furnace services improving fired heaters reliability using inclined firing fired...

Furnace

Improvements

Services

Improving Fired Heaters Reliability using Inclined

Firing Technology

Furnace Improvements

1

Furnace

Improvements

ServicesOperating 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

www.heatflux.com 2

Furnace

Improvements

ServicesBenefits 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

9/11/2014 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 areinclined at5-10 deg.

Inclined Firing

System

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INTERHEATER -2 INTERHEATER -1 CHARGE HEATER

35'-6" 35'-6"

5' 5'

6'

5' 5'

4'-6"

5' 5'

4'-6"

5-10deg.

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Furnace

Improvements

ServicesInclined Firing System

www.heatflux.com 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"

57'-

10" W

EL

D T

O W

EL

D L

EN

GT

H

61'-

4 1

/2"

45'-

8 5

/8"

5'-

0" 1

0'-

0" 15'-

0" 20'-

0" 25'-

0"

10'-5"

I/S INS.

Furnace

Improvements

ServicesCase 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

www.heatflux.com 7

Furnace

Improvements

ServicesCFD 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

ServicesGladieux Processing

Hot oil heater being built with 6 inclined burners

,commissioned in July 2014.

www.heatflux.com 9

Furnace

Improvements

ServicesFIS-392BClient-GLADIEUX PROCESSING

Location-HUNTINGTON, INDIANA

www.heatflux.com

Furnace

Improvements

ServicesFlue Gas Velocity Contours

Y-Plane

[ft/s]

Furnace

Improvements

ServicesFlue Gas Vector Plot

Long recirculation is observed.

Y-Plane

[ft/s]

Furnace

Improvements

ServicesFlame Contours (CO >2000 ppm)Colored by Temperature (o F)

[F]

Flame shapes are separate from each other.

[F]

Furnace

Improvements

ServicesFlame 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

ServicesWall Tubes Heat Flux Contours

Average Heat Flux on the Tubes:

10,482 Btu/hrft2

[Btu/hrft2]

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"

3.5o

3.5o

7.0000

C B

UR

NE

RL C B

UR

NE

RL C

BU

RN

ER

L

PROPOSED INCLINED BURNER

EXISTING PROPOSED20'-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"

3.5o

3.5o

7.0000

C B

UR

NE

RL C B

UR

NE

RL C

BU

RN

ER

L

PROPOSED INCLINED BURNER

Phillips 66 Billings, MT DownFired Steam Reformer

Furnace

Improvements

ServicesVelocity 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

ServicesTemperature 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

ServicesHusky Lima, OhioCharge Heater with 6 Burners

Furnace

Improvements

ServicesFlue 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

ServicesFlue Gas Temperature Contours

Plane

Location

Existing Case Proposed Modification

Temperature

near the tube

is high.

[F]

Furnace

Improvements

ServicesFluid Path Lines: from Fuel Inlet

Existing Case Proposed Modification

Outer

recirculation

pattern

[ft/s]

Furnace

Improvements

ServicesFlame Contours (CO >2000ppm)

[F]

Existing Case Proposed Modification

Colored by Temperature

[F]

Furnace

Improvements

ServicesFlame Contours (CO >2000ppm)

[ft]

Flame height is14 ft. Flame height is