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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 bustion of the fuel. Oil and natural gas are the major fuels
used in fired heaters. The hot flue gases of combustion sup-
Tools of pinch technology help in establishing energy efficient ply the required energy to the process fluid that flows inside
design of a modern process plant prior to its detailed design. the tubes. Tubes are contained within refractory lined cham-
Subsystems, independently designed and integrated into the ber that reradiate heat to the tubes and reduce heat leakage.
process may lead to suboptimal design of the overall plant. The heat duty of a fired heater is usually controlled through
Thus, appropriate integration of various subsystems into the fuel flow rate.
overall process has to be performed for optimal design of the The overshoot of the cold composite curve over the hot
entire process plant. The improved procedure for area-energy composite curve is the hot utility, Qhu required for a process
targeting of fired heater integrated processes considers indi- corresponding to a minimum approach temperature of Tmin
vidual component design-parameters along with their energy at the pinch. Similarly the overshoot of the hot composite over
and economic interactions. Fired heaters are energy as well as the cold composite is the cold utility, Qcu required for the pro-
capital intensive equipment. The cost of the furnace system cess. Recently, Bandyopadhyay and Sahu (2010) have proposed
usually ranges from 10% to 30% (Jegla et al., 2000) of the plant’s a modified problem table algorithm to target minimum utility
total investment. requirement for a given Tmin . The optimization of the pinch
Fired heaters are used in various chemical and process approach temperature Tmin is a trade-off between the capital
industries such as refineries, petrochemical, fertilizer, etc. In and energy (capital and operating cost). Heat exchanger area
industry, fired heaters are also known as process heaters, fur- required for the heat exchanger network is used to estimate
naces, and direct-fired heaters. The primary function of a the capital requirement. Area targeting involves area estima-
fired heater is to supply a specified quantity of heat to the tion of process to process heat exchangers and utility heat
process stream. Typically, when desired temperature of the exchangers in a heat exchanger network. The total capital can
process stream is above the practical range of steam heating be estimated using the total heat exchanger area and number
(363–477 K), fired heaters are used (Allen and Rosselot, 1997). of units with an appropriate cost correlation. Using the capital
The desired energy is generated in the fired heater by com- 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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The one gas zone model, also known as the stirred reactor
model for a furnace, is used for the fired heater area esti-
for different minimum approach temperature Tmin . The opti- mate. The stirred reactor model is reported to predict, with
mum range of Tmin may be determined corresponding to the a significant degree of accuracy, the overall heat-transfer per-
minimum total annualized cost. formance for a wide range of furnaces burning different fuels
Various authors (Hall and Linnhoff, 1994; Varghese and and having various configurations of the radiation chamber
Bandyopadhyay, 2007, 2009) have already reported the proce- (Varghese and Bandyopadhyay, 2007, 2009; Truelove, 2002). The
dure for integrating fired heater into the process. A graphical model assumes a radiating gas medium at a uniform effec-
procedure to target the minimum fuel firing, and air pre- tive temperature Teff . The tube surface acts as a heat sink at a
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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
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
T p,out
T air
To combustion
chamber
Fig. 2 – Fired heater system with air preheating using flue gas heat.
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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
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
A k3
Radiation section tube surface area requirement can be
Chx = N k1 + k2 (16)
obtained now, N
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 exchanger area corresponding to the minimum approach tem-
unit cost Cf and annual operating hour t. perature Tmin chosen. Using the fired heater integration
procedure target the minimum fuel required, air preheat tem-
Copr = mf tCf (22) perature and flue gas outlet temperature to supply the hot
utility requirement of Qhu . The integration results can be used
The total capital required is annualised using the CRF and to target the air preheater area and fired heater area. With
the overall annualised cost of the heat exchanger net work can these area targets and fuel flow rate the operating cost and
be estimated as capital cost can be obtained for the Tmin chosen. The pro-
cedure can be repeated for different values of Tmin and an
TAC = CRFCcap + Copr (23) optimum temperature range can be obtained by minimis-
ing the total annualised cost by varying Tmin. The optimum
The overall cost can be calculated for different values of temperature thus obtained will be the optimum for the heat
Tmin and the optimum temperature range can be selected. exchanger network along with the fired heater integrated.
This procedure can used to find the optimum temperature
range considering the fired heater capital, heat exchanger cap- 2.2. Case study
ital and operating cost.
The procedure developed can be programmed in to The following case study (Akbarnia et al., 2009) is presented
Microsoft excel and the optimum temperature range can to illustrate the procedure developed. Stream data for the pro-
be obtained using the solver application. For the given pro- cess is as given in Table 2. Interest rate of 10%, plant life 5 y
cess target the hot utility, cold utility requirements and heat and 8000 h operating hours are assumed in this case study.
mc (kW/K)
8400 kW
8000 kW
3.785
2092 K 533.33 K 433 K
Flue gas
5900 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 eters is developed. The sequential procedure presented is
in Table 3. For the fired heater integration the following param- simple and can be applied to heat exchanger network with
eters are assumed. Ambient temperature 300 K, excess air multiple fired heaters. The temperature difference between
required 15%, stoichiometric air fuel ratio of 18:1 and calorific the process streams, flue gas and air preheat can be treated as
value of fuel as 43 MJ/kg. Stack temperature is to be limited to variables for further improvement in the targeting procedure.
433 K, specific heat capacity for air 1.005 kJ/kg K and for flue The improved area-energy targeting procedure can be applied
gas 1.148 kJ/kg K. Minimum temperature difference between for different types of fuels and fired heaters.
the process stream, flue gas and air preheating is 50 K. For the
convection section of the fired heater the overall heat trans-
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