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  • 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

    http://www.animatedgif.net/fireexplosions/shflamez2_e0.gifhttp://www.animatedgif.net/fireexplosions/shflamez2_e0.gifhttp://www.animatedgif.net/fireexplosions/shflamez2_e0.gifhttp://www.animatedgif.net/fireexplosions/shflamez2_e0.gifhttp://www.animatedgif.net/fireexplosions/shflamez2_e0.gifhttp://www.animatedgif.net/fireexplosions/shflamez2_e0.gifhttp://www.animatedgif.net/fireexplosions/shflamez2_e0.gifhttp://www.animatedgif.net/fireexplosions/shflamez2_e0.gif

  • 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

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