
At = Ao/π = Acp/1.8
Acp = 1.8*At = 1.8Ao/π. Ao ≈2 αAcp
Literature
Qr = αAcp εeffective σ(Tg4 - Tt4) + hc Ao(Tg - Tt) or
Qr/αAcp εeffective = σ(Tg4 - Tt4) + 35 or 7 (Tg - Tt)
Ao ≈ 2αAcp
950°C
Example F = 30,000 W/~ Tt = 370 Tg = 870 / 925°C 850°C
750°C
69/66%
Tube Metal Temp
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Case Study - 3 MW
Method Radiant % BWT, °C
Simple F = 0.35 on OD. - Convection 69 875
GPSA WLH - No Convection 65 930
Nelson WLH - No Convection 67 900
Hottel & Sarofim (Add Convection) 65 (68) *935 (890) Chart = 890°C
Lobo & Evans - With Convection 65 *940
* BWT by trial & error. Need to assume firebox layout first to determine heat transfer in firebox
T-ambient
Parameter 100% Load 100% Load 67% Load
T- Stack
WLH Method 20% Xs Air 60% Xs Air 20% Xs Air
Stack Gas Temp, °C 385 405 340
BWT Overall
Efficiency, % 80.2 74.0 82.7
efficiency
Radiant Radiant Split, % 67.4 62.5 72.0
efficiency
Bridge Wall Temp, °C 900 825 800
Flame Temp
Arch Draft, mm WC -1.5 +4 -1.5
Xs air reduces flame temp; Air- Burner Draft, mm WC -6.3 -1 -6.3
preheat increases flame temp
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Duty = 3 MW
Fuel & Flue Gas VC Heater
Tin / Tout = 250/ 450°C
Stack Gas ∆T = 140°C
Verify heat duty = ẃ(Hout-Hin)
Stack Gas T = 390°C
Select heater type
No dew pt issue
Select stack temp = Inlet fluid temp + 30 ~ 150°C
Fuel = Refinery Gas
Check if inlet fluid temperature results in
Ex Air = 20%
Flue gas water dew point (≈ 60-70°C) and/or
Acid dew point (≈ 150°C). Stack gas T > Dew Point Thermal eff = 82.2 %
Find thermal efficiency based on stack gas Casing loss = 2%
temperature, Xs air and 1-3% casing loss Fired Duty = 30/0.802 =
Find fuel fired, flue gas and air demand 3.74 MW
NHV Air Air kg/ Fuel (LHV 46,250 kJ/kg) =
Fuel kCal/kg kg/kg 10,000 kCal 291 kg/h
H2 28,670 34.8 12.10
C 8,110 11.6 14.30
Air = 5,427 kg/h
S 5,650 4.4 7.80 Flue gas = 5,718 kg/h
Methane 13,290 17.3 13.00 Combustion Air Demand. Magic Number
Ethane 12,420 16.1 13.00 3.4 kg/10,000 kJ;14.0 kg/ 10,000 kcal; 7.8 lb/ 10,000 Btu
Coil Design
Based on flow and allowable ∆P, ∆P, allow = 3 bar
select tube size (4 or 6”) and passes 2 pass - 4”
Velocity = 17.7 m/s
Find velocity and heat transfer coefft
hi = 1,088 W/m².°C
Vacuum heater: Limit outlet velocity
hio = 983 W/m².°C
to 80% sonic to avoid shearing liquid
Ensure flow regime in vaporizing
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Measured Firebox Temperature could be less by 50-100°C, due to heat given up to shock tubes
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Radiant Q = 0.673*3 =
Radiant Section 2.02 MW
Radiant Area =
Based on radiant duty 2,200/Flux 30 = 67 m²
calculate tube area and length 4” NB 4.5” OD
Assume number of tubes, get tube length, tube Coil Length = 188 m
circle dia or width and L/D ratio or b:h:l ratio
Assume tubes = 36
A L/D ratio of 1.5 to 3 or b:h: l ≈ 1: 2-3: 5.
Smaller heaters L/D ≈ 1 or b:h: l ≈ 1: 1-1: 2 Even no/pass. Top out
L/D lower with more number of burners, as Each Tube L = 5.2 m.
D gets bigger with bigger Burner Circle Credit 180° bend 4.9m
Tube to Burner distance specified in API 560 2D (8”) pitch. Tube
Circle Diameter =
36*8”*/pi() = 2.3 m
L/D Ratio = 5.2/ 2.3 =
D 2.2 OK
Heat, MW Vertical, m Horizontal,
m Say 3 burners. 1.5 MW
L
1.5 5.6 0.9 @ 120% BCD = 0.7m.
H 2.5 8.3 1.2 H-clear = 0.8m V 0.9m
c L
B 5.5 11 1.4
Extract. Oil Firing. Full table in RP 560
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Convection Section
Extended Surface - Studs or Fins Qc = 1 -0.24 = 0.76 MW
Standard heat transfer correlations; Radiation from hot
gas is low. Thinner gas cloud 4 finned rows 160
Fins are less expensive than studs fins/m; 25 mm high 1.5
Fins: 0.05-0.1” thick, 2-5 fins per inch. Less on oil mm thick fins
firing; more on gas Tube Afinned = 226 m²
1.25 - 2.5 mm thick, 80 - 200 fins per meter
Studs ½” dia in 8-24 studs per plane with 19.2 Flue gas V = 3.4m/s
planes/ft (63 per m)
Height 0.5-1.25” (12 to 40 mm) based on tube
Tg out = 385°C
780°C
spacing 300°C
Max convection flux to may exceed max radiant flux - 385°C
on bare surface basis due to high extended area ratio 250°C
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Coil Design
Coil Design
Equilibrium Flash Vaporization Chart
0% Vaporized
Pressure
60% Vaporized
Temperature
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Tube Design
On internal pressure
Elastic deformation
linear stress - strain relation
once internal pressure is removed,
metal gets back to original state. Stress
at that point is called Yield Stress
Plastic deformation, on further stress
remains permanent even when load is
removed
Stress causing plastic deformation
before fracture is Ultimate Tensile
Stress
Design stress = 2/3 Yield or 1/3 UTS. For
CS plates it is about 17,000 psig (117 • Steam coils to ASME
MPa) • Corrosion allowance, high
Yield point at 1.5*design pressure; in initial life, indirectly
deform at 3*design pressure. adds to design life
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Tube Design
Hot tubes undergo
permanent growth or
creep This image cannot currently be display ed.
Time dependent
deformation below yield
strength at high temp
Stress rupture - short term;
Creep - long term failure
Heater tubes are usually
designed for 20,000 to
100,000 hours of creep-
rupture life per API RP 530
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Spheroidization: Aging of carbon and low alloy steels with loss of mechanical and creep strength
when exposed to 440°C - 760°C (850°F - 1400°F) where carbide phases (the strengthening element of
steels) become unstable and begin to agglomerate, which then results in loss of strength
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Tube Supports
Dead load and tube expansion
Horizontal Support: @35D / 6m
Tube Wall Thickness
Vertical: 70D or 12m OD = 114.33mm
25Cr-20Ni, 25Cr-12Ni, SS or CS. Design = 25 bar/540°C
High vanadium + sodium in fuel Allowable Stress - Elastic/
oil may call for expensive 50Cr- Rupture @ 100,000 hrs =
1,310/ 450 bar
50Ni to withstand fuel ash
t calculated = 1.08/3.09mm
corrosion
Corrosion Allowance = 2mm
Cast Iron: 425°C (800°F) (Note: Factored CA used)
25Cr-12Ni: 815°C (1,500°F) t min = 3.6/ 4.8mm
t average - pipes ±12.5% =
End tube sheets are CS lined with 5.49mm
castable t provided = 5.52 mm
Stack
Sizing based on: Stack dia, say = 0.6 m
Buoyancy effect of flue gas Arch draft min = 1.5mm
Frictional losses in convection bank, duct
and stack Firebox T = 900°C
Standard formulae for duct friction loss Firebox ht = 5.5 m
Stack draft affected by altitude/ Firebox draft = 5 mm
atmospheric pressure at site (Draft for burner)
Height to get draft or mostly suit GLC of Stack T = 390°C
emission
Due to heat loss, stack draft temperature <
Draft/100m = 66 -12 =
Stack gas inlet temperature 54 mm
Structural design of firebox and stack ∆Pconvn = 2.6 - 0.85
based on: Damper loss = 3 mm
Wind and seismic loads
Stack tip loss = 4 mm
Draft reqd = 10.4mm
Stack Ht = 20 m
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Burners
Heater performance depends on burner
performance
Number of burners decided by flame length
Service, fuel, firebox layout. Flame length < 2/3 firebox
height. Gas flame 1-2 m/MW (1-2 ft/MMBtu/hr)
Burner to tube clearance. Min 450mm (1.5’). See API 560
3 - in - Cluster burner for small heaters
Burner to burner space: Must avoid flame merging to
avoid unburnt fuel and longer flames; may increase NOx
Excess Air: 5-10-20-30: based on fuel and draft (FD?)
Burners, duct & stack sized for 110-120% firing and
higher excess air
Must avoid flame and hot gas impingement
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Utility Demand
Heater Utility 7
Snuffing Steam
Purge firebox of unignited hydrocarbon, before light up to avoid an explosion
Failure to purge - repeated cause of firebox explosions
LP steam @ firebox volume in 5 minutes; additional purge connections to
header boxes. Note: Use steam density at atmospheric pressure
Use snuffing steam to put out any small fire caused by tube leak
Run FD fan for few minutes, if no LP steam OR use steam ejectors
Atomizing Steam
Atomizing steam - to shear and froth fuel oil. @ 25-45% oil flow
Soot Blower Steam + Plant Air
Steam: 4,500 kg/h for retractable. Air: 80-100 Nm³/h for its pneumatic motor
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Intelligent Pig
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Recommended Reading
Furnace Operations, R D Reed
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API Publications
Spec 12K Specification for Indirect Type Oilfield
Heaters
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Std 530/ISO 13704 Calculation of Heater-Tube
Thickness in Petroleum Refineries
RP 535 Burners for Fired Heaters in General
Refinery Services
RP 556 Instrumentation, Control, and Protective
Systems for Gas Fired Heaters
Std 560/ISO 13705 Fired Heaters for General
Refinery Services
RP 573 Inspection of Fired Boilers and Heaters
“Heat Transfer in Radiant Section of Petroleum Heaters” WE Lobo, JE Evans; Trans. AIChE, pp 748-778, 1939
“Heat Transmission in Convection Section of Pipe Stills”, CC Monrad, Ind. Eng. Chem., Vol 24, 505, 1932
“Generalized Method Predicts Fired Heater Performance”, N Wimpress, ChE, May 22,1978
Stay Safe. The best for many years of safe and sustained operations
THANK YOU
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