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Lecture 05a - Fired Heaters
Lecture 05a - Fired Heaters
FIRED HEATERS
5.1
OBJECTIVES
5.2
PROCESS ENGINEERS FURNACE WORK
Furnace Screening/Design - Grass Roots & Modifications, Check of
Vendor Designs
Rating/Troubleshooting Existing Furnaces
Checking/Monitoring Furnace Operation
Efficiency Calculations/Encon
Analyzing Plant Data
References
ExxonMobil Design Practices Sec. VIII
Blue Book Section 10
Computer Programs include 3558 Fired Heater Simulation, PC-HeAT
5.3
FIRED HEATERS WITHIN ExxonMobil
Sizes range from 2 to 280 MW heat fired
5.4
FURNACE TERMINOLOGY
5.5
FURNACE TYPES
Others
Horizontal Tube Box Furnace
Specialty Furnaces (Reformers, Steam Crackers)
5.6
Vertical-Cylindrical Furnace
Heat Duties Up to
150 MBTU/Hr (45 MW)
5.7
Horizontal Tube Cabin Furnace
5.8
Hoop Tube Cabin Furnace
Common in Catalytic
Reformers
5.9
Trecate Hoop Tube - PWF
5.10
Hoop Tube Furnace
5.11
Vertical Tube Box Furnace
5.12
RADIANT/CONVECTION SECTIONS
GENERAL DESCRIPTION
Absorb heat released from burning of fuel and transfer to
process.
5.13
RADIANT/CONVECTION SECTIONS
HEAT TRANSFER MECHANISM
5.14
RADIANT/CONVECTION SECTIONS
MAJOR ELEMENTS
Casing -Generally 6mm CS plate.
Insulation system
Generally internal.
Castable refractory, ceramic fiber, maintain casing
<82C, (Design Basis)
Heat Transfer surface.
Tube support / guide.
Internal walls or baffles - select styles of heaters.
Observation doors / Access doors.
Platforms and ladders.
5.15
CONVECTION SECTION
EXTENDED SURFACE
5.16
STACKS
Disposes of flue gases at an elevation and velocity
consistent with safety and environmental considerations.
Types
Fired heater supported, ground supported
Internally lined, externally lined, unlined
Design considerations/procedures contained in DP
VIIIC.
5.17
STACKS
5.18
STACK EFFECT WITH COLUMN OF HOT
GAS
(NO FRICTION PRESSURE LOSS)
5.19
TYPICAL FIRED HEATER DRAFT PROFILE
5.20
Stack Draft, (contd)
Effect of Damper
5.21
Combustion System
Components
Burners, Pilots
Fuel system
Protective/Control systems
Flame Detection Low NOx
Burner
Air flow protection (Forced draft)
Process flow protection
5.22
Combustion System
Combustion Theory
Definition: Chemical Combination Of Fuel With Oxygen In
Air Which Releases Heat
5.23
OPTIMUM EXCESS AIR
5.24
COMBUSTION SYSTEM
Fuel System
Supplies fuel to the burners.
5.25
COMBUSTION SYSTEM
Air Supply System
Components include:
Air distribution plenum or header
Flow Control Device (damper or guide vanes)
Noise reduction device or silencer
Flow modeling often performed to verify flow distribution
5.26
SIMULTANEOUS CONTROL OF FLUE GAS AND
DRAFT FOR NATURAL DRAFT HEATER
5.27
COMBUSTION SYSTEM
Basic Control
Control of firing rate based upon process temperature.
Requirements in IP15-1-1
5.28
COMBUSTION SYSTEM
Protective Systems - Flame Monitoring
5.29
COMBUSTION SYSTEM
Protective Instrumentation
Protection against loss of total process flow.
Details in IP 15-1-1
5.30
General Instrumentation & Control for
Natural Draft Fired Heaters
5.31
Additional
Instruments
Required for Forced
Draft Process Fired
Heaters
5.32
Additional
Instruments
Required for
Fired Heaters
with Flue
Gas/Air Pre-
heaters
5.33
Fuel Instrumentation and Controls for
Fired Heaters with Continuous Pilots
5.34
INSTRUMENTATION AND PROTECTIVE SYSTEMS
5.35
FURNACE EFFICIENCY
DEFINITION OF TERMS
Excess Air
Heat Absorbed
Heat Fired
5.36
FURNACE EFFICIENCY
CALCULATIONS
Three Methods
Input/Output
Stack Loss Method
EMS or Simplified Method
5.37
FURNACE EFFICIENCY
INPUT/OUTPUT METHOD
Calculate Efficiency
5.38
FURNACE EFFICIENCY
5.39
FURNACE EFFICIENCY EXAMPLE
Fuel Type: Natural Gas LHV = 45400 kJ/kg
Calculate Efficiency
5.40
EXCESS AIR (Simplified Equation)
111.4 x %0
Excess Air, % (wet) EA 2
20.95 %0
2
91.2 x %0
Excess Air, % (dry) EA 2
20.95 %0
2
5.41
FURNACE EFFICIENCY EXAMPLE
Dry Analysis of O2
91.2 x3.8
Excess Air 20.2
20.95 3.8
Say 20%
5.42
FURNACE EFFICIENCY
2. Calculate Heat Absorbed by Process
2.1 Calculate Heat Available Per lb (kg) Fuel
-DPM Section VIII-M Figure 4 Thru 10 Maxwell pp. 184 - 188
Heat
Available
BTU/lb
(kJ/kg)
5.43
FURNACE EFFICIENCY EXAMPLE
2. Calculate Heat Absorbed
3. Efficiency
5.44
Heat Available From Combustion
of Refinery Fuel Gas
5.45
EMS Efficiency
(Simplified Method)
Efficiency, %
Eff = {100 - [0.0427 + 0.00034 * XSA] * [Ts - Tair]} * [100/(100 + Loss)]
5.46
EMS Efficiency
5.47
AIR PREHEATER
5.48
AIR PREHEATERS
Consider When:
5.49
PRINCIPLE TYPES
Rotary
Regenerative Air
Preheater Typical Installation
5.50
PRINCIPLE TYPES (Cont.)
Fuel Savings
If Qabsorbed = 50 MW,
Qfired (with APH) = 50/0.92 = 54.3 MW
Qfired (without APH) = 50/0.86 = 58.1 MW
Difference = 3.8 MW (Approx $227k per year)
5.52
Heat Available From Combustion
of Refinery Fuel Gas
5.53
Improvements in Heater Operation and
Efficiency
Well sealed heater
Low draft operation
Target -2.5 mm H2O
Low Excess air
Account for air leakage due to ineffective sealing
Check that
Burner fuel valve fully open and pressure increases
taken by all burners
Air dampers fully open so all burners have same air
(only close when burners out of service (repair or
possibly extended turndown)
Burners fire in combination when oil and gas firing
Check Flames for impingement, colour and profile
Fuel oil and steam temperature must be correct for
good combustion
5.54
Fired Heater Flooding
Definition
5.55
Fired Heater Flooding
How to recognise flooding
- The firebox may appear hazy and have long yellow flames.
(However, a clean flame does not necessarily mean the
furnace is not flooded).
5.57
Fired Heater Flooding
Combating Flooding
5.58
Consequences of Flooding
5.59
Consequences of Flooding
5.60
FURNACE DEFINITIONS
Air Pre-heater. A heat exchanger that heats the air required for combustion by
exchanging heat with the flue gases leaving the convection section.
Arch. The overhead (usually flat) portion of the radiant section, supported from
above.
Box. The burners and tubes are enclosed in the fire-box, which consists of a
structure, refractory lining and tube supports.
Breeching. The hood that collects the flue gas at the convection section
exit, for transmission to the stack.
Bridgewall Temperature. The temperature of the flue gas leaving the radiant
section. The term comes from the old horizontal box heaters, where a bridge-wall
physically separated the radiant and convection sections.
Casing. A steel sheathing which encloses the heater box and makes it
essentially air tight.
Cell. A portion of the radiant section, separated from other cells by tubes or a
refractory wall. Also called a "zone".
5.61
FURNACE DEFINITIONS
Center Wall. A refractory wall in the radiant section, which divides it into two
separate cells.
Critical Velocity. A fluid velocity equal to the velocity of sound through the fluid
at its temperature and pressure. Also called sonic velocity.
Damper. A device to regulate the flow of gas through a stack or duct and to
control draft in a heater. A typical device consists of a flat plate connected to a
shaft that can be rotated, similar to a butterfly valve.
5.62
FURNACE DEFINITIONS
Draft. The negative pressure (vacuum) at a given point inside the heater,
usually expressed in inches of water.
Extended Surface. Surface added to the outside of bare tubes in the convection
section to provide more heat transfer area. This may consist of cylindrical studs
butt-welded to the tube or fins continuously would and welded to the tube.
Film. A thin fluid layer adjacent to a pipe wall that remains in laminar flow,
even when the bulk flow is turbulent. The velocity profile in the film is
approximately linear, with zero velocity at the tube wall.
Film Coefficient. The maximum temperature in the film, at the tube wall.
Fire Box. A term used to describe the structure which surrounds the radiant coils
and into which the burners protrude.
Flue Gas.A mixture of gaseous products that result from combustion of the fuels.
Fouling. The building up of a film or dirt, ash, soot or coke on heat transfer
surfaces, resulting in increased resistance to heat flow.
5.63
FURNACE DEFINITIONS
Forced Draft. Use of a fan to supply combustion air to the burners and to
overcome the pressure drop through the burners. This is in contrast to natural
draft, where the buoyancy of the column of hot flue gas in the stack and heater
provides the "suction" to pull combustion air into the burners.
Fired Heater Efficiency. The ratio of heat absorbed to heat fired, on a lower
heating value basis.
Gross Fuel. The total fuel fired in the heater, including all losses (usually
expressed in kg/h (lbs/hr)).
Header. The fitting which connects two tubes in a coil. In common usage,
"header" refers to cast or forged 180 U-bends ("return" bends).
Header Box. The compartment at the end of the convection section where the
headers are located. There is no flow gas flow in the header box, since it is
separated from the inside of the heater by an insulated tube sheet. Header boxes
are sometimes also used in the radiant section.
Heat Available. The heat absorbed from the products of combustion (flue gas) as
they are cooled from the flame temperature to a given flue gas temperature.
5.64
FURNACE DEFINITIONS
Heat Density. The rate of heat transfer per unit area to a tube, usually based on
total outside surface area. Typical units are W/m2 (Btu/hr/ft2). Also called "heat
flux".
Heat Duty. The total heat absorbed by the process fluid, usually expressed in MW
(Megawatts) or M Btu/hr (million Btu per hour). Total fired heater duty is the sum
of heat transferred to all process streams, including auxiliary services such as
steam super-heaters and drier coils.
Heat Fired. The total heat released in the heater, equal to gross fuel times lower
heating value (LHV) of the fuel. Usually expressed in MW (MBtu/hr)
Higher Heating Value (HHV). The theoretical heat of combustion of a fuel, when
the water formed is considered as a liquid (credit taken for its heat of combustion).
Also called gross heating value.
Hip Section. The transition zone at the top of the radiant section in cabin type
furnaces. The wall of this section is usually at a 45 degree angle.
Induced Draft. Use of a fan to provide the additional draft required over that
supplied by the stack, to draw the flue gas through the convection section, and
any downstream heat recovery equipment (i.e. air pre-heater).
5.65
FURNACE DEFINITIONS
Inspection Doors. Openings in the convection section side-walls to allow
inspection of tubes, extended surfaces and supports, when the heater is out of
service.
Lower Heating Value (LHV). The theoretical heat of combustion of a fuel, when no
credit is taken for the heat of condensation of water in the flue gas. Also called net
heating value. Usually expressed in kJ/kg (Btu/lb)
Mass Velocity. The mass flow rate per unit of flow area through the coil. Typical
units of measurement are kg/s m2 (lb/sec ft2)
Natural Draft. System in which the draft required to move combustion air into the
heater and flue gas through the heater and out of the stack is provided by stack
effect alone.
Net Fuel. The fuel which would be required in the heater if there were no radiation
losses. Usually expressed in kg/h (lb/hr).
Observation Doors. Openings in the radiant section floor and at selected points
along the walls, to permit viewing of tubes, supports and burners.
5.66
FURNACE DEFINITIONS
One-Sided Fired Tubes. Radiant section tubes located adjacent to a heater wall
have only one side directly exposed to a burner flame. Radiation to the back sides
of the tubes is by reflection/re-radiation from the refractory wall.
Pass. A coil which transports the process fluid from fired heater inlet to outlet.
The total process fluid can be transported through the heater by one or more
parallel passes.
Peepholes. Small observation ports usually placed in the radiant section floor
and/or arch to permit viewing of tubes, supports and burners. They are usually
glass covered.
Radiant Section. The section of the fired heater in which heat is transferred to the
heater tubes primarily by radiation from high temperature flue gas.
5.67
FURNACE DEFINITIONS
Shield Section. The first two tube rows of the convection section. These tubes
are exposed to direct radiation from the radiant section and usually receive about
half of their heat in this manner. They are usually made of more resistant material
than the rest of the tubes in the convection section. Extended surfaces are not
used in this section.
Sootblower. A steam lance (usually movable) in the convection section for blowing
soot and ash from the tubes using high-pressure steam.
Stack. A cylindrical steel, concrete or brick shell which carries flue gas to the
atmosphere and provides necessary draft.
Stack Effect. The difference (buoyancy) between the weight of a column of high
temperature gases inside the heater and/or stack and the weight of an equivalent
column of external air, usually expressed in inches of water per foot of height.
Stack Temperature. The temperature of the flue gas as it leaves the convection
section, or air pre-heater directly upstream of the stack.
Transfer Line. Piping used to connect the fired heater outlet to downstream
processing equipment (tower, reactor etc.)
5.68
FURNACE DEFINITIONS
Tube Sheet. A large tube support plate located in the convection section and
supporting a number of tubes. The end supports are usually carbon steel or low-
alloy steel and make up one side of the header box. The inside of the end
supports, which is exposed to the flue gas, is insulated. Intermediate supports are
exposed to flue gas on both sides and are fabricated of a suitable alloy material,
usually castings.
Tube Support. A metal part which supports the weight of the tube.
Two-Side Fired Tubes. Radiant tubes which are exposed on both sides to direct
radiation from the burners.
5.69