Welcome to Training Program on OPERATION OF FURNACES & BOILERS

? YOUR EXPECTATIONS

MIND

SPIRIT

Presentation Session 1
Type of furnaces / boilers in refinery Heater nomenclature Associated equipments (Burners, APH, Soot blowers etc.) Fuel System Combustion Q & A
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Types of furnaces
1. Natural draft furnaces (FCC, DHDS, Small furnaces in AU-I/II of JR, NSU, GR)

2. Balanced draft furnaces (All furnaces and boilers of PDRP, AU-I/II/III/IV/V, new DCU and Russian Boilers of BR, )
3. Forced draft furnaces (New DHDT JR and Boiler-IV BR) 4. Induced draft (VBU, JR)

Natural Draft Furnace System

Old system

Convection

Hut type furnace

Radiation

Furnace

Horizontal firing History Hut, Vertical cylindrical/ box type, balanced draft
Atomizing steam

Vertical firing

Oil
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Balanced draft Furnace System

Furnace

APH

Damper

Oil

FD fan

Induced Draft Fan

Boiler System (balanced draft)

Boiler

Economiser

APH

Damper

Oil

FD fan

Induced Draft Fan

Boiler System (forced draft)

Boiler

Economiser

APH

Oil

FD fan
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Forced draft Furnace System

APH in top of convection bank

Furnace

Oil

FD fan
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Induced draft Furnace System

Furnace

Damper Atomizing steam

Oil

Induced Draft Fan

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 Heater Nomenclature

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BURNERS

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Types of burners
1. Pressure atomized oil burners in Russian boilers 2. Steam atomized oil burners in Boiler-IV and process heaters 3. Mixed burners (Oil & Gas)

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Burners
Burners convert fuel oil into millions of small droplets process called atomization

High surface to volume ratio in oil to facilitate evaporation and combustion

3 basic types of burners are pressure jet, air or steam blast burners and Rotary Cup
TURNDOWN ratio is the relationship between the maximum and minimum fuel input without affecting the excess air level is called Turn-Down Ratio. For example, a burner whose maximum input is 250,000 Kcals and minimum rate is 50,000 Kcals, has a Turn-Down Ratio of 5 to 1.
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Energy Efficiency Measures

Replace old, oversized burner and inefficient burners with modern, efficient and properly sized burner. Consider variable firing rates and/or dual fuel capabilities allowing you to choose low cost fuel at any time. Potential efficiency improvement-up to 5%

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DCU

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Vacuum Unit

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FCC

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APHs

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Air pre-heaters
Type Recuperative and regenerative Recuperative Shell and tube type (all balance draft furnaces and boilers) Regenerative rotating metal element (Boiler-IV & CO-Boiler)

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SOOT BLOWERS

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Soot Blowers
Motor driven (retractable / fixed) Pneumatic driven (retractable / fixed) Shot cleaning (old system)

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Fuel System
Fuel oil tank, pump, heater, back pressure control Ensure water free oil Minimum ash and metal content Catalyst particles not desired Heat up to desired temperature for attaining desired viscosity Fuel gas system Ensure condensate free fuel gas Steady fuel gas pressure

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Oil
The oil used in refinery is a blended fuel consisting of residue from FCC, DCU and AGO. The important properties of oil are viscosity at burner tip, water content, density, specific gravity, Calorific value, Sulphur, metal and ash content.

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COMBUSTION

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What is COMBUSTION ?

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Oil Combustion
Stoichiometric or theoretical air is ideal amount of air required for burning 1 kg of fuel 1 kg of fuel oil requires ~14.1 kg of air for complete combustion
C + O2 CO 2 + 8084 Kcals/kg of Carbon 2C + O2 2 CO + 2430 Kcals/kg of Carbon 2H 2 + O2 2H2O + 28,922 Kcals/kg of Hydrogen S + O2 SO2 + 2,224 Kcals/kg of Sulphur

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Combustion products
CO2, H2O, SO2 CO is undesirable loss of fuel Water vapour carries away heat as water is in vapour form i.e. latent heat loss Gas fuel more hydrogen more latent heat loss

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Stoichiometric Air requirement

The furnace oil quality is as under:
Constituents
Carbon Hydrogen Oxygen

% weight
85.9 12 0.7

Nitrogen
Sulphur H2O Ash

0.5
0.5 0.35 0.05

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Stoichiometric Air requirement

Basis : 100 Kg of furnace oil C + O2 = CO2 12 + 32 = 44 12 Kg of carbon requires 32 Kg of Oxygen to form 44 Kg of CO2 1 Kg of Carbon requires 32/12 = 2.67 Kg of Oxygen 85.9 Kg of C + (85.9 x 2.67) O2 = 315.25 Kg of CO2

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Stoichiometric Air requirement

2H2 + O2 = 2H2O 4 + 32 = 36 4 Kg of hydrogen requires 32 Kg of Oxygen to form 36 Kg of H2O 1 Kg of hydrogen requires 32/4 = 8 Kg of Oxygen 12 Kg of H2 + (12 x 8) O2 = 108 Kg of H2O

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Stoichiometric Air requirement

S + O2 = SO2 32 + 32 = 64 1 Kg of sulphur requires 32 Kg of Oxygen to form 64 Kg of SO2 0.5 Kg S + (0.5 x 1) O2 = 1Kg of SO2

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Stoichiometric Air requirement

Total oxygen required = (229.35+96+.5)=325.85 Kg Oxygen already present in fuel = 0.7 Kg Additional oxygen required = 325.85 - .7 = 325.15 Kg Theoretical quantity of dry air required = 325.15/0.23 = 1413.69 Kg Theoretical air required per Kg of fuel = 1413/100 = 14.13 Kg of air

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Theoretical CO2 content in fuel gas

Nitrogen in flue gas (QTY air O2) = 1413.69 325.15 = 1088.54 Kg

Moles of CO2 = 315.25/44=7.16

Moles of Nitrogen = 1088.54/28=38.87 Moles of SO2 = 1/64 = 0.016 Total moles = 46.06 Theor % CO2 by volume = (7.16/40.06)*100=15.5%

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Flue gas components with excess air

% CO2 measured in flue gas = 10% by volume Excess air = [(Theoretical CO2%/actual CO2%)-1]x100 = 55% Theoretical air for 100 Kg of fuel burnt = 1413.69 Kg Supply with 55% excess air = 1413.69 x 1.55 = 2191.22 Kg Excess air quantity = 2191.22 1413.69 = 777.53 Kg

Oxygen = 777.53 x .23 = 178.83 Kg

Nitrogen = 777.53 178.83 = 598.7 Kg
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Final components of flue gas with 55% excess air

CO2 = 315.25 Kg = (315.25/44) = 7.16 moles SO2 = 1 Kg = 1/64 = 0.016 moles

Oxygen = 178.83 Kg = 178.83 /32 = 5.59 moles

Nitrogen = 1687.24 Kg = 1687.24 / 28 = 60.25 moles Total moles = 73.016

Theor %CO2 by volume = (7.16/73.016)x100=9.8%

Theor % O2 by volume = (5.59/73.016)x100=7.6%

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3 Ts of Combustion
TEMPERATURE Temperature high enough to ignite and maintain ignition of fuel (viscosity of oil at burner tip 15-20 CST, heating of oil) TURBULENCE

Intimate mixing of fuel and air (primary air, secondary air, tertiary air and angle of contract of air with fuel) TIME
Sufficient time for complete combustion

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What are the various types of combustion?

There are three types of combustion: -- Perfect -- Complete -- Incomplete Perfect Combustion is achieved when all the fuel is burned using only the theoretical amount of air, but perfect combustion cannot be achieved in a boiler. Complete Combustion is achieved when all the fuel is burned using the minimal amount of air above the theoretical amount of air needed to burn the fuel. Complete combustion is always our goal. With complete combustion, the fuel is burned at the highest combustion efficiency with low pollution. Incomplete Combustion occurs when all the fuel is not burned, which results in the formation of soot and smoke.

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Critical success factor of combustion

Atomization Mixing of oil and air (oil pressure drop and air pressure drop)

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Atomization
Oil as a liquid must be converted to oil as gas (vapour) before it can mix with air and begin to burn

Oil is passed to burner through atomizer which converts liquid oil into millions of tiny droplets 10-50 micron size Tremendous increase in the ratio of surface to mass permitting substantially instantaneous heat absorption by droplets to change physical state from oil to gas in micro second

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Atomization
Atomization with the help of steam, air or high pressure gas

Pressure atomization TPS old Russian boilers

Mechanical atomization Swirl chamber and rotary cup

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Factors of atomization
Oil temperature at burner tip for attaining 15-20 CST Dry atomizing steam Delta P between steam and fuel about 2 Kg/Cm2 Cleanliness of burner

Impurities in oil like water, catalyst particles and metal contents etc.

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What the Nozzle Does

Atomizing
speeds up the vaporization process One litre of oil becomes 15 billion droplets at 7kg/cm2 with size 0.0002 inch 0.010 inch

Metering
deliver a fixed amount of atomized fuel to the combustion chamber

Patterning
uniform spray pattern and spray angle

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What Affects Droplet Size?

Higher Flow Rate Nozzles usually produce larger droplets Wider Spray Angles produce smaller droplets High Viscosity fuel produces larger droplets in the spray Heating Fuel reduces its viscosity and produces smaller droplets. Increasing Fuel Pressure reduces droplet size.

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Spray at 10 psi pressure

Spray at 100-psi pressure

Spray at 300-psi pressure

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Effects of Viscosity On Nozzle Performance

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The nozzle orifice is polished to a glasslike finish. Dont ruin it with a wire or pin, or by bumping it with a wrench. This can cause streaks in the spray.

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Dont blow into the nozzle. While this may seem to be the handiest and quickest way to clean a nozzle, you run the risk of contaminating it instead.

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Make sure the fuel tank is clean. Water and sludge in the tank can clog lines, filter or nozzles.

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Thank You

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