International Journal of Engineering Trends and Technology- VolumesIssue2- 2013 Fired Heater Design and Simulation Mahesh » Jethva’, C. G. Bhagchandani™ ALE. Chemical Engineering Department, LD. College of Engineering, Almedabad-390 015 “Assoctate Professor, Chemical Engineering Department, L.D. College of Engineering, Ahmedabad 380 015 Abstract- In fired heaters, heat is released by combustion of fuels {nto an open space and transferred to process fluids inside tubes. ‘The tubes are ranged along the walls and roof of the combustion chamber. The heat is transferred by direct ra ‘convection aud also by reflection from refractory walls lining the ‘chamber. The design and rating of a fired heater is a moderately complex operation. Here forced draft fired heater, which Is fred by fuel gas, hss been treated. For that all required equations and generalizations are listed from different fired heater design methods as per requirement, A fired heater design calculations are performed using Microsoft Excel Programming software and ‘the same fired heater data are used in HTRI simulation software for simulation and comparision purpose. fon and Keywords. Radiant heat transfer, Convective heat transfer, Shield section, Heat balance, HTRI simulation, Comparision. L._ 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 fumaces 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 ‘mote fired heaters as start-up heater, fired reboiler, crackin, furnace, process heater, process heater vaporizer, crude oil heater or reformer fumace. 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 (rectangular c/s) or vertical (cylindrical c/s) in shape. Same ‘way, a fired heater may be classified depending on location of the burners and type of the draft. u. Radiant Section Design A. Radiant Heat Transfer in Radiant Section: Applying basic radiation concepts to process-type heater design, Lobo & Evans developed a generally applicable rating method that is followed with various modifications, by many heater designers, Direct radiation in the radiant section of a dissct fred heater can be described by the equation shown below. Op = odd yF(Td Tt) Where, Qe = Radiant heat transfer, Brw‘br o = Stefan-Boltzmann constant 0.173E-8 Btu/f’-br-R* c= Rolativeetfectivensss fret ofthe mbe bank Acy = Cold plane area of the tube bank, f F = Exchange factor Ty Effective gas temperature in firebox, °R Ty = Average be wall emperanre, °R B, Heat Balance In The Radiant Section: ‘There are four primary sources of heat input as well as four sources of heat output to the radiant section. We can now set up the heat balance equation as follows: Qruct * Qair * steam + Qara = Qa + Qs + Quose + Rone ‘heat liberated by fuel, Brwhr (LHV) sensible heat of combustion air, Btwhr sensible heat of steam used for oil atomization, Baur sensible heat of recirculated flue gases, Brwhr heat absorbed by radiant tubes, Bru/hr Radiant heat to shield tubes, Bruhhr heat loss in firebox through fumace walls, bridgewall, easing. ete., Brwhr heat of flue gases leaving the radiant section, Bawhr ISSN: 2231-5381 http:/Awww. internationaljournalssrg.org, Page 159International Journal of Engineering Trends and Technology- VolumesIssue2- 2013 C, Total Heat Transfer in Radiant Section (if Shield Section is present) ‘The total heat transfer in firebox when shield section is present will be as follows: Qrireaax = O(% Acp) ag * F(@Acp) 5, TE — TH) + Qen + Qs Where, Qca = Convective heat transfer to radiant tubes, Brw/hr Qcs = Convective heat transfer to shield tubes, Brurhr IIL Convection Section Design A. Overall Heat Transfer Coefficient, U,: Where, Uy = Overall heat transfer coefficient, Brwhr-ft"-F R.. = Total outside thermal resistance, hr-f-F/Ba And, Rig = Bo + Ryo + Rio Where, R, = Outside thermal resistance, br-ft-F/Btu Ryo = Tube wall thermal resistance, hr-f”-F/Bru Rig = Inside thermal resistance, br-ft™-F/Btu ‘And the resistances are computed as, R 4 oh tie Ao Roo = GIG ty a, Re = (E+ IGE) Where, he Effective ouside heat transfer coefficient, Bruhr- er Inside film heat transfer coefficient, Brw/hr-ft7-F Tube-wall thickness, ft Tube wall thermal conductivity, Buwhr-f-F Outside tube surface area, f/ft Mean area of tube wall, f/f Inside tube surface area, #°/8 Inside fouling resistance, he-ft-F/Bmu B. Inside film heat transfer coefficient, ‘The inside film coefficient needed for the thermal calculations may be estimated by several different methods. The API RPS30, Appendix C provides the following methods, For liquid flow with R >10,000, hy=0. o2a(yne*n? (ee And for vapor flow with R, 215,000, A, =O. can ynpsnes Geos Where the Reynolds number is, Heat ansfer coefficient, liquid phase, Bru/br-f’-°F ‘Thermal conductivity, Btwhe-f-"F Inside diameter of tube, f Absolute viseosity at bulk temperature, Ib/f-hr ‘Absolute viscosity at wall temperature, Ibft-hr Heat transfer coeificient, vapor phase, Brwhr-ft!°F Bulk temperature of vapor, °R Wall Temperature of vapor, °R ‘Mass flow of fluid, Ibvhe-ét Heat capacity of fluid at bulk temperature, Brullb-°F For two-phase flow, hap = ha + hy Heat transfer coefficient, two-phase, Brur-f2.°F Weight fraction of liqui Weight fraction of vapor % - C. Effective outside heat transfer coefficient (he) for Fin tubes: le (Ese he) Where, ° kh, ~ Average outside heat transfer coefficient, Btw/hr- eF E = Finefficiency Ay = Total outside surface area, f/ft Aye = Fin outside surface area, #/ft Ay = Outside tube surface area, 8 i. Average outside heat transfer coefficient. ho: ISSN: 2231-5381 http:/Awww. internationaljournalssrg.org Page 160International Journal of Engineering Trends and Technology- VolumesIssue2- 2013 1 + Teh) * Fre Outside heat transfer coefficient, Btw/hr- Outside radiation heat transfer coefficient, Bru/hr- PF Outside fouling resistance, br- hy FB i, Outside film heat transfer coefficient, he: i he = jGney(— YP” Puy Colburn heat transfer factor Mass velocity based on net free area, Ibvhr-ft Heat capacity, Brwlb-F Gas thermal conductivity, Brw/hr-f-F Gas dynamic viscosity, bvhr-ft 1, Colburn heat transfer factor, j: os d,\°* 1, + 460 (%) @ yo2s izcce(4) GR Reynolds aumber correction Geometry correction ‘Nou-equilateral & row correction Outside diameter of fin, in Outside diameter of tube, in Average gas temperature, F “Average fin temperature, F Where, Reynolds number correction, C,: = 025R,°* Where, axG Me R, ~ Reynolds number ~ Geometry correction, C3 For segmented fin tubes arranged in, a staggered pattern, C, = 0.554045 7 > 2a inline pater, 026% C= 03540500 7? For solid fin tubes arranged in, a staggered pattern, 35+ 065e" 7 an inline pattern ossi, 6, =0.20+ 0.656" % Where 1, = Finheight, in sy = Fin spacing, in ‘Non-equilateral & row correction, C3 For fin tubes arranged in, Staggered pattem, ay cr08t C5 = 07 + (0.7 — 082-9350) ) oF Inline patra, = 1A (0.75 — 1 Bel-0708,)) 025%) Where, 1M, = Number of ube rows PL = Longitudinal tube pitch, ia P, = Transverse tbe pitch, in ii, Mass Velocity, Gy ‘Where, Wy = Mass flow rate of gas, Ibvhe An = Net free area, And, Net Free Area, An Ay = Aa etal) Where, ‘Cross sectional area of box, fi” Fin tube cross sectional area/ft, ft'/ft Effective tbe length Number bes wide Ag = NeLePe aces * Dying Fin height Outside diameter of ube, “Transverse ibe pitch finthickness f number of fins, fins/ft y= ¥. Surface Area Calculations: For the prime tube, Aye = nd (4 — nyt) And for solid fins, ISSN: 2231-5381 http://www. internationaljournalssrg.org, Page 161International Journal of Engineering Trends and Technology- VolumesIssue2- 2013 where, Ag = g(t — ny) + angl2lp(d +L, + tye #24) Ty -. Gas Tesperarue,F Te = Tube Wall Temperature, F ‘And for segmented fins, y= nd(1— nye) +04an (dy +02) [Witiceei Biopransing (d, +0.2)((2i, —0.4)(wy + ty) + (wsty)) Design of different sections of fired heater has been Sn EL! prrformed vsing Microsolt Excel Programming. For the where, calculation purpose, different calculation methods and dy = Outside diameter of tbe, ft onalonemma! it theposemmis ny = umber of fins, fins’ = fimthickess Table Radian Section Dsizn f= Finheight, PROPERTY DETAIL ‘AMOUNT a = 2 Tube OD, ind) 3.626 wy = Width offin segment, thickness in Ge) | 008118, No of mbes (N) 40 And thea, (Racist) Ayo = Ao ~ Ayo No of ubes (Ny ra (shield) vi Fin Efficiency, E Eifectve Tength, [3507 For segmented fis, (L) (Radiant) Effective lenath, | 1831 £=x(09+ 04%) (L.) (Shield) Tube spacing, in (CC) | 16 ‘And for soli fins, (Radiant) a No oftubesperrow | 4 in (Shield) e=yoasn(£)o—n+0 Traore aia] 76 Where, (Py Ghicid) y=x(07 +03) Combustion Fraction excess air | 0.15 Firebox Diameter, f(D) 19.98 And, rovers fluid Mean wall 109758 tanh(me) temperature, (T) °R TE Fhe ga Flue gas temperature] 3077.1 Where, , (Tp. =e a (Radiant) oO 75086 Beles) (Shield) ‘Assumed ©) 7 (Radiat) # 1370S Focsepmented fins: (Shield) = 37.68 a Radiant) | F 1699.51 pnw Ql" ae ie Skytyw, (WAgiHGAsgh fe 1797.15, an Ant 2103.31 ‘And for soli fins (GA MeAy)) [Aten oF Shiela 97.64 Section, f(A.) Ig An 306.66 Biya; an 017 (Gg) HeAs)) vit Fin Tip Temperature, Ty Partial pressare | atm (P) ed “The avernge fn tip temperature is calculated as follows, ‘Mena beam length 13.32 ' Pe nm 3.406 Emissiiy E 05087 T=, + (Ip “mG Ta prime! ‘Exchange factor F 05109 ISSN: 2231-5381 http://www. internationaljournalssrg.org Page 162International Journal of Engineering Trends and Technology- VolumesIssue2- 2013 Radiantion Bur 337107 | Gas Heat Transfer MM Kealihr SA85 Colbum HT Factor |] 0.00543 Outside Film HT eo- | he, Brvhr-i°F 2.0291 efficient ‘Table2 Gomecton Section Design Average Outside HT | h,, Brulhr-f?°F 2599 PROPERTY DETAIL AMOUNT | co-efficient Fin Height, in (lg 1 Fin Ffficiens E DOSE Thickness, in (i 0.05118 | Effective Outside HT | hy, Brwhr- °F 2.5595 No of fins. fins/ftag | 60 co-efficient Ther, Cond., Btwhr-f- [21.292 __ | Overall HT co- Vo, Brwhr-it °F TORE SF (ky) efficient Tube OD. in) $626 | LMTD F 430.28 Thickness, in (=) 0.5 “HT Area r 0102.93 No of rows (N) S Convection Heat ‘Buh 5.4°10"6 No oftubes perrow | 4 Transfer ‘MM Keallhe 2.119 Wy) Effective tube length, | 18.307 iL) Table Heat Balance Pitch, in (P) 16 PROPERTY DETAIL | AMOUNT. Wall temp, °F (Ts) | 959 ‘Assumed amount of % 80 Wall Ther. Cond, | 1283 Radiant HT Brwhr-tF (ks) ‘Assumed amount of % 20 Process Fluid Inlettemp. °F (t) | 609.8 Convection HT Outlet temp, F(t) | 621.1 Thermal Efficiency %6 (given) 30.7 Ther. Cond., (Lig), | 0.04939 || Total Heat Input (Qex) | MM Kalbe 11.70 Bhubnf-F tkp Total Heat Transferred | MM Keal br 10.61 Ther. Cond. (Vap), | 0.11995 | (Qs) (given) Biufhe F Qe) Radiant HT (Q) ‘MM Kealihr Tae Sp. Feat (Ligh Biwllb- | 0.654 Convection HT (Q) MM Kealihr 2122 oF fe) Heat Loss (Qu) ‘MM Keallhr( 0.2924 Sp. Heat (Vap) 5985 of Qiu Bialb"r(e,) Heat ont fom HT areato_| MM Keallr D955 Viscosity (Lig), Ibvhr- | 0.31448 [Stk (Qeas) (Que Qu Qos) fC) Viscosity (Wap), Ibiie- | 0.0508 fu) V. HIRI Introduction Mass flow rate, Ibvir_| 10549053 | ETRY Xchanger Swite® 6.0 combines in a single graphical user We fraction (Lig) (W)_ | 0.7 environment the design, rating, and simulation of fired heaters, We fraction (Vap) | 0.3 (Gh), Xfi simulates the behavior of fired heaters. The (we) programm calculates the performance of the radiant section for Fouling factorhr-f*- [0.00391 | cylindrical and box (cabin) heaters and the convection section SF Bra (Re) of fired heater. It also designs process heater tubes using API Flue Gas Inlet temp, °F (%) 1472 530 and performs combustion calculations. Xfi contains Outlet temp. F (ty) | 788 different calculation modules to simulate the different pats of Mass flow rate. Ibvhr | 42630.545 | a fired heater. One can run these modules separately or in we) combination to model part or all of a fired heater. Ther. Cond, Brumhr-R | 0.0353 SF (ks) Sp. Heat, Baul F | 03087 VL. Comparision of given/calculated data and (2) simulated data Viscosity, Ibbrft (ig) | 0.0883 | The following table of comparision between given or Tnside Film AT co | hy, Bru °F 461.16 | calculated data or results and simulated results proves that the efficient prepared design module is trustable tool for fired heater ‘Mass Velocity of Flue | G,, Ibi TOIT79_| desien ISSN: 2231-5381 http://www. internationaljournalssrg.org Page 163International Journal of Engineering Trends and Technology- VolumesIssue2- 2013 ‘Table 4 Comparision of given/ealculated data and simulated data PROPERTY DETAL | CAL. | SIMU. paTA_|_DaTA ‘Overall Performance Heat day MM. 1061] 1073 abe Efficiency CHV) | % 90.7 3% “Heat release (Total) _ | MM 1.69 [1268 abe Foal LAV Keabkg [13380 [T3371 Process Aid temp at | C a2728 P3278 crossover Process Hid temp at [C 36 BOG heater outlet ‘Radiant Section Fuel gastemp out | C 800 R71 ‘Average flux rate | keaViram? [29000 | 256112 Duty NM sass [7.987 kale Surkace area ry 166.96 | 3187 Pressure drop kgm” [1.292 [1.75 Coavestion Section Foal gas temp out [C 20 381.56 ‘Outside film [Real [12.5 17.68 coefficient mc Tnside film coeficient [kealhe- | 2251.58 | 185499 nrc ‘Overall HT | Kea [945 127 coefficient (U) mc ‘Convection duty MM zine 27aae abe Surface area me 93859 [98527 EMID ¢ 221.27 | 220.4 Draft ar bridgewall | mam 23043 [2.54 Pressure drop Kgfem™ | 0.58 ‘Bumers Fodlwaie [ighie [38235 VII. Conclusion Using Microsoft Excel Programming software, a design ‘module has been prepared which can be used for different data values and gives satisfactory results. In present ease, the design module gives required radiant heat transfer and convective heat transfer in the fired heater. The specified fired hheater is alse simulated in HTRI heat exchanger suite 6.0 using the same fired heater data which are used in MS Exel design module. The table of comparision illustrates that the fired heater design and simulation been performed in satisfactory way. wy a 8 a fa} References Process Hest Tranter by Donald Q Kern, np nomhentechanperesien com, [ADL 560, Fired Henters foe General Refinery Sersice 4 edition, Aveost, 2007, HIRI Xchange Sate 60 software, HIRE Manual and Help Sle ISSN: 2231-5381 http://www. internationaljournalssrg.org Page 164