This is an innovative technique to control draft in Fired Heaters.

It is possible to save
substantial amount of energy by proper operator training and installing smart stack
dampers in your fired heaters.

70% of total energy consumption in a refinery is consumed in Fired Heaters. For 100,000 BPD
refinery, 1% improvement in thermal efficiency translates to savings of $ 1 Million Dollars/ year.

Draft in Fired Heaters

 90% heaters in US are Natural Draft
 These depend on draft inside the heater
 Draft is slight negative pressure maintained
to draw air for combustion
 Sufficient stack height is provided to ensure
negative draft in the heater
 Damper blades are used to control draft
 Draft varies with ambient air temperature
 Needs to be adjusted at least twice a day to
Smart Stack Damper
optimize heater operation

Stacks are Highly Oversized Problems with Damper Operation

 Stacks designed for 115-120% of heater load  Mostly damper blades are left fully open
 Stack diameters and height are decided by  Average draft in the fired heaters is
 Structural stability maintained at 3-4 times the value
 Minimum height considerations recommended
 Oversizing causes damper to consume lot  Tramp air is directly dependent upon the
more pressure drop during actual operation draft inside the heater
 Stack damper position for 115% load is around  Tramp air absorbs heat that should be
55-60° open transferred to heater tubes
 With decrease in load, damper opening must  High draft can even affect the flame
 Two dampertoblades
be reduced maintainconfiguration.
draft
 Two blades have areas in ratio of 60:40
or 70:30
Conventional Damper Design
 Dual actuators allow to operate damper
All damper
 blades blades have equal areas
individually
 Area
Blades are operated
surrounding with
the a singleisactuator
dampers sealed
Area
 to around
prevent blades
flue available for flue gas leakage
gas leakage
 One
Blades move
blade in a parallel
provides macro or control
opposed mode
and
 the
Bothother provides
modes micro control
have non-linear characteristics
 Independent control of damper blades Opposed Blade Parallel Blade
changes damper characteristics
 Linear control characteristics can be
It is recommended to inspect the damper at every shutdown. Make necessary modifications as needed.
achieved providing
The damper easier
shouldand reliable
be kept fully closed and should be tested every two weeks.
 SMART STACK DAMPER
Each blade can be operated individually. One blade provides macro control and other
provides micro control. Better controlling characteristics. Operator friendly. Avoids tramp
air leakage. Automatic control from control room possible. Hand controllers at panel.

Smart Stack Damper

 Two damper blades configuration
 Two blades have areas in particular ratio
 Two actuators operate each blade individually
 Seal plate to prevent flue gas leakage
 Better controlling
` characteristics Seal Plates Leakage
 One blade provides macro control and the
Unequal Blades Equal Blades
other provides micro control
 Operator Friendly Dual Actuator Single Actuator

Smart Stack Damper Conventional Damper

Smart Stack Damper Case Study
Smart Stack Damper Operation
 FIS performed study for a Fired Tube Boiler in
Clinton, Iowa
 Existing stack had 2 damper blades operated
with single actuator
Heater Load Macro Adjustment Micro Adjustment
 Stack designed for 120% load Blade
Percentage% and heater
Angle, °was
Open
100
generally operated at 50% load67.5 67.5
80 67.5 46
 At lower loads,65
damper was 67.5
required to be 31 100% Load 80% Load
almost closed45.5 67.5 5
 Operators concerned about closing the
damper and tripping the heater
 Damper was left fully open
 Issues of high draft and tramp air, reducing
heater efficiency
 FIS designed a new damper design with two 65% Load 45% Load
blades having areas in ratio of 3:2 Heater Load Macro Adjustment Micro Adjustment
 Keeping smaller damper blade at a fixed Percentage% Blade Angle, ° Open
(Macro) position, larger damper blade could 100 67.5 67.5
be operated for a wide range of heater load 80 67.5 46
65 67.5 31
45.5 67.5 5

If you need a reliable stack damper for your Fired Heater, please contact Furnace Improvements and
we will be able to supply you the right damper for your Fired Heater
Furnace Improvements Services
Uniform Heat Transfer in Fired Heaters
Email: info@heatflux.com
www.heatflux.com