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chemical engineering research and design 9 0 ( 2 0 1 2 ) 213–219

Contents lists available at ScienceDirect

Chemical Engineering Research and Design

journal homepage: www.elsevier.com/locate/cherd

Improved area—energy targeting for fired heater integrated

heat exchanger networks

James Varghese a,∗ , Santanu Bandyopadhyay b

a Mechanical Engineering, School of Engineering, Cochin University of Science and Technology, Kochi 682022, Ernakulam, India
b Department of Energy Science and Engineering, Indian Institute of Technology Bombay, Mumbai 400076, India

a b s t r a c t

Effective integration of various subsystems into the overall process, results in an energy efficient and economic plant
design. In this paper, issues related to the area-energy targeting for fired heater integrated heat exchanger networks
are studied. Performance of a fired heater is affected by the variables such as fuel fired and air-preheat temperature.
These variables along with the minimum approach temperature difference for the heat recovery of the background
process, affect the performance of the overall system. A methodology is proposed for the area-energy targeting for
fired heater integrated processes. In the proposed methodology, the fired heater heat duty split between the radiation
and the convection section is determined using the one gas zone furnace model.
© 2011 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.

Keywords: Fired heater; Fired heater integration; Heat exchanger network; Cost targeting

1. Introduction
Tools of pinch technology help in establishing energy efficient
design of a modern process plant prior to its detailed design.
Subsystems, independently designed and integrated into the
process may lead to suboptimal design of the overall plant.
Thus, appropriate integration of various subsystems into the
overall process has to be performed for optimal design of the
entire process plant. The improved procedure for area-energy
targeting of fired heater integrated processes considers indi-
vidual component design-parameters along with their energy
and economic interactions. Fired heaters are energy as well as
capital intensive equipment. The cost of the furnace system
usually ranges from 10% to 30% (Jegla et al., 2000) of the plant’s
total investment.
Fired heaters are used in various chemical and process
industries such as refineries, petrochemical, fertilizer, etc. In
industry, fired heaters are also known as process heaters, fur-
naces, and direct-fired heaters. The primary function of a
fired heater is to supply a specified quantity of heat to the
process stream. Typically, when desired temperature of the
process stream is above the practical range of steam heating
(363–477 K), fired heaters are used (Allen and Rosselot, 1997).
The desired energy is generated in the fired heater by com-
bustion of the fuel. Oil and natural gas are the major fuels
used in fired heaters. The hot flue gases of combustion sup-
ply the required energy to the process fluid that flows inside
the tubes. Tubes are contained within refractory lined cham-
ber that reradiate heat to the tubes and reduce heat leakage.
The heat duty of a fired heater is usually controlled through
fuel flow rate.
The overshoot of the cold composite curve over the hot
composite curve is the hot utility, Qhu required for a process
corresponding to a minimum approach temperature of Tmin
at the pinch. Similarly the overshoot of the hot composite over
the cold composite is the cold utility, Qcu required for the pro-
cess. Recently, Bandyopadhyay and Sahu (2010) have proposed
a modified problem table algorithm to target minimum utility
requirement for a given Tmin . The optimization of the pinch
approach temperature Tmin is a trade-off between the capital
and energy (capital and operating cost). Heat exchanger area
required for the heat exchanger network is used to estimate
the capital requirement. Area targeting involves area estima-
tion of process to process heat exchangers and utility heat
exchangers in a heat exchanger network. The total capital can
be estimated using the total heat exchanger area and number
of units with an appropriate cost correlation. Using the capital
and operating cost, the total annualized cost may be estimated

∗
Corresponding author. Tel.: +91 9495672695, fax: +91 484 2550952.
E-mail address: jamesvar@cusat.ac.in (J. Varghese).
Received 16 January 2011; Received in revised form 29 May 2011; Accepted 22 June 2011
0263-8762/$ – see front matter © 2011 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
doi:10.1016/j.cherd.2011.06.011
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214 chemical engineering research and design 9 0 ( 2 0 1 2 ) 213–219

heat temperature was reported by Hall and Linnhoff (1994).

Nomenclature Fuel firing, air preheat temperature and excess air are used
to construct the utility grand composite curve (UGCC). The
A area, m2 UGCC with flue gas and air preheating is matched against
C cost ($) process grand composite curve (GCC) to form a utility pinch.
CRF capital recovery factor The corresponding fuel firing and air preheat temperature
c specific heat, kJ/kg K are the targets for the fired heater integrated. Varghese and
d stirring factor Bandyopadhyay (2007, 2009) have reported an analytical proce-
E excess air fraction dure to integrate fired heater with the process. The procedure
f radiation fraction helps to target analytically the fired heater fuel firing, air
GCC grand composite curve preheat temperature using process heat below pinch as well
HV lower calorific value, kJ/kg as using flue gas heat. It was reported that a fired heater
h heat transfer coefficient, kW/m2 K integrated against GCC require less fuel compared to the com-
K radiation coefficient posite curve based targets (Hall and Linnhoff, 1994; Varghese
k, k1, k2, k3 cost coefficients and Bandyopadhyay, 2007, 2009). The fuel saving is reported to
m mass flow rate, kg/s be in the range of 1–2.5% against the composite curve targets
N number of heat exchanger units (Varghese and Bandyopadhyay, 2007, 2009). In certain cases,
Q heat duty, kJ the process may require multiple fired heaters to supply the
q average design radiation flux, kW/m2 hot utility required. In such cases, it is important to estimate
S stoichiometry air fuel ratio the minimum number of fired heaters required. Varghese and
T temperature, K Bandyopadhyay (2009) have reported a procedure to target the
t annual operating hour, h minimum number of fired heaters and the duties of these fired
TAC total annualised cost ($/y) heaters prior to the synthesis of the heat exchanger network.
UGCC utility grand composite curve Heat exchanger network with fired heaters may be opti-
mized with assumed fired heater efficiency to calculate the
Greek letters fuel cost (Fraser and Gillespie, 1992). The capital cost of the
˛ setting loss fraction in the radiation chamber fired heater is estimated as a function of the heat duty. Such
 difference a procedure assumes same cost function for the radiation
 Stefan–Boltzmann constant, as well as convection section along with fixed fired heater
5.67 × 10−11 kW/m2 K4 efficiency during optimization. The furnace retrofit proce-
dure reported by Jegla et al. (2000) is based on the furnace
Subscript
integration approach using principles of pinch analysis after
0 ambient
considering limitations of the existing furnace. Through cost
1 heat sink
minimisation, both the stack temperature and the air preheat-
air air
ing system are optimized. An algorithm was reported by Jegla
ap air preheater
et al. (2003) for the furnace retrofit to increase the plant capac-
bw bridge wall
ity. The hydrodynamic behaviour of the process fluid in the
cap capital
fired heater was also considered for the retrofit strategy.
con convection
In this paper an improved procedure for area-energy tar-
cu cold utility
geting of fired heater integrated processes is presented. Fired
eff effective
heater parameters such as fuel fired and air preheat tem-
f fuel
peratures are obtained using the fired heater integration
FB fire box
procedure. Fuel cost is calculated using the fuel flow rate
FT adiabatic flame condition
targeted. The fired heater area targeting using the one gas
g flue gas
zone model is described in the next section. The fired heater
hu hot utility
cost and associated heat exchanger costing are presented in
hx heat exchanger
the following section. The overall cost for a minimum pro-
in inlet
cess approach temperature is estimated using this procedure.
ln natural logarithm
An optimum process approach temperature range can be
min minimum
obtained corresponding to the minimum overall cost. A case
out out
study is presented illustrating the procedure developed.
opr operating
p process
r radiation 2. Fired heater area targeting
s stack

for different minimum approach temperature Tmin . The opti-
mum range of Tmin may be determined corresponding to the
minimum total annualized cost.
Various authors (Hall and Linnhoff, 1994; Varghese and
Bandyopadhyay, 2007, 2009) have already reported the proce-
dure for integrating fired heater into the process. A graphical
procedure to target the minimum fuel firing, and air pre-
The one gas zone model, also known as the stirred reactor
model for a furnace, is used for the fired heater area esti-
mate. The stirred reactor model is reported to predict, with
a significant degree of accuracy, the overall heat-transfer per-
formance for a wide range of furnaces burning different fuels
and having various configurations of the radiation chamber
(Varghese and Bandyopadhyay, 2007, 2009; Truelove, 2002). The
model assumes a radiating gas medium at a uniform effec-
tive temperature Teff . The tube surface acts as a heat sink at a
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chemical engineering research and design 9 0 ( 2 0 1 2 ) 213–219 215

perature using flue gas heat Tair , temperature of the flue gas
Hot utility required
leaving the fired heater Tg,out and flame temperature TFT .
Tp,out The stoichiometric air–fuel ratio for the fuel is assumed as
Hot
composite S and the fraction of excess air E provided for complete com-
Process
bustion of the fuel. The flame temperature may be calculated
Cold composite
heat recovery from heat balance of combustion with appropriate air preheat
Temperature

temperature Tair and ambient temperature T0 .

T p,in
 
(1 + E)Scair (Tair − T0 ) + HVeff
TFT = T0 + (1)
[(1 + E)S + 1]cg
Pinch ΔΤ

where cair and cg are the specific heat capacity of air

Cold utility
Heat
Fig. 1 – Fired heater duty as the overhang of composite
curve.
mean metal tube temperature T1 , and the radiatively adiabatic
refractory is considered as a gray surface.
The procedure for the area-energy targeting for fired heater
integrated processes is initiated with the integration of fired
heater into the network for the given Tmin . The overhang of
the cold composite curve is considered as the heat duty of the
fired heater as shown in Fig. 1. In this case the process stream
is entering the fired heater after completing process to pro-
cess heat recovery. The stream absorbs the hot utility target
inside the fired heater and leaves at the target temperature.
Schematic of a fired heater system is shown in Fig. 2. The pro-
cess stream after process heat recovery enters the fired heater
at Tp,in and leaves at the target temperature Tp,out . Ambient air
at T0 is preheated using flue gas heat to Tair . The fired heater
integration procedure provides fuel target mf , air preheat tem-
and flue gas respectively and the effective heating value
HVeff = (1 − ˛)HV, ˛ is the setting losses.
The average design radiation section heat flux is gener-
ally specified, depending on the fired heater application. If
the heat flux selected is high, the radiation tube surface area
required would be less and, hence, produces a smaller and
more-compact heater with lower investment cost. However,
this result in the refractory, the tubes, and its supports exposed
to higher temperature. High radiation flux may reduce the ser-
vice life of the fired heater and increases the maintenance
cost of the fired heater. Also it increases the potential for coke
deposition and product degradation (Berman, 1978). The aver-
age design radiation flux q is related to the mean radiating
temperature Teff as per the one gas zone stirred reactor model
(Varghese and Bandyopadhyay, 2007, 2009),
   
4
q = K Teff − T14 + hr Teff
4
− T14 (2)
where K accounts for the geometric complexities of the radi-
ation chamber, multiple reflections from different surfaces,
and reradiation from the refractory. T1 is the mean tube metal
temperature. The mean metal tube temperature T1 can be
obtained from the fluid inlet temperature to the radiation

To
stack T g,out
T Air
s Flue gas
preheater T
p,in
T0 Process stream in
Convection
Combustionair section

T bw

T r,in

T
eff
Radiation
chamber

Process stream out

T p,out

T air

To combustion
chamber

Fig. 2 – Fired heater system with air preheating using flue gas heat.
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216 chemical engineering research and design 9 0 ( 2 0 1 2 ) 213–219

Table 1 – Radiation factor, convective heat transfer and degree of stirring for fired heaters (Varghese and Bandyopadhyay,
2007, 2009).
Parameters Horizontal fired heater Vertical fired heater

Radiation factor (K) 0.237 0.233

Convective heat transfer factor (hr ) 0.0165 0.0263
Degree of stirring (d) 1.03 1.03

chamber Tr,in and outlet temperature Tp,out (Varghese and The convection section heat transfer coefficient can be cal-
Bandyopadhyay, 2007, 2009). culated as

1 1 1
Tr,in + Tp,out = + (9)
T1 = + 42 (3) hcon hp hg
2

The cross over temperature of the fluid can be obtained

Eq. (2) can be solved to find effective gas radiating tem-
from the heat balance
perature Teff . Imperfect stirring within the radiation chamber
results in a reduction in the temperature of the flue gas Tbw
leaving the radiation chamber. The bridge wall temperature Qcon = mp cp (Tr,in − Tp,in ) (10)
Tbw can be estimated based on the mean effective tempera-
ture of the radiating gas Teff , the adiabatic flame temperature With the logarithmic mean temperature difference
TFT , and the degree of stirring d (Varghese and Bandyopadhyay,
2007, 2009). [Tbw − Tr,in ] − [Tg,out − Tp,in ]
Tln = (11)
ln((Tbw − Tr,in )/(Tg,out − Tp,in ))

Tbw = dTeff − (d − 1)TFT (4)

The convection section area can be obtained from the con-
vection section heat duty,
The numerical values of K, hr , and d are dependent on
the design variables of the fired heater selected, type of fuel,
Qcon = Acon hcon Tln (12)
etc. (Varghese and Bandyopadhyay, 2007, 2009). For the target-
ing and conceptual design stage, detailed design parameters
The area of the air preheater can be targeted next. The air
of a fired heater are not defined. However approximate val-
preheat temperature Tair , stack temperature Ts and heat duty
ues of these parameters have been estimated for different
Qap are available from the fired heater targeting procedure.
operating scenarios and reported in Table 1 (Varghese and
Heat transfer coefficient for the air preheater can be obtained
Bandyopadhyay, 2007, 2009). The radiation duty fraction can
as
be now calculated as
1 1 1
TFT − Tbw = + (13)
f = (5) hap hair hg
TFT − Tg,out
With the logarithmic mean temperature difference
where Tg,out is the temperature of the flue gas leaving the fired
heater convection section. For the initial iteration, to find the [Tgout − Tair ] − [Ts − T0 ]
Tln = (14)
mean metal tube temperature T1 the radiation duty can be ln((Tgout − Tair )/(Ts − T0 ))
assumed as 60% of the total heat duty. The heat transfer inside
a furnace radiation chamber is approximately 45–55% (Stehlik Area of the air preheater can be targeted now.
et al., 1995). Convection section heat transfer is between 45%
and 25% and the remaining stack and other losses account for Qap = Aap hap Tln (15)
10–20%. The result of radiation duty fraction from Eq. (5) can
be used in the next iteration for refining the calculation. 2.1. Cost targeting
With the heat duty of the radiation chamber and convec-
tion section known, the area targets for the fired heater can be With the fired heater area for the radiation chamber and
now targeted. convection section targeted, the overall cost for the heat
exchanger network with fired heater can be estimated now.
Qr = fQhu (6) Heat exchangers cost is calculated as (Ahmad et al., 1990),

  A k3
Radiation section tube surface area requirement can be
Chx = N k1 + k2 (16)
obtained now, N

Qr where A is the total area of process heat exchangers and N is

Ar = (7)
q the number of heat exchanger units targeted and k1, k2, k3 are
the cost coefficients. Cost of the air preheater in the convection
The convection section area requirement can be targeted section can be calculated using the area targeted as (Stehlik et
from the convection section heat duty as al., 1995)

Qcon = Qhu − Qr (8) Cap = k1 + k2Ak3

ap (17)
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Table 2 – Stream data.

Stream Supply Target Mass flow rate Specific heat Heat transfer
temperature (K) temperature (K) (kg/s) capacity (kJ/kg K) coefficient (kW/m2 K)

Reactor feed 1 293 453 78.43 2.55 0.8

Reactor product 1 523 313 73.17 2.05 0.8
Reactor feed 2 413 503 122.15 2.456 0.8
Reactor product 2 473 353 119.05 2.10 0.8
Cooling water 293 303 4.184 0.8

Cost of the fired heater is calculated based on the area of

Table 3 – Cost parameters for the case study.
the convection section and radiation section as (Mussati et al.,
2009), Description Cost

Cooling water 10 ($/kW)

Cr = kr Ar (18) Fuel cost 300$/t
Heat exchanger capital 40,000 + 500 A ($)
Radiation section unit cost 1250$/m2
where kr is the radiation section cost coefficient for unit area.
Convection section unit cost 740$/m2
And convection section cost is obtained as
Fired heater box cost 40,000 + 360 (Ar + Acon ) ($)

Ccon = kcon Acon (19)

3.5

3.25
TAC (10 $/y)
where kcon is the convection section cost coefficient for unit 6
area. The firebox cost is calculated as (Mussati et al., 2009), 3

2.75
CFB = (k1 + k2(Ar + Acon )) (20)
2.5
0 2 4 6 8 10 12
Total capital required includes the cost of the heat
Δ Tmin (K)
exchanger, air preheater and fired heater.
Fig. 3 – Total annualised cost for different process approach
Ccap = Chx + Cr + Ccon + CFB + Cap (21) temperature.

The operating cost is calculated from the fuel targeted with
unit cost Cf and annual operating hour t.
Copr = mf tCf
The total capital required is annualised using the CRF and
the overall annualised cost of the heat exchanger net work can
be estimated as
TAC = CRFCcap + Copr
The overall cost can be calculated for different values of
Tmin and the optimum temperature range can be selected.
This procedure can used to find the optimum temperature
range considering the fired heater capital, heat exchanger cap-
ital and operating cost.
The procedure developed can be programmed in to
Microsoft excel and the optimum temperature range can
be obtained using the solver application. For the given pro-
cess target the hot utility, cold utility requirements and heat
exchanger area corresponding to the minimum approach tem-
perature Tmin chosen. Using the fired heater integration
procedure target the minimum fuel required, air preheat tem-
(22) perature and flue gas outlet temperature to supply the hot
utility requirement of Qhu . The integration results can be used
to target the air preheater area and fired heater area. With
these area targets and fuel flow rate the operating cost and
capital cost can be obtained for the Tmin chosen. The pro-
cedure can be repeated for different values of Tmin and an
(23) optimum temperature range can be obtained by minimis-
ing the total annualised cost by varying Tmin. The optimum
temperature thus obtained will be the optimum for the heat
exchanger network along with the fired heater integrated.
2.2. Case study
The following case study (Akbarnia et al., 2009) is presented
to illustrate the procedure developed. Stream data for the pro-
cess is as given in Table 2. Interest rate of 10%, plant life 5 y
and 8000 h operating hours are assumed in this case study.

Table 4 – Fired heater target results.

Tmin Hot utility Cold utility Heat Fired heater Fired heater Air pre
(kW) (kW) exchanger radiation convection heater area
area (m2 ) area (m2 ) section area (m2 )
(m2 )

2 4300 6800 14608.8 102.3 161.2 193.6

4 5100 7600 10861.2 121.1 191.1 222.5
6 5900 8400 8858.9 139.7 221.1 249.2
8 6700 9200 7557.8 158.23 251.1 273.9
10 7500 10,000 6629.9 176.67 281.2 296.5
12 8300 10,800 5929.2 195.52 310.5 318.6
14 9100 11,600 5378.7 213.8 340.5 337.2
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218 chemical engineering research and design 9 0 ( 2 0 1 2 ) 213–219

Table 5 – Cost targets for different minimum approach temperature.

Tmin (K) Heat Fired heater Total capital Fuel targeted Operating cost Total
exchangers total cost cost (106 $/y) (kg/h) (105 $/y) annualized
cost (106 $/y) (105 $/y) cost (106 $/y)

2 7.46 3.82 7.983 398.67 9.568 3.132

4 5.59 4.45 6.187 472.85 11.348 2.844
6 4.71 5.08 5.382 547.03 13.128 2.818
8 3.94 5.71 4.687 621.2 14.909 2.820
10 3.595 6.34 4.417 695.4 16.689 2.935
12 3.125 6.96 4.020 769.7 18.472 3.016
14 2.969 7.59 3.937 843.6 20.248 3.180

mc (kW/K)

250 473 K 419 K 353 K

523 K 472.3 K 419 K 386.8 K 313 K

150

8400 kW

200 453 K 413 K 333.5 K 293 K

8000 kW 16500 kW 7500 kW

503 K 483.33 K 458 K 413 K

300

8000 kW
3.785
2092 K 533.33 K 433 K
Flue gas
5900 kW

3.161 420.1 K 300 K

Air
379.8 kW

Fig. 4 – Heat exchanger network with fired heater system for approach temperature of 6 K.

The cost parameters assumed in this example is provided
in Table 3. For the fired heater integration the following param-
eters are assumed. Ambient temperature 300 K, excess air
required 15%, stoichiometric air fuel ratio of 18:1 and calorific
value of fuel as 43 MJ/kg. Stack temperature is to be limited to
433 K, specific heat capacity for air 1.005 kJ/kg K and for flue
gas 1.148 kJ/kg K. Minimum temperature difference between
the process stream, flue gas and air preheating is 50 K. For the
convection section of the fired heater the overall heat trans-
fer coefficient is 0.04 kW/m2 K and air preheater overall heat
transfer coefficient is 0.02 kW/m2 K, design radiation flux is 29
MW/m2 .
Fired heater integration results for different process
approach temperature difference is given in Table 4. The
cost targets for the network are given in Table 5. It is to be
noted that the cost of fired heater increases with increasing
approach temperature difference Tmin due to the increas-
ing heat duty. The optimum temperature difference for the
network is found to be in the range of 5–8 K, this is shown
in Fig. 3. The optimum temperature difference of 6.02 K is
obtained using the Microsoft excel solver, with a Pentium IV
processor and processing time of 0.06 s. The heat exchanger
network corresponding to 6 K temperature difference is given
in Fig. 4.
3. Conclusion
A detailed procedure for the area-energy targeting for fired
heater integrated processes along with utility system param-
eters is developed. The sequential procedure presented is
simple and can be applied to heat exchanger network with
multiple fired heaters. The temperature difference between
the process streams, flue gas and air preheat can be treated as
variables for further improvement in the targeting procedure.
The improved area-energy targeting procedure can be applied
for different types of fuels and fired heaters.
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