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Coupled simulation of convection section with dual stage steam feed mixing
of an industrial ethylene cracking furnace

Article  in  Chemical Engineering Journal · November 2015

DOI: 10.1016/j.cej.2015.10.093

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 Chemical Engineering Journal 286 (2016) 436–446

Contents lists available at ScienceDirect

Chemical Engineering Journal

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

Coupled simulation of convection section with dual stage steam feed

mixing of an industrial ethylene cracking furnace
Guihua Hu, Benfeng Yuan, Liang Zhang, Jinlong Li, Wenlin Du, Feng Qian ⇑
Key Laboratory of Advanced Control and Optimization for Chemical Processes of Ministry of Education, East China University of Science and Technology, Shanghai 200237, China

h i g h l i g h t s

A complete coupled simulation method of convection section is proposed.

Velocity fields are not uniform along width direction due to asymmetrical structure.

Recirculation zones cause a longer residence time of flue gas and local overheating.

Process gas and tube skin temperature and heat flux have axial and radial profiles.

Changes of flow pattern are effected by gravity and centrifugal force.

a r t i c l e i n f o a b s t r a c t

Article history: A complete coupled simulation of the convection chamber and tubes with dual stage steam feed mixing
Received 30 July 2015 of an industrial ethylene cracking furnace has been carried out with the computational fluid dynamics
Received in revised form 26 October 2015 (CFD) method for the first time. In the convection chamber, the standard k–e model and discrete ordi-
Accepted 28 October 2015
nates (DO) radiation model were respectively used in the descriptions of turbulence characteristics
Available online 2 November 2015
and radiative heat transfer. In the tubes, renormalization group (RNG) k–e model and volume of fluid
(VOF) model were respectively applied to the turbulence flow and the liquid–vapor two phases flow.
Keywords:
Simulation results agree well with the industrial data. Based on the coupled result, a dynamic simulation
Coupled simulation
Convection section
was calculated in the feedstock preheater (FPH). Simulation results show that the velocity and temper-
Dual stage steam feed mixing ature fields are inhomogeneous distributions along the width direction due to the asymmetrical structure
Cracking furnace of convection chamber. Two recirculation zones occur at the corner both near and away from the
Computational fluid dynamics entrance to the convection chamber, which will cause a longer residence time of flue gas and local over-
Evaporation heating in furnace wall of convection chamber. The process gas temperature, tube skin temperature and
heat flux profiles are respectively different along the axial and radial direction of the high temperature
coil (HTC-I). The changes of flow pattern from bubble flow to spray flow are effected by gravity and cen-
trifugal force during evaporation. The results will be helpful for the design and operation in cracking
furnace.
Ó 2015 Elsevier B.V. All rights reserved.

1. Introduction
Ethylene cracking furnace is the key equipment in the produc-
tion of ethylene, which influences the yield efficiency of feedstock,
selectivity of important products, equipment energy consumption,
etc. In the world 99% of ethylene production has been adopted by
tubular cracking furnace [1].
Tubular cracking furnace mainly includes two parts: radiation
section and convection section. For the study of radiation section,
many achievements have been gained at home and abroad.
⇑ Corresponding author at: No. 130 of Meilong Road, Shanghai 200237, China.
E-mail address: fqian@ecust.edu.cn (F. Qian).
Heynderick et al. [2], Oprins et al. [3,4], Stefanidis et al. [5,6],
Coelho [7] and Habibi et al. [8] early used the numerical method
to study the information of velocity and temperature fields of
radiation section in the cracking furnace. The influences of the grid
formation, combustion model and radiation model on the numer-
ical simulation of cracking furnace were suggested. Lan et al. [9]
and Han et al. [10] simulated different types of cracking furnace
using computational fluid dynamics (CFD) software, and got a
detailed velocity, temperature and concentration fields. Liu et al.
[11] improved the CFD models of the firebox, and thus improving
the computational efficiency. Hu et al. [12,13] improved coupled
method in which CFD software was used to simulate the firebox,
and the software Coilsim1D was used to simulate the tube.

http://dx.doi.org/10.1016/j.cej.2015.10.093
1385-8947/Ó 2015 Elsevier B.V. All rights reserved.
 G. Hu et al. / Chemical Engineering Journal 286 (2016) 436–446
Nomenclature
I radiation intensity (J/m2/s)
m_ pq , m
_ qp mass transfer from phase p to phase q and from phase q
to phase p respectively (kg/m3/s)
m_ l!v , m_ v !l rates of mass transfer due to evaporation and con-
densation respectively (kg/m3/s)
n refractive index (–)
~
r position vector (–)
~
s direction vector (–)
~
s0 scattering direction vector (–)
s path length (m)
Saq mass source term of the phase q (kg/m3/s)
Su source term (–)
t time (s)
T local temperature (K)
Tl temperature of the liquid phase (K)
Tv temperature of the vapor phase (K)
u fluid velocity (m/s)
The results show that the method can greatly improve the compu-
tational efficiency of the process gas side.
Convection section study early focused on the calculation of the
macroscopic phenomenon. For example, He et al. [14] developed a
simulation software of convection section based on Pro-II. Liu et al.
[15] and Zhou and Yang [16] respectively established their convec-
tion section programs based on Aspen Plus [17] platform. However,
the previous studies focused on the process modeles of convection
section, and greatly simplified the fluid flow and heat transfer pro-
cesses inside the tube, thus, the improved understanding of the
occurring processes could not be taken into account. With
the development of CFD technique and computer technology, the
research in microscopic phenomena of the convection section has
also been paid more and more attention. The difficulty of numeri-
cal simulation study in the convection section lies in vaporization
of hydrocarbon feedstock in the tube. The existence of two-phase
flow makes the fluid flow, heat transfer and mass transfer become
more complicated. De Schepper et al. [18] added source terms of
the energy and mass source to the control equations by using the
volume fraction method, thereby preliminarily studying the fluid
flow boiling process of convection section. Mahulkar et al.
[19,20] and De Schepper et al. [21] studied numerical simulation
of coking phenomena of heavy feedstock pyrolysis, which provided
suggestions for reducing thickness of coke layer. Mertinger et al.
[22] studied the cause of heat tube corrosion in the convection sec-
tion with ANSYS FLUENT 14.0 software, providing theoretical refer-
ence for the dangerous case judgement.
In the convection section, vaporization process of feedstock
hydrocarbon is an endothermic process, and the vaporization heat
required is provided by the waste heat of the flue gas. Therefore,
flue gas flow field has a close relationship with heat transfer and
vaporization inside tubes. Only efficient coupling heat transfer pro-
cess between the convection chamber and tubes does accurately
get the vaporization and heat transfer and other such characteris-
tics inside tubes, thus accurately predicting outlet temperature of
flue gas and process gas in convection section. De Schepper et al.
[23] used the CFD method to carry out coupled simulation of flue
gas side and the internals of the heat exchanger tubes in the con-
vection section. However, they simulated convection section with
only one steam flux, and did not consider the heat changes of feed-
stock in the evaporation section, which may impact the coupled
simulation results.
437
Greek letters
a absorption coefficient (1/m)
aq volume fraction of the phase q (–)
q gas density (kg/m3)
ql density of the liquid phase (kg/m3)
qv density of the vapor phase (kg/m3)
qq density of the phase q (kg/m3)
Cu generalized diffusion coefficient (–)
r Stefan–Boltzmann constant (r = 5.672  108 W/m2-
K4)
rS scattering coefficient (1/m)
u dependent variable (–)
U phase function (–)
X0 solid angle (°)
In this work coupled convection section/tubes with dual stage
steam feed mixing simulations have been performed for an indus-
trial naphtha cracking furnace. The highly complex coupling pro-
cess such as fluid flow, heat transfer and mass transfer in the
convection section is considered in the process of calculation. In
the convection chamber, the compressible formulation of the
Reynolds-averaged Navier–Stokes (RANS) equations is adopted to
simulate the fluid flow. The standard k–e model is used for closure.
The discrete ordinates (DO) radiation model is used for modeling
the radiative heat transfer. For the tubes simulations, the Renor-
malization Group (RNG) k–e model is applied to turbulence flow
inside tubes. VOF model is used for two-phase flow. Temperature
and velocity distributions of the flue gas in the convection chamber
and process gas temperature, heat flux, tube skin temperature pro-
files along the tubes are obtained. The simulation results are in
agreement with the industrial data.
2. Mathematical models
2.1. Flow model
The fluid flow in the convection section complies with the law
of nature conservation, including the conservation of mass, energy
and momentum, and control equations are described by mathe-
matics method. In this paper, Navier–Stokes Reynolds average is
used to model the fluid flow of convection chamber and tubes.
For convection chamber, the standard k–e model is used for clo-
sure. For tubes, because there is amount of swirling flow, RNG k–
e model is more suitable for turbulence flow inside tubes than
the standard k–e model [24]. Control equations are mass, energy
and momentum conservation equations, and convection chamber
also includes species transport equation. Because each equation
has the similarity in form, so the following general form of repre-
sentation can be described as:
@ðquÞ
þ divðquuÞ ¼ divðCu graduÞ þ Su ð1Þ
@t
2.2. Multiphase flow model
In the FPH, hydrocarbon feedstock is heated and vaporization
occurs from liquid into vapor. Therefore, the volume of fluid
438 G. Hu et al. / Chemical Engineering Journal 286 (2016) 436–446

Z 4p
(VOF) model based on Eulerian–Eulerian approach is applied rT 4 rs
r  ðIð~
r;~ sÞ þ ða þ rs ÞIð~
sÞ~ sÞ ¼ an2
r;~ þ Ið~
r;~
s0 ÞUð~ s0 ÞdX0
s ~
to simulation of the multiphase flow in the feedstock preheater p 4p 0
(FPH). ð6Þ
In the VOF model, the volume fraction of the phase is added in
the computational cell. In each control volume, the volume frac- Domain-based weighted-sum of gray gas model (WSGGM) is
tions of all phases sum to unity. Thus, if the qth fluid’s volume frac- used for the calculation of the emissivity of the flue gas mixture
tion in the cell is denoted as aq, then the following three conditions [13].
are possible:
2.4. Physical properties
d aq = 0: the cell of the qth fluid is empty;
d aq = 1: the cell of the qth fluid is full; In the industry, there are many kinds of hydrocarbon
d 0 < aq < 1: the cell contains the interface between the qth fluid feedstock which usually include naphtha, diesel oil of ordinary
and one or more other fluids. pressure, light hydrocarbon, heavy-vacuum gas oil, etc. And
online detection instrument is expensive, which is seldom
For the qth phase, the continuity equation of volume fraction adopted in actual production, therefore it is difficult to get the
has the following form: detailed physical property data of hydrocarbon feedstock in indus-
" # try, thus leading to difficulty for the numerical simulation of
1 @

!
 Xn
 
aq qq þ r  aq qq v q ¼ Saq þ _ pq  m
m _ qp ð2Þ convection section.
qq @t p¼1 In this work, the combinations of COILSIM1D [28] and Aspen
plus give rise to the detailed information of material using indus-
The volume fraction equation will not be solved for the primary
trial data. The detailed steps are described as follows: first of all,
phase; the primary-phase volume fraction will be computed based
the collected industrial data such as the density, distillation range,
on the following constraint:
PIONA value of naphtha are input to COILSIM1D. The industrial
X
aq ¼ 1 ð3Þ indices of the naphtha feedstock are described in Table 1. Secondly,
q¼1 COILSIM1D is adopted to build feedstock model and to obtain the
detailed feedstock component data. Thirdly, these components
This paper adopted the evaporation–condensation model pro-
are input to Aspen Plus, which is used to calculate the physical
posed by Lee [25]. The model added the mass and energy exchange
properties of mixture based on Soave–Redlich–Kwong equation
source terms of between vapor and liquid to the control equations,
[29]. Finally, based on the data of calculation above, polynomial
and correlated fluid saturation temperature. Based on the follow-
functions expressing the variation of the physical properties with
ing temperature regimes, the mass transfer can be described as
temperature are obtained by least square method, as shown in
follows:
the Supporting information. Among these physical properties, the
polynomial functions of the flue gas, the dilution steam and the
If Tl > Tsat
mixture of naphtha and dilution steam are calculated by Aspen
Plus, similar to the last two steps of the physical properties’ calcu-
ðT l  T sat Þ
_ l!v ¼ bl al ql
m ð4Þ lation of naphtha. These polynomial functions of physical proper-
T sat ties are input into Ansys Fluent 14.0 [30] for the numerical
If Tv < Tsat simulation work in the next step. The detailed calculation process
ðT sat  T v Þ is shown in Fig. 1.
_ l!v ¼ bv av qv
m ð5Þ
T sat
In this work, the saturation temperature Tsat is assumed 3. Simulation procedure
to the average temperature of bubble and dew points of
hydrocarbon feedstock, 366.65 K. The heat transfer corresponding 3.1. Geometry and operating conditions
with the evaporation or condensation process can be
calculated by multiplying the calculated mass transfer with the The structure diagram of dual stage steam feed mixing of con-
latent heat. vection section of ethylene cracking furnace is shown in Fig. 2. This
In equations above, bl and bv is the mass transfer time relax- section consists of eight tube sections, which are the FPH, econo-
ation parameters, 100 s1 [26], which make the difference between mizer (ECO), high temperature coil I (HTC-I), high temperature coil
the interfacial temperature and the saturation temperature the
minimum under meeting the calculation convergence.
Table 1
Industrial indices of the naphtha feedstock.
2.3. Radiation model
Specific density (20 °C) (g/cm3) 0.715
Specific density (15 °C) (g/cm3) 0.7196
The DO model is probably the best suited for computing radia-
ASTM D86 boiling points (K)
tion for the problems with localized sources of heat. The DO model IBP 318.15
has a broader application range, and is to be preferred [27]. The DO 10% 342.15
radiation model solves the radiative transfer equation (RTE) for a 50% 365.15
finite number of discrete solid angles, each associated with a vector 90% 434.15
95% 442.15
direction ~ s fixed in the global Cartesian system (x, y, z). The DO
FBP 464.15
model solves for as many transport equations as there are direc-
PIONA (wt%)
tions ~s. The solution method is identical to that used for the fluid n-Paraffins 30.16
flow and energy equations. The DO model uses a conservative vari- i-Paraffins 41.56
ant called the finite-volume scheme, and its extension to unstruc- Olefin 1.37
tured meshes. The mathematical expression of the DO model is as Naphthenes 16.13
Aromatics 10.78
follows:
 G. Hu et al. / Chemical Engineering Journal 286 (2016) 436–446 439

Input
Computing feedstock 1. Density NAP
information
information with 2. Distillation range FPH
COILSIM1D 3. PIONA value

BFW ECO
Drum
DS
Output 1. Density HTC-I
Computing feedstock information 2. Thermal conductivity
properties with Aspen Plus 3. Heat capacity HTC-II
4. Dynamic viscosity
Drum

Fig. 1. Model structure of hydrocarbon feed. HPSSH-I

Desuperheater
HPSSH-II
High pressure steam

DS DSSH

HTC-III

Radiation section
Inlet of convection
section

Fig. 3. Diagram of convection section process with dual stage steam feed mixing.

The convection section dimensions and operating conditions

are given in Table 2. As there are a large number of straight tubes
and heat flux change of each straight tube is taken into considera-
tion, the journal and executable exe files are compiled, which are
used to treat with the larger repetition works such as automatic
processing of the conversion of heat flux. The detailed structure
of each tube sections is described as follows.

3.1.1. Convection chamber

The convection chamber is the part of convective heat transfer
which depends on the flue gas from the outlet of radiation section.
In the convection chamber, the multiple rows of tubes are densely
arranged, and the flue gas scours these tubes by the great velocity,
and carries out effective convection heat transfer. Hexahedral cells
are used to discretize the convection chamber. Grid refinement is
used in the tube skin zones with small diameter such as FPH and
ECO. The number of grid cells of the convection chamber is
1,563,462.

3.1.2. Tube sections

Fig. 2. Schematic diagram of convection section with dual stage steam feed mixing.
II (HTC-II), high pressure steam super-heater I (HPSSH-I), high
pressure steam super-heater II (HPSSH-II), dilution steam super-
heater (DSSH) and high temperature coil III (HTC-III), respectively.
Feedstock is heated in the FPH and gradually from the liquid phase
to gas phase. Boiler feed water is heated in the ECO. The first steam
flux is carried out before the feedstock enters the HTC-I. The sec-
ond steam flux enters the DSSH and mixed with the mixture of
HTC-II outlet, then entering the HTC-III to be heated. The detailed
process diagram of convection section is shown in Fig. 3.
FPH tube section adopts staggered arrangement, as shown in
Fig. 2. It consists of 6 horizontal tubes, and each tube has 24 tube
passes, so this tube section contains a total of 144 straight tubes.
There are two kinds of tube structure whose layer numbers are
all 16. In the first structure, the number of tube passes s of each
layer from the top to the bottom is 2, 1, 2, 1, 2, 1, 2, 1, 2, 1, 2, 1,
2, 1, 2, 1, respectively. In the second structure, the number of tube
passes of each layer from the top to the bottom is 1, 2, 1, 2, 1, 2, 1, 2,
1, 2, 1, 2, 1, 2, 1, 2, respectively. The grid cell number of each tube is
431,483.
ECO tube section also adopts staggered arrangement, as shown
in Fig. 2. The straight tube number of each layer from the top to the
down is two. The grid cell number of each tube is 305,501.
Cracking feedstock heated in FPH, together with dilution steam,
will enter HTC-I, therefore, the inner diameter of straight tube
HTC-I (high temperature section) is bigger than that of FPH and
ECO. HTC-I tube section also consists of 6 tubes where each tube
consists of 6 straight tubes and 5 bend tubes. The grid cell number
of each tube is 212,848. HTC-II tube section consists of 6 tubes
440 G. Hu et al. / Chemical Engineering Journal 286 (2016) 436–446

Table 2 DSSH tube section consists of 6 tubes where each tube includes
Convection section dimensions and operating conditions. 4 straight tubes and 3 bend tubes. The grid cell number of each
Convection chamber specifications tube is 13,417.
Length (z-direction) (m) 10.3689 The mixture of hydrocarbon feedstock and dilution steam from
Width (x-direction) (m) 2.26 outlet of HTC-II and dilution steam from outlet of DSSH are mixed
Height (y-direction) (m) 13.385 to enter HTC-III. HTC-III tube section consists of 6 horizontal
Number of tube sections 8 arrangement tubes where each tube includes 4 straight tubes
Number of total tubes 432
Straight length of each tube pass 10.368
and 3 bend tubes. There are two structures which respectively
have 241,970 and 323,273 grid cells.
FPH tube section
Number of tube passes 24
Number of tubes 6 3.2. Boundary condition and computing method
Tube outer diameter (m) 0.0603
Thickness of tube (m) 0.00554
The real industry data are applied to boundary conditions of dif-
Mass flow rate of naphtha (kg/s) 8.4861
Tube inlet temperature (K) 333.15
ferent modules of convection section. For the convection chamber
Tube outlet pressure (g) (MPa) 0.48 and tube sections, mass flow inlets are respectively adopted as
ECO tube section
inlet boundary, and pressure outlet is adopted as outlet boundary
Number of tube passes 18 condition.
Number of tubes 6 The non-linear governing equations are discretized implicitly
Tube outer diameter (m) 0.0603 through a second-order upwind scheme and linearized to produce
Thickness of tube (m) 0.00874
a series of equations for the dependent variables in every compu-
Mass flow rate of boiler feed water (kg/s) 10.4475
Tube inlet temperature (K) 418.15 tational cell. Semi-Implicit Method for Pressure-Linked Equations
Tube outlet pressure (g) (MPa) 11.92 (SIMPLE) algorithm is used to solve the coupled momentum,
HTC-I and HTC-II tube section energy and species transport equations. The convergence was
Number of tube passes 6 judged by monitoring residuals and the overall mass and energy
Number of tubes 6 balances. The convergence criterion is that all scaled residuals
Tube outer diameter (m) 0.1143 decrease to 103. The exceptions are the energy and the radiation
Thickness of tube (m) 0.00602
Mass flow rate of naphtha (kg/s) 8.4861
equations, where the criterion is 106.
Mass flow rate of dilution steam (kg/s) 0.8486
Tube inlet temperature in HTC-I 406.15 3.3. Coupled convection chamber and tubes simulation
HTC-2 tube outlet pressure (g) (MPa) 0.40
HPSSH-I and HPSSH-II tube section In order to make the computation results more accurate and
Number of tube passes 3
effective, a coupled simulation method of convection chamber
Number of tubes 10
Tube outer diameter (m) 0.0603 and tube sections is adopted. The coupled calculation algorithm
Thickness of tube (m) 0.00874 is shown in Fig. 4. In the first iteration, an external tube skin tem-
Mass flow rate of high pressure steam in HPSSH-I and HPSSH-II 10.2428 perature profile from industrial measurement is adopted in the
(kg/s) convection chamber simulation. The simulated heat flux profile
Mass flow rate of boiler feed water in HPSSH-II (kg/s) 0.5850
HPSSH-1 tube inlet temperature (K) 597.15
to the tubes is then applied in the tubes simulation. Because of
HPSSH-2 tube inlet temperature (K) 656.15 the complex structure for tubes, it is necessary to respectively
HPSSH-1 tube outlet pressure (g) (MPa) 11.69 divide grids and compute for each tube section. For example, the
HPSSH-2 tube outlet pressure (g) (MPa) 11.55 inlet boundary condition of HTC-II is the outlet boundary condition
DSSH tube section of HTC-I. After finished all the tube sections calculation, updated
Number of tube passes 4 external tube skin temperature profiles for the furnace simulation
Number of tubes 6
are output. This procedure is repeated until the maximum differ-
Tube outer diameter (m) 0.1143
Thickness of tube (m) 0.00602 ence of the external tube skin temperature between two successive
Mass flow rate of dilution steam (kg/s) 4.2431 iterations is below a specified predefined threshold value of 1 K.
Tube inlet temperature (K) 458.15
Tube outlet pressure (g) (MPa) 0.40
4. Results and discussion
HTC-III tube section
Number of tube passes 4
Number of tubes 6 A naphtha is adopted hydrocarbon feedstock of convection sec-
Tube outer diameter (m) 0.1413 tion of the dual stage steam feed mixing. Table 3 is the comparison
Thickness of tube (m) 0.00655 of simulation results and industrial data. The simulated average
Mass flow rate of naphtha (kg/s) 8.4861 outlet temperature of each tube section is in good agreement with
Mass flow rate of dilution steam (kg/s) 5.0917
Tube inlet temperature (K) 719.15
the industrial data. The exhaust gas temperature of convection
Tube outlet pressure (g) (MPa) 0.33 chamber is 385.15 and 388.65 K for industry data and simulation
result, respectively. The relative error is 0.9%. The cross section
temperature of tube section is 884.15 and 887.38 K for industry
data and simulation result, respectively. The relative error is 0.36%.
where each tube consists of 6 straight tubes and 6 bend tubes. The
grid cell number of each tube is 101,036. 4.1. The simulation results of convection chamber
HPSSH-I tube section consists of 10 tubes where each tube con-
sists of 3 straight tubes and 2 bend tubes. The grid cell number of Fig. 5 shows flue gas velocity contours at section z = 0.5, 5 and
each tube is 48,650. 10 m of convection chamber respectively for dual stage steam feed
HPSSH-II tube section structure is the same as the HPSSH-I. The mixing. The same velocity distributions are discovered in the three
grid cell number of each tube is 48,804. sections, thus showing the flue gas velocity field is basically
 G. Hu et al. / Chemical Engineering Journal 286 (2016) 436–446 441

Construct geometric model

Start
and grid of tubes

Construct geometric model Establish initial conditions of

and grid of convection tubes
chamber

Calculate Calculate Calculate Calculate

Establish initial conditions of equations of equations of equations of
equations of FPH
convection chamber DSSH HPSSH-I ECO

N
Convergence? Convergence? N N N
Input the measured tube skin Convergence? Convergence?
temperature profiles Y
Y Y Y
Calculate equations
of HTC-I Calculate equations of
Calculate equations of HPSSH-II
mass, momentum, energy N
and species Convergence?
Y
N
Calculate equations of Convergence?
N
Convergence? HTC-II
Y
N
Y Convergence?

Y
Output heat flux of tube skin
Calculate equations Y
Convergence?
of HTC-III
N
N Output new temperature
Convergence?
of tube skin

End

Fig. 4. Coupled calculation procedure of tubes and furnace with dual stage steam feed mixing.

Table 3 and its velocity field along the x axial direction is gradually uni-
Comparison of simulation results and industry data. form. While arriving at the outlet of convection chamber, the flue
Items Industry data Simulation results gas velocity is basically consistent along x axial direction.
Exhaust gas temperature (K) 385.15 388.65
Fig. 7 shows flue gas temperature contours at section z = 0.5, 5
Outlet temperature of FPH (K) 430.15 437.41 and 10 m of convection chamber respectively for dual stage steam
Outlet temperature of ECO (K) 523.15 527.78 feed mixing. One can see that flue gas temperature distribution
Outlet temperature of HTC-I (K) 609.15 615.75 along the x axial direction is not uniform in the bottom of convec-
Outlet temperature of HTC-II (K) 677.15 681.61
tion chamber. With the increase of height, the flue gas passes
Outlet temperature of HPSSH-I (K) 695.15 698.66
Outlet temperature of HPSSH-II (K) 793.15 792.44 through the staggered tube bundles and its temperature field along
Outlet temperature of DSSH (K) 844.15 843.18 the x axial direction is gradually uniform. Fig. 8 shows flue gas tem-
Outlet temperature of HTC-III (K) 884.15 887.38 perature profiles along x and z axial direction. In Fig. 8a, when the
height of 3.10 m, flue gas temperature at x = 0.1 m is smaller than
that of x = 1.0 m. This is because the flue gas velocity of x = 0.1 m
consistent along z axial direction. At the corner both near and away which is near the entrance to convection chamber is smaller than
from the entrance to the convection chamber, flue gas velocity is that of x = 1.0 m (this is can be seen in Fig. 5), leading to a smaller
less than that in the other places. Fig. 6 shows flue gas velocity vec- heat transfer coefficient, and thus a lower flue gas temperature.
tor field at cross section z = 5 m. At the corner both near and away The flue gas of upward flow carries out heat exchange with the
from the entrance to the convection chamber, there are two recir- tubes, and the flue gas temperature field also gradually becomes
culation zones obviously. The recirculation zone will make resi- uniform. From Fig. 8a, the temperature basically arrives at
dence time of high temperature flue gas lengthen in the consistence at y = 8.88 m, showing that the flue gas temperature
convection chamber. At the same time, it will cause local overheat- field gradually becomes uniform through the heat exchange with
ing in furnace wall of convection chamber, thus being not con- staggered tubes. While arriving at the outlet of convection
ducive to the stable operation of the cracking furnace. When chamber, the flue gas temperature is basically consistent along x
high temperature flue gas entering the convection chamber, its axial direction, showing staggered tube facilitates the exchange
velocity is larger and will scour the furnace wall of opposite side. of heat. Both figures show with the increase of height, flue gas
In the convection chamber bottom, flue gas velocity distribution temperature gradually decreases. As can be seen from Fig. 8b, the
along the x axial direction is not uniform. This is because the struc- flue gas temperature field is basically consistent along z axial
ture of the convection chamber is asymmetrical. With the increase direction, which is caused by the uniform flow field along z axial
of height the flue gas passes through the staggered tube bundles direction in Fig. 5.
442 G. Hu et al. / Chemical Engineering Journal 286 (2016) 436–446

Fig. 7. Flue gas temperature contours with dual stage steam feed mixing. (a)
z = 0.5 m; (b) z = 5 m; (c) z = 10 m.

Fig. 5. Flue gas velocity contours of furnace with dual stage steam feed mixing. (a)
z = 0.5 m; (b) z = 5 m; (c) z = 10 m. 1400

1200
Flue gas temperature (K)

1000

800

600

400 y=3.10 m y=4.84 m

y=5.76 m y=6.53 m
200 y=7.31 m y=8.88 m
(a) y=10.34 m
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4
Width (m)

1400
Flue gas temperature (K)

1200

1000

800

600

400 y=3.10 m y=4.84 m

y=5.76 m y=6.53 m
200 y=7.31 m y=8.88 m
(b) y=10.34 m
0
0 2 4 6 8 10
Length (m)
Fig. 6. Flue gas velocity vector filed at cross section z = 5 m. (a) Velocity vectors
enlarged diagram at corner away from the entrance to the convection chamber; (b)
Fig. 8. (a) Flue gas temperature distribution along x axial direction in convection
velocity vectors enlarged diagram at corner near the entrance to the convection
chamber; (b) flue gas temperature distribution along z axial direction in convection
chamber.
chamber.
 G. Hu et al. / Chemical Engineering Journal 286 (2016) 436–446
Fig. 9. External tube heat flux profiles of different passes in HTC-I.
Fig. 10. Process gas temperature contours of different cross sections along z axial
direction in HTC-I. (a) 3 m; (b) 6 m; (c) 9 m.
4.2. The simulation results of tubes section
In view of the similarity of the simulation results of different
tube sections, this paper will take the simulation results of HTC-I
section as example to describe and analyze.
Fig. 9 shows external tube heat flux profiles of different passes
along tube axial position in HTC-I. The heat flux at the two ends of
tube is obviously lower than that of the other place. This is because
Fig. 11. Process gas temperature profiles of different passes in HTC-I.
443
Fig. 12. External tube skin temperature profiles of different passes in HTC-I.
the two ends of tube lie in near the furnace wall, where the flue gas
temperature is low, leading to a low difference between the flue
gas temperature and tube skin temperature, thus resulting in a
low heat flux. One can also see from this figure that in the Pass
1, Pass 3 and Pass 5, the heat flux increases along tube axial posi-
tion, while in the Pass 2, Pass 4 and Pass 6, the heat flux decreases
along tube axial position.
Fig. 10 shows the process gas temperature contours of
different cross sections along z direction. Along the hydrocarbon
feedstock flow direction, the temperatures of the hydrocarbon
feedstock near the tube wall firstly rise, then the heat is gradually
transferred to the center of tube. It shows that temperatures near
the tube wall are higher than that of tube center. When reaching
the tube outlet, the temperature profile has been average in z axial
direction.
Fig. 11 shows the process gas temperature profiles of different
passes along tube axial position in HTC-I. The process gas temper-
ature increases from Pass 1 to Pass 6. This is because the process
gas absorbs the heat transferred by flue gas, resulting in the
increase of temperature.
Fig. 12 shows the external tube skin temperature profiles of dif-
ferent passes along tube axial position in HTC-I. The external tube
skin temperature increases from Pass 1 to Pass 6 except near
the two ends of tubes, that is, in the crossover position of two tube
passes, the staggered external tube skin temperature exists. This is
because the two ends of tubes connects the bend tubes that is
outside of the convection section, which are not heated by flue
gas, leading to the lower tube skin temperature than inside the
convection section.
Fig. 13. Mass fraction profiles of liquid along FPH tube.
444 G. Hu et al. / Chemical Engineering Journal 286 (2016) 436–446
Fig. 14. Mass fraction profile of FPH straight tube: (a) bubble flow; (b) elongated
bubble flow; (c) stratified flow; (d) spray flow.
4.3. Dynamic simulation results
In the previous research of FPH [21], a dynamic model was used
to calculate. The advantage of the dynamic model is accurate calcu-
lation, however, the disadvantage of this model is long computa-
tional time. In the course of the coupling, the dynamic
calculation will greatly increase the time of the coupled calcula-
tion. In order to speed up the calculation efficiency, a piecewise lin-
ear interface calculation (PLIC) method [31] is used in the interface
interpolation of the coupled calculation in this paper. After the
coupled calculation, the tube skin heat flux profile is defined as
the boundary condition, and the PLIC method is used as the inter-
face reconstruction one in the dynamic calculation. They can result
in a more accurate gas–liquid two-phase change result.
Fig. 13 shows mass fraction profile along FPH tube. The feed-
stock vaporization begins in the fifteenth pass of tube. At the outlet
of tube, the liquid phase has been basically changed into the gas
phase.
The mass fraction profile of FPH straight tube is shown in
Fig. 14. Because of the long tube length, in order to clearly show
the calculation results, the x, y, z axes are adopted as the proportion
of 5:5:1. The flow pattern change of hydrocarbon feedstock has a
close relationship with the tube wall temperature. In the tube,
the liquid near tube wall first reaches the saturation temperature,
and forming the bubble that distributes in a continuous liquid
phase, which is called the bubble flow, as shown in Fig. 14a. With
the influence of gravity, the bubble will move to the top of tube,
and thus the liquid is gradually divided by long and thin bubble.
At this time the fluid will become chaotic, forming the elongated
Fig. 15. Temperature profile of vapor–liquid mixture in FPH tube.
Fig. 16. Velocity distribution in horizontal bend tube of FPH.
bubble flow, as shown in Fig. 14b. When a lot of bubbles gather
in the top of tube and form a continuous gas phase, leading gas–
liquid two-phase to form a significant interface. Then, the liquid
phase lies below the gas phase, forming the stratified flow, as
shown in Fig. 14c. When most of liquid phase finish vaporization,
a small amount of liquid phase disperses in the continuous gas
phase, forming the spray flow, as shown in Fig. 14d. In the vapor-
ized part of the feedstock, the tube wall temperature will sharply
increase, and thus tube wall temperature in this place will be
higher than that near the tube wall.
Fig. 15 shows temperature profile of vapor–liquid mixture along
FPH tube. From the entrance into the tube, the hydrocarbon feed-
stock gradually absorbs the heat of the flue gas, and the tempera-
ture gradually increases. The outlet temperature of tube is in
agreement with the value of the industrial plant.
Fig. 16 shows velocity distribution in horizontal bend tube of
FPH. In Fig. 16, x, z coordinate directions are the horizontal ones,
y coordinate direction is the vertical one. 100 points are chosen
at the equal intervals in the horizontal bend tube of FPH, and the
horizontal and vertical velocities of these points are calculated.
The horizontal velocity is much higher than that of the vertical
velocity. Fig. 17 shows flow pattern in horizontal bend tube of
FPH. From the figure, we can see gas phase velocity is different
from that of liquid phase, causing liquid phase the waves in the
flow direction. The mass fraction of the liquid phase at the position
A is much higher than that of the vicinity. Combined with the anal-
ysis of Fig. 16, it shows that after entering bend tube, the liquid
phase is influenced by the action of the centrifugal force, and lead-
ing to a large horizontal velocity, thus resulting in the erosion of
the tube wall.
5. Conclusions
A complete coupled convection chamber/tube simulation of an
industrial cracking furnace with dual stage steam feed mixing is
carried out for the first time. The detailed simulation results
including the flue gas velocity and temperature fields in the con-
vection chamber and the process gas temperature, tube skin tem-
perature and heat flux profiles in the tubes are obtained. The
simulation results are in good agreement with the industrial data,
which explains the accuracy of model and could be used for the
further research:
(1) There is recirculation zone at the corner both near and away
from the entrance to the convection chamber. The recircula-
tion zone will make residence time of high temperature flue
 G. Hu et al. / Chemical Engineering Journal 286 (2016) 436–446
Fig. 17. Mass fraction of liquid in horizontal bend tube of FPH.
gas lengthen in the convection chamber. It will cause local
overheating in furnace wall of convection chamber, thus
being not conducive to the stable operation of the cracking
furnace.
(2) There is a high degree of coupling between the velocity field
and temperature field of the convection chamber. The higher
the flue gas velocity, the higher the heat transfer coefficient,
the higher flue gas temperature. With the increase of height,
the flue gas passes through the staggered tube bundles and
its temperature field along the x axial direction is gradually
uniform. It shows the staggered tube facilitates the exchange
of heat.
(3) In the HTC-I, the heat flux at the two ends of tube is obvi-
ously lower than that of the other place. The heat flux
increases along tube axial position in the Pass 1, Pass 3
and Pass 5, whereas the heat flux decreases along tube axial
position in the Pass 2, Pass 4 and Pass 6. The process gas
temperature has different profiles along radial direction,
that is, at the beginning of several passes the temperature
near the tube wall is higher than that of the center of tube,
at the outlet of tube the temperature becomes average.
The process gas temperature increases along axial direction
from Pass 1 to Pass 6. The external tube skin temperature
increases from Pass 1 to Pass 6 except near the two ends
of tubes.
(4) A dynamic model is established for the FPH with dual stage
steam feed mixing on the basis of the coupled simulation.
The PLIC method is applied to the interface reconstruction
algorithms. The simulation results show the changes of flow
pattern in the FPH. Meanwhile, the influences of gravity on
two-phase flow are studied. The influence of centrifugal
force on flow pattern changes in bend tube section is also
analyzed.
Acknowledgments
This work is supported by Major State Basic Research Develop-
ment Program of China (2012CB720500) and National Natural
Science Foundation of China – China (Key Program: U1162202).
Appendix A. Supplementary data
Supplementary data associated with this article can be found, in
the online version, at http://dx.doi.org/10.1016/j.cej.2015.10.093.
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