Furnace

Improvements
Services
Improving Fired Heaters
Reliability using Inclined
Firing Technology
Furnace Improvements
1
Furnace
Improvements
Services
Operating and Reliability Issues
High tube metal temperatures
Localized flame impingement
Fired heaters have burners that are
fired vertically upright, sideways or
downwards
FIS patented technology reorients
the burners at a slight angle away
from the tubes
Hottest part of the flames and flue
gases are moved away from the
tubes
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2
Furnace
Improvements
Services
Benefits of Inclined Firing System
Significant reduction in
tube metal temperatures
Low coking rates
Higher tube life and run
lengths
Increased capacity
possible in most heaters
Uniform firing achieved
across the tubes
www.heatflux.com
3
Furnace
Improvements
Services
9/9/2014 www.heatflux.com 4
4'
BCD
12'-9"
TCD
12'-9"
INLET
OUTLET
4'
4'-4
2'-7"
4'
BCD
6'
5'
2'-7"
12'-9"
TCD
12'-9"
INLET
OUTLET
4'
Burners are
inclined at
5-10 deg.
Inclined Firing
System
INTERHEATER -2 INTERHEATER -1 CHARGE HEATER
35'-6" 35'-6"
5'
5'
6'
5'
5'
4'-6"
5'
5'
4'-6"
5-10deg.
Furnace
Improvements
Services
Inclined Firing System
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6
Height in
Elevation
BCD
0-0 8-0
5-0 7-1.5
10-0 6-3
15-0 5-4.5
20-0 4-6
25-0 3-7.5
8 burner system
TCD of 20-8
2'-7"
21'-9 1/2"
I/S INS.
20'-8"
TCD
8'-0"
B.C.D.
7'-1 1/2"
B.C.D.
6'-3"
5'-4 1/2"
4'-6"
3'-7 1/2"
5
7
'
-
1
0
"

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1
'
-
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1
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"
4
5
'
-
8

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"
5
'
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"1
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'
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"
1
5
'
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0
"
2
0
'
-
0
"2
5
'
-
0
"
10'-5"
I/S INS.
Furnace
Improvements
Services
Case Studies
Case studies to be presented include:
Hot Oil Heater
Reformer Heater
Charge Heater, Vertical Cylindrical
Coker Heater
Crude Heater, Cabin Type
Crude Heater-Vertical Cylindrical
CFD Modeling carried out to
demonstrate the benefits of Inclined
Firing System
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7
Furnace
Improvements
Services CFD Modeling
Start
CAD Geometry
CAD Geometry &
Meshing
Boundary
Conditions
Solver
Converged
Solution
Post Processor
Analysis
End
Diverge
Optimization
CFD
Computational Fluid
Dynamics
Uses numerical methods
and algorithms to study
fluid flow
Flow patterns in fired
heaters, burners, fireboxes
3D models of fired
equipment are created
www.heatflux.com
8
Furnace
Improvements
Services
Hot oil heater being built with 6 inclined burners
,commissioned in July 2014.
www.heatflux.com 9
Furnace
Improvements
Services
Hot Oil Heater
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Furnace
Improvements
Services
Flue Gas Velocity Contours
Y-Plane
[ft/s]
Furnace
Improvements
Services
Flue Gas Vector Plot
Long recirculation is observed.
Y-Plane
[ft/s]
Furnace
Improvements
Services
Flame Contours (CO >2000 ppm)
Colored by Temperature (
o
F)
[F]
Flame shapes are separate
from each other.
[F]
Furnace
Improvements
Services
Flame Contours (CO >2000 ppm)
Colored by height (ft)
[ft]
[ft]
Furnace
Improvements
Services
Tube Metal Temperature Contours
Wall Tubes
Tube Metal Temperatures Flue Gas Temperatures near Tubes
[F] [F]
Furnace
Improvements
Services
Wall Tubes Heat Flux Contours
Average Heat Flux on
the Tubes:
10,482 Btu/hrft
2
[Btu/hrft
2
]
Furnace
Improvements
Services
20'-0 7/8" (SHELL WIDTH)
24.0000
8 0.7500
113.0000 113.0000
4.0000 4.0000
24.0000
8 0.7500
EXISTING
4'-0"
2'-8 1/2"
2'-8 1/2"
7.0000
5'-5" 5'-5"
20'-0 7/8" (SHELL WIDTH)
24.0000
8 0.7500
113.0000 113.0000
4.0000 4.0000
24.0000
8 0.7500
PROPOSED
4'-0" 2'-8 1/2"
2'-8 1/2"
7.0000
5'-5" 5'-5"
3.5
o
3.5
o
7.0000
C

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PROPOSED INCLINED BURNER
EXISTING PROPOSED
20'-0 7/8" (SHELL WIDTH)
24.0000
8 0.7500
113.0000 113.0000
4.0000 4.0000
24.0000
8 0.7500
EXISTING
4'-0"
2'-8 1/2"
2'-8 1/2"
7.0000
5'-5" 5'-5"
20'-0 7/8" (SHELL WIDTH)
24.0000
8 0.7500
113.0000 113.0000
4.0000 4.0000
24.0000
8 0.7500
PROPOSED
4'-0" 2'-8 1/2"
2'-8 1/2"
7.0000
5'-5" 5'-5"
3.5
o
3.5
o
7.0000
C

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PROPOSED INCLINED BURNER
Down Fired Steam Reformer
Furnace
Improvements
Services Velocity Vectors on Center Plane
In the proposed case, velocity vectors clearly show improvement in the flue gas flow
pattern with no direct contact of high velocity vectors on radiant tubes.
Base Case Proposed Case
[ft/s]
Furnace
Improvements
Services
Temperature Contours on Center Plane
High flue gas temperature
going towards the tubes.
High flue gas temperature
going away from the tubes.
Base Case Proposed Case
In the proposed case, temperature contours clearly show the reduction in the flue gas
temperature around the radiant tubes.
[F]
Furnace
Improvements
Services
Charge Heater with 6 Burners
Furnace
Improvements
Services
Flue Gas Temperature Contours
Central Plane
[F]
Temperature
near the
tube is high.
Flame angled
towards the center of
the furnace / away
from tubes.
Existing Case Proposed Modification
Furnace
Improvements
Services
Flue Gas Temperature Contours
Plane
Location
Existing Case Proposed Modification
Temperature
near the tube
is high.
[F]
Furnace
Improvements
Services
Fluid Path Lines: from Fuel Inlet
Existing Case Proposed Modification
Outer
recirculation
pattern
[ft/s]
Furnace
Improvements
Services
Flame Contours (CO >2000ppm)
[F]
Existing Case Proposed Modification
Colored by Temperature
[F]
Furnace
Improvements
Services
Flame Contours (CO >2000ppm)
[ft]
Flame height is14 ft. Flame height is reduce to 9 ft.
Existing Case Proposed Modification
Colored by Height
[ft]
Furnace
Improvements
Services
Flame Contours (5% O2)
[ft]
Existing Case Proposed Modification
Flame
height
is16 ft.
Flame height is
reduce to 9.8 ft.
Colored by Height
[ft]
Furnace
Improvements
Services
Flame Contours (3% O2)
[ft]
Flame height is 15.2 ft
at 3% O
2
.
Colored by Height
[ft]
Furnace
Improvements
Services
Tube Metal Temperatures
[F]
Existing Case Proposed Modification
Hot spots due
to flame
impingement.
TMTs more
uniform.
Furnace
Improvements
Services
Tube Heat Flux
High heat flux
distribution at
bottom of the
tubes
Existing Case Proposed Modification
[Btu/hrft
2
]
[Btu/hrft
2
]
Furnace
Improvements
Services Coker Heater
High tube metal temperature
issues
Fuel gas fired low NOx
burners
www.heatflux.com
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Furnace
Improvements
Services
Coker Heater Geometry
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31
Proposed Existing
Burners are
inclined by
7.5 towards
the walls.
Furnace
Improvements
Services Velocity Vectors
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32
Expanded View
[ft/s]
Plane at primary tip
Furnace
Improvements
Services
Velocity Vectors by Temperature
www.heatflux.com
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[F]
Plane at primary tip
Furnace
Improvements
Services
Tube Metal Temperature Contours
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[F]
Furnace
Improvements
Services Refractory Temperature Contours
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[F]
Furnace
Improvements
Services
Flame Shapes (Iso-Surface of
CO 2000 ppm)
36
Colored by Temperature
[F]
B-4 B-1 B-2 B-3
Furnace
Improvements
Services
Flow Profiles - Vertical Up Firing
vs Inclined Firing
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Inclined Firing Vertical Up Firing
[ft/s]
Furnace
Improvements
Services
Flue Gas Temperature Profiles
Vertical Up Firing vs Inclined Firing
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Inclined Firing Vertical Up Firing
[F]
Furnace
Improvements
Services
Flame Profiles - Vertical Up Firing
vs Inclined Firing
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39
Inclined Firing Vertical Up Firing
Furnace
Improvements
Services
Crude Heater Horizontal Cabin
Cabin heater suffering
from high tube metal
temperatures at arch
Originally 6 large
burners-30 MMBtu/hr
each
Proposed 36 burners-5
MMBtu/hr each with
inclined firing mode
Furnace
Improvements
Services
Flames Colored by Height
CO 2000 PPM
Base Case Proposed Design
[ft]
Furnace
Improvements
Services
Velocity Vectors - Z-1 Section
Base Case Proposed Design
Z-1
Z-1
Z-2
Z-2
[ft/s]
Furnace
Improvements
Services
Temperature Contours at Z Sections
Base Case Proposed Design
[F]
Furnace
Improvements
Services
Radiant Tube Temperature
Contours
Base Case Proposed Design
[F]
Furnace
Improvements
Services
Crude Heater- Vertical Cylindrical
Client facing flame
impingement and high tube
metal temperatures in radiant
section
FIS recommended inclined
burner firing system to eliminate
flame impingement
Carried out CFD modeling of
the burners and radiant section
to demonstrate the benefit of the
inclined burner firing system
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45
Furnace
Improvements
Services
Existing Burner Arrangement
EXISTING FLOOR & PLENUM ARRANGEMENT
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46
Furnace
Improvements
Services
Inclined Firing System
Burner Arrangement
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47
Furnace
Improvements
Services
Crude Heater
Floor Design
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Furnace
Improvements
Services
Crude Heater
Plenum Chambers
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Furnace
Improvements
Services
Velocity Vectors
Base Case vs Inclined Firing System
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50
0 ft
Height in
Feet
19 ft
36 ft
50 ft
[ft/sec]
Existing Case
with Vertically Fired
Burners
Proposed Case
with Inclined Firing
System
Furnace
Improvements
Services
Temperature Contours
Base vs Inclined Firing System
Base Case Inclined Firing System
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51
[F]
Furnace
Improvements
Services
Temperature Contours at 10ft
Base Case vs Inclined Firing System
Base Case Inclined Firing System
At 10 ft At 10 ft
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52
[F]
Furnace
Improvements
Services
Temperature Contours at 15 ft -
Base Case vs Inclined Firing System
Base Case Inclined Firing System
1
At 15 ft At 15 ft
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53
[F]
Furnace
Improvements
Services
CO Mass Fraction Contours at 10 ft
Base Case vs Inclined Firing System
At 10 ft
Inclined Firing System
1
Base Case
At 10 ft
www.heatflux.com
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[ppm]
Furnace
Improvements
Services
CO Mass Fraction Contours at 15 ft
Base Case vs Inclined Firing System
At 15 Ft
Inclined Firing System
1
Base Case
At 15 Ft.
www.heatflux.com
55
[ppm]
Furnace
Improvements
Services
Iso Surface of CO MF 2000 PPM Colored by
Temperatures
Base Case vs Inclined Firing System
Base Case Inclined Firing System
Top View
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56
[F]
[F]
Furnace
Improvements
Services
Iso Surface of CO Mass Fraction
2000 ppm Colored by Flame Height
Base Case Inclined Firing
System
www.heatflux.com
57
[ft]
Furnace
Improvements
Services
Radiant Wall Temperatures
Base Design Proposed Design
For h =100 Btu/ft
2
h
and T= 800 F
www.heatflux.com
58
[F]
Furnace
Improvements
Services
Summary
Client reported almost 250 F reduction
in tube metal temperatures after the
revamp.
Inclined Firing is proven in solving high
tube metal temperatures problems
CFD modeling demonstrated the ability
of IFS to improve performance
FIS is ready to evaluate your heater to
determine whether it is a suitable
candidate for Inclined Firing at no cost.
www.heatflux.com
59
Furnace
Improvements
Services DHT Heater
Installation of 4 burners in inclined firing pattern
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60
Furnace
Improvements
Services
DHT Heater
Floor Layout
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Furnace
Improvements
Services
SEU Units
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62
F-4202
F-4201
1650
2350
(T
Y
P
.)
3
(T
Y
P
.)
5.5
C

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3200 (P.C.D.) 3962 (P.C.D.)
762 1372
B.C.D. B.C.D.
FLOOR PLT. FLOOR PLT.
L
L
C

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Furnace
Improvements
Services
Vertical Cylindrical Heaters
Two vertical cylindrical heaters working for almost 3
years with Inclined Firing System
Reduced fouling and hot spots
Provided 10% extra capacity
with Inclined Firing Technology
Furnace
Improvements
Services
Reboiler Heaters
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Furnace
Improvements
Services
We hope you found our presentation helpful
and informative.
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65