Furnace Improvements

Services

Maximize Profits
By
Revamping Fired Heaters

✓ Increased Capacity ✓ Higher Efficiency

✓ Longer Run Lengths ✓ Lower NOx Emissions

Furnace Improvements Services Inc. A.G. Furnace Improvements Pvt. Ltd.

1600 Highway 6, Suite 480 A-74, Ground Floor, Sector-2,
Sugar Land, TX 77478 Noida (UP)-201301, India
Tel: (281)980-0325 Tel 1: +91-120-4146823
Fax: 1-877-395-0760 Tel 2: +91-120- 4149921

Email: info@heatflux.com
Web: www.heatflux.com
 FURNACE IMPROVEMENT SERVICES
Maximize Profits by Revamping Fired Heaters

FIS ENGINEERING SERVICES

FIELD
SERVICES
» Energy Survey
» Safety Audits
REVAMPING » Furnace Audits
SERVICES
» Reliability Audits NEW HEATER
» Re-tubing Fired
Heaters » Combustion » Longer Run
Optimization Lengths
» Upgrading
Convection Section » Capacity Increases
» Heater Tuning & » Efficiency
Optimization Improvement
» NOx Reduction

OUR COMPANY
Maximize Profits by Revamping Fired Heaters
Furnace Improvements Services (FIS) est. 1996 in Sugar Land, TX.

Mission: to improve performance and provide uniform heat transfer in fired

heaters.

For over 20 years now, FIS has provided engineering services to improve the
performance and efficiency of their fired heaters and boilers as well as help
reduce refinery NOx emissions. FIS has performed over 400 projects for clients
like Citgo, Valero, Phillips 66, Alon, Frontier, and Total.

Our vision is to be the ultimate technology provider for fired heaters and
boilers.

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 FURNACE IMPROVEMENT SERVICES
Maximize Profits by Revamping Fired Heaters

OUR EXPERTISE
FIS revamp for refinery fired heaters includes: Crude, Vacuum, Catalytic Reformer, Hot
Oil, Coker Heaters, and CO boilers.
FIS provides complete turn-key services for the design, engineering, and supply of new
fired heaters to end users. Our designs are the most economical, efficient, and reliable.
Furnace Improvements has several patented technologies for improving the
performance of fired heaters. These patented technologies are aimed at improving
performance of existing fired heaters.

Technology Application
Split Flow Technology Increases capacity with limited process side pressure drop
Flue Gas Injection Reduces coking & tube metal temperatures
Inclined Firing System Reduces flame impingement and high tube metal temperatures
Spider Gas Tip Shorter flame gas burners
Stack Damper Provides Smooth Control of Heater Draft

INCLINED FIRING SYSTEM

One of the most common issues faced by operators and owners is high
tube metal temperature in fired heaters. Most tube failures in fired heaters
occur due to high tube metal temperatures (TMTs).
‘Furnace Improvements developed the patented INCLINED FIRING
SYSTEM (IFS) to eliminate flame impingement on heater tubes.’

We install burners at 5 – 7 angles away from the tubes with this burner
arrangement; a heater will have the following advantages:
▪ Lower Tube Metal Temperature
▪ Longer Tube Life
▪ Increased Heater Run Lengths
▪ Uniform Heat Transfer
▪ Lower Coking Rates

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INCLINED FIRING IN A CATALYTIC REFORMER

INTERHEATER -2 INTERHEATER -1 CHARGE HEATER

INCLINED FIRING IN A DOWN FIRED STEAM

REFORMER
Base case Inclined Firing case

High flue gas temperature High flue gas temperature

going towards the tubes. going away from the tubes.

[°F] In the Inclined firing case, temperature contours clearly show the reduction in the flue
gas temperature around the radiant tubes.

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INCLINED FIRING IN A DOUBLE FIRED

COKER HEATER

Vertical Up Firing Inclined Firing

INCLINED FIRING IN HORIZONTAL TUBE CABIN HEATER

WITH END WALL FIRING
Existing Case

High temperature
region is in the
centre of the
heater, flue gas
temperature near
7° Inclined Firing Case the radiant tubes is
reduced.

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Maximize Profits by Revamping Fired Heaters

SOME PROJECTS WHERE WE USED

INCLINED FIRING SYSTEM (IFS)

Refinery Unit
Alon USA LP Reboiler Heaters H-102 & H-205
Citgo Twin Cell Crude Heater 11-H-01
CountryMark LLP DHT Charge Heater 210-H-100
Gladieux Processing Hot Oil Heater
Valero Crude Heater (in progress)

*Patent # US 7,484,478 B2

SPLIT FLOW TECHNOLOGY

Split Flow aims to improve the utilization of thermal energy for process heating.
This objective is achieved by splitting the process fluid into two parallel streams:
Main Stream Split Stream

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SPLIT FLOW TECHNOLOGY

Main Stream
-The fluid in the Other Advantages of the
first stream is
heated Split Flow Technology
predominantly by The streams are then include:
the convective combined at the heater
and radiant heat outlet. The Catalytic ▪ High heater efficiency
transfer
mechanism
Reformer technology ▪ Low process pressure
has been very
successful for capacity drop
increase of fired ▪ Low firebox
Split Stream heaters particularly in temperature
heaters. Increases the
-The fluid in the capacity of a heater by ▪ Low radiant heat
second stream is 15% to 30 %. fluxes
heated
predominantly by ▪ Low TMTs
the convective ▪ Low installation costs
heat transfer
mechanism.

SOME PROJECTS WHERE WE USED

Split Flow Technology
Refinery Unit
Alon USA LP H2 Heater
Alon USA LP DHT Heater
Citgo Catalytic Reformer
ConocoPhillips Reformer Catalytic Heater
Gladieux Processing Hot Oil Heater
Valero Catalytic Reformers

*Patent # US 7,204,966 B2 B2

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 FURNACE IMPROVEMENT SERVICES
Maximize Profits by Revamping Fired Heaters

CFD MODELING
At Furnace Improvements, we utilize CFD modeling to analyze problems and provide
solutions.
This tool enables us to study the existing design and operating conditions of heaters
and determine recommendations for solving any difficulties.
CFD gives a competitive edge over other analyses due to its visual presentation of the
observed conditions and proposed modification.

The following are a few areas where FIS has used this tool effectively:

Mixing (ammonia
Study Flow injection grid & Combustion Tube Heat transfer
flue gas (burner &
Mal-distribution recirculation mix heater design) Failures studies
box design)

CFD MODELING
Temperature contours (ºF) Base Case

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CFD MODELING
Temperature contours (ºF) Proposal Case

VELOCITY CONTOURS AND VECTORS AT CRUDE

HEATER CELL

Cell Cell
Heater 1 Heater 2

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FIS 3-D MODELING

A B C D
(A) Model of Inclined Firing Technology applied to an 8 burner system
(B) Model of a vertical cylindrical heater with a common stack
(C) Model of a Naphtha Splitter Reboiler Heater
(D) Model of a Compressed Air Heater

REVAMPED HEATERS
Revamping fired heaters is a practical and effective way to improve heater
performance. This strategy focuses on working with existing components, and as
a result, capital investment and downtime are minimized.

Above Photo: NOx Reduction in

Above Photos: #4 Platformer Heater Citgo Corpus Christi
Alky Heater
Before (Left) and After Revamp (Right)
Phillips66 Wood River

Above Photo: NOx Reduction in Crude Heater

Premcor/Husky Lima Refinery

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 FURNACE IMPROVEMENT SERVICES
Maximize Profits by Revamping Fired Heaters

NEW HEATERS

Above Photos: New hot oil heater at Phillips 66 Wood River; FIS was responsible for
the design, engineering, procurement, and fabrication services on this project.

OUR CLIENTS

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 Furnace Improvements Services
Organization Chart
Ashutosh Garg
(Vice-President)

Bala Saligram Arun Garg

(Director)

Structural/ 3D Design Poject/Estimation Quality Mamta

Process CFD Group IT Administration
Mechanical Modeling Group Proposal & Planning Assurance Garg

Balwant Amarvir Chrish Slaten Tung Tran Sandhya

Harsh Ghuge Ajay Malik Julio Vimla Pawar
Singh Bisht Lalit Nainwal Chilka (Contract) (Contract) Goel
Hernandez
Naseem Ananth Sharad N Umakant Jessica
Sadam Ahmad Talib Hussain Bijal Gangar Ron Mahinder
Ahmad Krishna Pachpute Sharma Ponce
(Contract) Hallman Kumar
Mukesh Kumar Meghna Nilesh Aher
Anuj Nigam Fahad P. HSE & Site Sheela Mehto
Mathuria
Services
Digvijay Deepika Amit Mani
Davinder Singh Muhammad Ali Tiwari Sapna Tyagi
Tomar Umlani
Don
Kunal Sopori Jordan
Ajay Saini Naulesh Kumar (Contract)
Disha
Shakeel Ahmad Ravi Gaba Mangal
Sushil
FIS TEAM Pradeep Kushal Singhania Sharma
AGFIS TEAM
Contract Manoj Ashutosh

Harmanpreet
Neeraj Singh www.heatflux.com