FIRED HEATERS

SCOPE

TYPE OF HEATERS

IN GENERAL IN MRPL

NOMENCLATURE BURNERS

TYPES

REFRACTORIES

TYPES OF HEATERS

Classified on
Draft Fuel used Orientation of burners Orientation of tubes Shape of the heater

DRAFT

Flow of gas/air in the heater As gases become hotter they become lighter, and this makes it to rise up When this is routed through a narrow space, a negative pressure is generated.

Draft
PRESSURE Weight of Air column

P1 = Wt of Cold Air + Wt of Hot Air

P2 = Wt of Cold Air
P2 > P1

DRAFT..

This pressure differential causes air to come into the heater Why Essential?

Scavenging Gas Out Bringing New Air Distribute Heat

NATURAL DRAFT

Draft by density difference. The weight of air inside the heater/stack is lesser than the weight outside This forces the air to come rushing in from the outside creating a draft

EXAMPLES OF NAT DRAFT

NSU HEATER NAPTHA VAPOURISER CIRCULAR HEATERS IN HCU KERO HEATER IN CDU2

(EFFICIENCIES OF NAT DRAFT FURNACES ARE VERY LOW. SO NOT GENERALLY PREFERRED)

FORCED DRAFT

Fresh air is forced into the heater

Forced draft fan

Hot air/flue gases goes out by itself thru a stack The heater will be under positive pressure

EXAMPLES OF FD

Boilers in CPP

(Box is under positive pressure. Therefore prone to leakage/ accidents)

INDUCED DRAFT

Flue gases induced out of the heater

By a fan or blower

The gases so induced are forced into the stack Because of the -ve pressure, cold air comes into the box

EXAMPLES

No pure ID heaters in MRPL

(Fine control not possible on inlet air)

BALANCED DRAFT
Cool air forced into the heater Flue gases induced out of the heater Forcing & Inducing by Fans Net Negative Pressure inside box

BALANCED DRAFT

MRPL BALANCED DRAFT. ADVANTAGES

Better draft control Smaller heights of chimneys Air-pre heaters increasing efficiency

TYPICAL DRAFT IN HEATERS

FUELS

Varied Fuels

Gas Fired Oil Fired Combination Fired Waste Heat (Only Flue Gases) Solid Fuel

FUELS...

SOLID FUEL

Low Cost Large Peripherals (Grate, Mills etc) Precise control Minute Variation Fluctuating Loads

GAS

FUELS...

OIL

High Heat Duty Steady Loads Advantages of Both Higher Heat Duty

COMBINATION

FUELS- IN MRPL

Solid Fuel

None HCU Reactor, H2 Reformer, CCR1 Reformer Boilers Of CPP Crude, HCU, CCR2, VBU

Gas Fired

Oil Fired

Combination

BURNER ORIENTATION

SIDE FIRED

BURNERS IN THE SIDE CCR1 REFORMER Shorter Heaters Different Arrangements (RW)

BURNER ORIENTATION

TOP FIRED

BURNERS ON THE TOP FIRING DOWN H2 REFORMER Better Heat Flux Control Heater Size Smaller Material Near Cracking

BURNER ORIENTATION

BOTTOM FIRED

BURNERS ARRANGED AT THE BOTTOM ALL HEATERS Oil can be used High Heat Duty

BURNER ORIENTATION

RADIANT WALL

Burner fires to Wall Heat Radiates from Wall Tubes see heat not fire Even Distribution of Heat

BURNER ORIENTATION

INDIRECT FIRED

Better Control of Skin Material in tubes near cracking

ORIENTATION OF TUBES
- HELICAL COIL

- VERTICAL COIL

- HORIZONTAL COILS

SHAPE OF HEATER

CYLINDRICAL

NSU, HCU-REACTOR, NAPHTA VAPOURISER CDU, VDU,HCU FRACTIONATOR CDU2

CABIN

BOX

NOMENCLATURE

Shock Tubes

Nomenclature
Stack Damper Arch Convection Tubes Shock Bank Radiant Tubes Refractory Lining

Firebox

HEAT TRANSFER

Heat transfer takes place in two ways

By radiation By convection

Zones of the heater are also defined by the mode of ht tfr

HEAT TRANSFER
Convection Section Heat transfer from hot gases to tubes

Radiant Section Tubes directly see Fire

BURNERS

Functions of a burner
Carries fuel into the heater Mixes fuel with air Provides area for safe burning

TYPES OF BURNERS

Gas

Normal Flat flame Mechanical Atomization Air Atomization Steam Atomization

Oil

TYPES

Combination

Oil and gas

Pilot

Low heat duty, provides a flame inside Normally gas fired

PILOT BURNERS

Provide flame inside heater at all times Low heat duty burners Normally gas fired Air and gas is pre-mixed in a mixer Mixture is burned in the pilot

PILOTS
MIXER ASSEMBLY

GAS BURNERS

Fuel used is Fuel Gas/ LPG/ Methane Low heat duty burners No need for special atomization Clean burning- no deposition on tubes Can be round flames or flat flames

GAS BURNERS

ROUND FLAME

FLAT FLAME

OIL BURNERS

Fuel used is fuel oil LSHS/ VR Atomizes the fuel into easily burnable particles Atomization by means of

Mechanical/ Swirler (CPP1) Air atomization Steam atomization

OIL BURNERS

ATOMIZATION

Atomized Mixture OilEnters Oil & Steam Spud Mixes Velocity is Sprayed Increased

COMBINATION BURNERS

Combination of oil, gas and pilot burners Advantages

Heavy duty Fine control possible by gas burners

COMBINATION BURNERS

AIR

3 different airs exist in burners Primary Air

Provides air for combustion to oil gun Provides air for combustion for gas burners

Secondary air

AIRS

Tertiary Air

Found in low NOX burners At high temperature Nitrogen in air and Oxygen tend to form NO or NO2 To prevent this tertiary air or cooling air is provided around the burner

AIRS
TERTIARY AIR

SEC AIR

PRIMARY AIR

TROUBLESHOOTING

Problems

Flame Impingement Tall Flame Bushy Flame Oil Seepage Clinker Formation Meltdown

FLAME IMPINGEMENT

Probable Cause

Misalignment

Correction

Correct Alignment

TALL FLAME/ BUSHY FLAME

Tall flame

Excess fuel pressure/ atomizing media pressure Burner too high in the block Lower pressure of fuel/ atomizer Burner too low in block

Bushy flame

OIL SEEPAGE

Cause

Improper atomization Burner height too low

Oil impinges on tile Causes seepage

CLINKER FORMATION

Improper atomization Low oil flow thru oil tip

Higher heat pick up from gas burners

Incorrect gun position

MELTDOWN

Any Above left Unattended High Heat of Tip Melting Spillage Fire Meltdown

REFRACTORY

Types

Castables

Applied after forming a mortar Ready use, applied with mortar Std dimensions, locked with ceramic cup locks Preformed sections, locked to holders

Bricks/ preformed section

Ceramic blankets

Ceramic modules

REFRACTORY - APPLICATION

Type -- Location Floor

Castable Fire Brick / Insulating Brick Fire brick, Insulating brick, Ceramic blankets

Radiant wall

REFRACTORY-APPLICATION

Hip arch/ convection section

Castable/ ceramic modules

Corbel

Castable
Castable with potassium silicate coating

Ducts

REFRACTORY - DRYOUT

Refractory uses Water Sudden Increase in Heat

Steam Formation Sudden Expansion Collapse of Refractory

Slow Increase in Heat Hold at different steps (60, 80, 100, >100)

Outside Wall Temperature = 100** (>60)

THANK YOU