Firing high sulphur fuel

An evaluation of schemes to improve firing efficiency and ensure the

reliability of combustion equipment

ADIL REHMAN, C STEVEN LANCASTER, SANDEEPAN GHOSH, OM PRAKASH SAHU and PAWAN KUMAR SHARMA
KBR Technology

P
ressure to reduce the car- case models have been devel- with an absorbed duty of
bon footprint of processing oped, and simulations for a 15 Gcal/h with heat recovery in
facilities means a reduc- hydrotreater fractionator feed the form of an off-board ground
tion in fuel consumption by the furnace have been carried out mounted cast and glass type air
energy consuming plant. At using typical industrial data preheater.
the same time, the ever increas- and studied using commercial • Revamp Case B4 [Option
ing price of fuel means that software, FRNC-5PC Version IV] is the revamp case
refiners are compelled to uti- 4.18 Mod 7.6. of a balance draft heater
lise cheaper fuels like fuel oil, with an absorbed duty of
refinery gas, or sub-grade fuels Definition of cases 15 Gcal/h with heat recovery in
with a high content of sulphur The various process cases con- the form of an off-board ground
and other impurities. On the sidered for the study are as mounted cast type air preheater
credit side, there is the possibil- follows: with an upstream steam air pre-
ity of increased profit margins • Base Case A is the exist- heater required to maintain the
as a result of increasing energy ing base case of a natural draft lowest tube metal temperature
demand worldwide. heater with an absorbed duty of above acid dew point.
Thus refiners and petrochem- 15 Gcal/h. • Revamp Case B5 [Option
ical companies aim for process • Revamp Case B1 [Option IV] is the revamp case
revamps in order to improve I] is the revamp case of of a balance draft heater
their profit margins as well as a balance draft heater with an absorbed duty of
decrease their carbon footprint. with an absorbed duty of 15 Gcal/h with heat recovery in
Furnaces are major consum- 15 Gcal/h with on-board heat the form of an off-board glass
ers of fuel in a typical refin- recovery in the form of a conven- coated tube type air preheater.
ery or a petrochemical plant, tional air preheater with multiple
and various process schemes carbon steel tube bundles. Comparing the base case
are explored here in order to • Revamp Case B2 [Option scheme with revamp schemes
process dirty fuels without II] is the revamp case of Basic schematics of the existing
severe corrosion problems or a balance draft heater base case along with various
compromising the life of the with an absorbed duty of other process revamp schemes
equipment and avoiding any 15 Gcal/h with heat recovery in are shown in Figures 1, 3, 4, 5, 6,
unwanted shutdowns. the form of an on-board glass and 7.
coated tube type air preheater.
Basis of study • Revamp Case B3 [Option Methodology for study
For the sake of the study, hypo- III] is the revamp case Typical base case and revamp
thetical base case and revamp of a balance draft heater case process flow rate, duty of

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 the furnace, process inlet and Although extra footprint is
outlet temperature, process Exhaust to not envisaged for an on-board
inlet and outlet pressure have safe location air preheater, ducting and foot-
been considered and a feed print would be required for a
property grid has been gener- Fuel
Combustion flue gas fan and combustion air
system
ated using commercially avail- fan to take care of extra pres-
able process simulator PRO sure drop across the flue gas
II. Results of the various pro- Ambient air side and air side. Thus, where
cess schemes were compared there is a plot limitation, for
Air circuit
to evaluate their relative advan- Flue gas circuit example in a revamp, such a
tages and disadvantages scheme is a feasible option for
The study was carried out Figure 1 Existing process scheme improving fuel efficiency, pro-
with the following assump- (Base Case A) vided space is available for fans
tions and data for modelling: and ducting.
the base case is considered to ciency. Overall structural weight In the event of acid conden-
be a process scheme with a 15 would be increased due to the sation, the carbon steel tubes of
Gcal/h natural draft heater addition of an on-board air pre- an on-board air preheater are
without any heat recovery, heater, thereby increasing load expected to corrode at an esti-
radiant heat loss of 1.5%, excess on the foundation as compared mated rate of approximately 2
air of 20%, ambient air datum with the existing base case mm/y. Thus for low ambient
temperature of 15.6°C and rel- configuration. or winter conditions, a steam
ative humidity of 60%. The air preheater is envisaged for
revamp case is considered to avoiding any acid corrosion
be a process scheme with a 15 issues, which will add to the
Step 1
Gcal/h balanced draft heater hardware requirement of the
Building the base case simulation
with heat recovery, radiant heat model, and running the simulation Option I configuration. This sit-
loss of 2.5%, excess air of 15%, base case. uation is not envisaged with
ambient air datum temperature the base case as there is no heat
of 15.6°C and relative humidity Step 2 recovery and no chance of acid
of 60%. Building the revamp case corrosion.
simulation models, and running
The typical refinery fuel gas the simulation revamp cases. Efficiency improvement for
composition in mole% is as fol- Option I is around 9% com-
lows: hydrogen, 44; methane, 13; Step 3
pared with the base case and
ethane, 15; propane, 22; isobu- Evaluating various process thus would bring down fuel
tane, 5; hydrogen sulphide, 0.6; schemes available for efficiency consumption substantially.
improvement for the revamp cases.
and isopentane: 0.4. CO2 emissions would fall from
A typical algorithm followed 105 to 95 t/d, thereby saving
Step 4
for the purposes of the study is 3300 t/y of CO2 being emitted
Comparison of various revamp
shown in Figure 2. options with the base case. to the environment, consider-
Important parameters and ing 330 on-stream operation
simulation results for the base Step 5 days. However, quantities of
case and revamp cases are Comparison of various revamp other emissions like NOx will
shown in Table 1. options with each other. go up for the revamp case
compared with the base case
Results and discussions Step 6 configuration.
Revamp Option I Evaluating merits/demerits of Because this scheme introduces
various revamp options.
This scheme is identical to the fans, electrical power consump-
base case scheme except that tion would be required com-
Step 7
conventional on-board metal- pared with the base case, which
Conclusion/inference.
lic tube bundles have been used essentially does not require any
for heat recovery, thereby tar- electric consumption.
geting improvement in fuel effi- Figure 2 Algorithm followed for the study Soot deposits on the outside

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of the tubes, especially in the
Parameters and simulation results for base case and revamp cases
case of fuel oil firing, is a mat-
ter of concern as it reduces the
Heater system under study Base Revamp Revamp Revamp Revamp Revamp
efficiency of the system. In the Case A Case B1 Case B2 Case B3 Case B4 Case B5
case of on-board air preheater Process flow, kg/h 259 416 259 416 259 416 259 416 259 416 259 416
designs, water washing in gen- Process in/out temp., °C 317/378 317/378 317/378 317/378 31/378 317/378
Absorbed duty, Gcal/h 15 15 15 15 15 15
eral is not recommended for Fired duty, Gcal / h 18.47 16.72 16.25 16.25 16.72 16.25
cleaning of soot since water Fuel flow, kg/h 1551 1411 1372 1372 1411 1372
% excess air 20 15 15 15 15 15
may spill below and may cause Efficiency,% 81.2 89.7 92.3 92.3 89.7 92.3
unnecessary damage to coils, Acid dew point,°C 140 140 140 140 140 140
Lowest tube metal temp., °C 293 155 N/A3 1555 155 N/A3
refractory and so on. Thus Max tube metal temp., °C 415 428 429 429 428 429
steam cleaning can be recom- Avg. radiant heat flux, Kcal/h.m2 18 869 19 617 19 758 19 758 19 617 19 758
mended by installation of soot Bridge wall temp., °C 787 797 799 799 797 799
APH duty, Gcal/h N/A 1 1.8 1.8 1 1.8
blowers in the on-board air APH air in/out temp., °C N/A 851/233 15.64/295 15.66/295 856/233 15.64/295
preheater region. This would Total CO2 emitted MTPD 105 95 93 93 95 93
NOx2 emission, ppm 46 81 95 95 81 95
require installation of access
platforms for the operation 1 During low ambient conditions such as in winter, a steam air preheater or electric heater may be required
to increase air inlet temperature for avoiding any acid corrosion issues.
and maintenance of these soot 2 Considering low NOx burner design.
blowers. 3 Lowest tube metal temperature is not applicable here as the metal tubes are coated with glass. Thus
more appropriate terminology may be the lowest glass temperature. Acid condensation would not cause any
Carbon steel tube bundles are corrosion problem as metal is coated with glass in the cold zone.
4 During low ambient conditions, the air inlet temperature would be lower but would not have any acid corrosion
easy to manufacture and can issues due to glass tubes construction in the cold zone.
be fabricated by most construc- 5 Lowest tube metal temperature shall be maintained by vendor in the cast section.
6 During low ambient conditions, the air inlet temperature would be required to be increased using a steam air
tion vendors compared with preheater and/or air may be partly bypassed for avoiding any acid corrosion issues.
a cast and glass type air pre- *Note the figures mentioned in the tables are indicative in nature and meant for study purposes only.

heater or a glass coated tube

air preheater, which are spe- Table 1
cialised designs available from
only a few vendors. This option nance shutdowns/turnarounds of installation and erection
in general is mechanically may be required. would be relatively easy and
more robust compared with Delivery at site would be quick, and can be done by most
a glass type air preheater or comparatively quicker than for construction contractors com-
glass coated tube air preheater, a cast and glass type air pre- pared with cast and glass type
which are thought of as fragile heater or glass coated tube air or glass coated tube designs,
in nature. Since a carbon steel preheater, which are relatively which may require supplier
tube bundle is relatively robust fragile. Construction in terms supervision and services during
compared with a glass type installation and erection.
air preheater or glass coated Exhaust to
tube air preheater, there are safe location Revamp Option II
no transportability issues with This scheme is identical to
this design. Modularisation is On-board Option I except that con-
conventional
also possible with this type of APH ventional on-board metal-
design. lic tube bundles have been
If designed and operated Combustion replaced by glass coated metal-
Fuel system
properly – always maintain- lic tube bundles in the cold
ing the lowest tube metal tem- zone region for heat recovery,
Preheated
perature above acid dew point air thereby targeting improve-
– this type of design would ment in fuel efficiency. Overall
Air circuit
require minimal maintenance. Flue gas circuit structural weight would be
However, if acid corrosion is increased due to the addition of
encountered, then carbon steel an on-board air preheater,
tubes would corrode in a few Figure 3 Process scheme (Option I: thereby increasing load
years and unwanted mainte- Revamp Case B10 on foundations compared with

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 the base case configuration. the existing fired heater con-
Although extra footprint is Exhaust to vection section. This type of
not envisaged for an on-board safe location design may require supplier
air preheater, ducting and foot- supervision and services during
print would be required for a On-board installation.
glass coated
flue gas fan and combustion air APH
fan to take care of extra pres- Revamp Option III
sure drop across the flue gas Combustion This scheme is identical
Fuel
side and air side. Thus where system to Option II except that an
there is a plot limitation, for on-board glass coated metallic
example in a revamp, such a Preheated tubular air preheater is replaced
air
scheme is a feasible option for by a cast and glass type off-
improving fuel efficiency, pro- Air circuit board air preheater mounted on
Flue gas circuit
vided that space is available for the ground for heat recovery,
fans and ducting. Since metal- thereby targeting improvement
lic tubes are coated with glass, Figure 4 Process scheme (Option II: in fuel efficiency. Overall struc-
acid corrosion issues are not Revamp Case B2) tural weight would be increased
envisaged in this scheme. due to the addition of an off-
Maximum efficiency from only a few vendors. In board air preheater, but load on
improvement can be achieved general, it would be mechan- the heater foundation would be
with Option II of around 11% ically less robust compared less compared with the exist-
compared with the base case with an on-board metal tube ing base case configuration and
and thus would bring down air preheater design but may be on-board air preheater designs
fuel consumption substantially. slightly better than a glass type. since the load would not be on
CO2 emissions would fall from Transportability may be a mat- the furnace but shifted to the
105 to 93t/d, thereby saving ter of concern compared with ground.
3960 t/y of CO2 being emitted metal designs. Extra plot area is envisaged
to the environment, considering Modularisation is possi- for an off-board air preheater
330 on-stream operation days. ble with this type of design. design scheme. Ducting and
However, other emissions like The only concern is that this footprint would be required
NOx will go up for the revamp option may offer standard for a flue gas fan and com-
case compared with the base module dimensions governed bustion air fan to take care of
case configuration. by glass coated tube lengths extra pressure drop across the
As this scheme introduces and other fabrication aspects. flue gas side and air side. Thus
fans, electrical power consump- However, tailor-made modular- where there is a plot limitation
tion would be required com- isation may be offered by sup- such a scheme does not seem to
pared with the base case. Soot pliers upon request. This type be a suitable option for improv-
deposits on the outside of the of design will require minimal ing fuel efficiency.
tubes, especially in the case of maintenance. Since this design comprises a
fuel oil firing, is a matter of con- Delivery at site may be in gen- glass module in the cold zone,
cern as it reduces the efficiency eral comparatively slower than acid corrosion issues are not
of the system. In the case of for the other options since man- envisaged. Maximum efficiency
on-board air preheater designs, ufacture of glass coated com- improvement can be achieved
water washing in general is ponents may be limited to few with Option III and should be
not recommended for cleaning manufacturers. However, deliv- around 11% compared with the
soot since water may spill. Thus ery time can be improved and base case, which would bring
steam cleaning can be recom- is a matter of further optimi- down fuel consumption sub-
mended by the installation of sation during project execu- stantially. CO2 emissions would
soot blowers in the on-board air tion. Construction and erection fall from 105 to 93t/d, or 3960
preheater region. may be relatively slow as an t/y, considering 330 on-stream
This type of air preheater is on-board glass coated air pre- operation days. Other emis-
a specialised design available heater may not fit exactly over sions like NOx will rise for the

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revamp case compared with the ery. Overall structural weight
base case. Exhaust to would be increased due to the
As this scheme introduces safe location addition of an off-board air pre-
Fuel
fans, electrical power con- heater and steam air preheater,
sumption would be required. Off-board but load on the heater founda-
ground mounted Combustion
In the case of off-board air pre- cast and glass system tion would be less compared
heater designs, water washing APH with the base case configura-
is generally available for soot Preheated tion and on-board air preheater
cleaning. This would require air designs since the load of the air
installation of access platforms Air circuit preheater would not be on the
Flue gas circuit
for the operation and mainte- furnace.
nance of soot blowers. Extra plot area is envisaged
This type of air preheater is Figure 5 Process Scheme (Option III: for an off-board air preheater
a specialised design available Revamp Case B3) and steam air preheater design.
from a few vendors. It would Ducting and footprint would be
in general be mechanically Delivery at site may be com- required for a flue gas fan and
less robust compared with an paratively slow since the combustion air fan to take care
on-board metal tube design. manufacture of glass com- of extra pressure drop across
Transportability may be a ponents may be limited to a the flue gas side and air side.
matter of concern compared few manufacturers, whereas Thus where there is a plot lim-
with metal designs due to their installationanderectionarecompa- itation such a scheme does not
more fragile construction. The rable with other options. This seem to be a suitable option for
cast components also contrib- type of air preheater may improving fuel efficiency.
ute to weight. Modularisation require supplier supervision/ Since this design comprises a
is possible with this type of services during installation/ steam air preheater to maintain
design. The only concern is that erection. the lowest tube metal tempera-
this option may offer standard ture above acid dew point, acid
module dimensions governed Revamp Option IV corrosion issues are not envis-
by glass tube lengths and other This scheme is identical to aged. However, there is an addi-
fabrication aspects. However, Option III except that an off- tional requirement for steam in
tailor-made modularisation board cast and glass type air the steam air preheater, so the
may be offered by suppliers preheater has been replaced utility requirement would be
upon request. by a cast only type off-board increased, which might be a lim-
This type of design may call air preheater coupled with a itation for some plants.
for maintenance along with steam air preheater upstream Efficiency improvement for
service by the supplier as and of the air circuit mounted on Option IV would be around 9%
when required. Breakage of the ground for heat recov- or more compared with the base
glass tubes may also occur case whilst the impact on CO2
during operation if excessive and other emissions would be
vibration is induced due to fac- Exhaust to comparable with the revamp
safe location
tors like fan motor and blade Fuel options already described.
induced vibration, and air and The scheme introduces fans,
flue gas induced turbulence. Off-board
Combustion thus electrical power consump-
ground mounted
There are other maintenance cast APH system tion would be required com-
issues like damage of poly- pared with the base case. This
meric sealing material in the Preheated type of air preheater is a spe-
air
tube sheets of the glass mod- Steam APH cialised design compared with
Air circuit
ule at flue gas temperatures Flue gas circuit
an on-board metal tube bun-
greater than 280°C. However, dle type air preheater and may
these types of issues may be be limited to a few suppliers,
addressed during the project Figure 6 Process Scheme (Option IV: but it would be mechanically
execution stage. Revamp Case B40 more robust compared with

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 Acknowledgement
an air preheater having glass
Special thanks to Mr Sandeepan Ghosh
components. Exhaust to for his contribution in carrying out
safe location
Fuel detailed analysis of the study work.
Revamp Option V
This scheme is identical Off-board
Adil Rehman is Technical Advisor
to Option II except that an Combustion ground mounted – Process with KBR Technology,
system cast APH Gurgaon, India. He has over 14 years of
on-board glass coated type
air preheater is replaced by experience in process design in various
Preheated companies and holds a master’s degree
an off-board glass coated type air
Air circuit in petrochemical engineering from AMU
configuration for heat recov-
Flue gas circuit Central University, India.
ery. Overall structural weight Email: [email protected]
would be about the same as for C Steven Lancaster was formerly with
an on-board glass coated air Figure 7 Process Scheme [Option V: KBR Technology. He has over 31 years
preheater, with the load shifted Revamp Case B5] of experience in furnace and fired heater
to the ground. Extra plot area is design and specialised heat transfer
envisaged and footprint would imal maintenance and service applications and holds a bachelor’s degree
be required for a flue gas fan by the supplier. in chemical engineering from Vanderbilt
and combustion air fan. Where Compared with the base case, University, Nashville, Tennessee.
there is a plot limitation, such which is a natural draft sys- Sandeepan Ghosh is Principal Technical
Professional – Process with KBR
a scheme does not seem to be tem, all revamp options would
Technology, Gurgaon, India. He has
a suitable option for improving necessitate replacement of nat-
over 12 years of experience in process
fuel efficiency. ural draft burners with forced design in various companies and holds a
The design includes a glass draft types because of the addi- bachelor’s degree in chemical engineering
coated tubular construction in tional air side resistance of the from Delhi College of Engineering, India.
the cold zone, so acid corrosion air preheater. However, this Email: [email protected]
issues are not envisaged in this is subject to review since the Om Prakash Sahu is Technical
scheme. Maximum efficiency original equipment supplier Professional Leader – Mechanical with
improvement with Option V may recommend some modifi- KBR Technology, Gurgaon, India. He has
should be around 11% more cations to existing burners and over 16 years of experience in mechanical
than with the base case, whilst total replacement might not be design with various companies and
holds a bachelor’s degree in mechanical
the impact on CO2 and other required.
engineering from Barkatullah University,
emissions would be compara-
India.
ble with the revamp options Conclusion Email: [email protected]
already described. Various process schemes are Pawan Kumar Sharma is Chief Technical
This scheme introduces fans, available and currently in oper- Advisor – Mechanical with KBR
so electrical power consump- ation in plants worldwide for Technology, Gurgaon, India. He has over
tion would be required. Water efficiency improvement in high 25 years of experience in mechanical
washing is generally availa- sulphur fuel scenarios. Each design in various companies and holds
ble for cleaning soot from off- of these schemes has its mer- a bachelor’s degree in mechanical
board air preheater designs. its and demerits. The aim of this engineering from Kurukshetra University,
This would require installa- study is only to provide basic India.
Email: [email protected]
tion of access platforms for the guidelines for comparison of the
operation and maintenance of available options. Contractors
soot blowers. and suppliers will typically
A specialised design, this provide tailor-made engineer-
type of air preheater may only ing solutions and provide pro- LINKS
be manufactured by a few ven- ject-specific optimisation.
dors. It is less robust compared Selection of a particular scheme More articles from the following
with an on-board metal tubes is frequently driven by project categories:
design but may be slightly bet- economics and client and oper- Revamps and Turnarounds
ter than a cast and glass type air ating companies’ previous expe- Sulphur Removal and Recovery
preheater and would need min- riences and preferences.

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