4-Eclairage 6p
4-Eclairage 6p
FIRED HEATERS
5.1
OBJECTIVES
By the end of the session you should:
5.2
References
ExxonMobil Design Practices Sec. VIII
Blue Book Section 10
5.3
Antwerp: 11
- Fos: 9
- Rotterdam: 9
Augusta: 22
- Ingolstadt: 6
- Slagen: 8
Fawley: 26 - Port Jerome: 13 - Trecate: 10
Dunkirk: 3 - Gravenchon: 10 (approx.)
5.4
FURNACE TERMINOLOGY
5.5
FURNACE TYPES
Others
Horizontal Tube Box Furnace
Specialty Furnaces (Reformers, Steam Crackers)
5.6
Vertical-Cylindrical Furnace
Heat Duties Up to
150 MBTU/Hr (45 MW)
5.7
5.8
Common in Catalytic
Reformers
5.9
5.10
5.11
5.12
RADIANT/CONVECTION SECTIONS
GENERAL DESCRIPTION
5.13
RADIANT/CONVECTION SECTIONS
HEAT TRANSFER MECHANISM
Radiant section heat absorption primarily radiant.
Qr = F(T4absgas - T 4abstube)
Radiating gas temperatures typically 800 - 900C
High average heat transfer rates, 28,500 to 38,000W/m2
typical design range.
Highest rates for non-coking services
Maldistribution of heat around tube and vertically in firebox.
Convection section mainly convective heat transfer.
Lower 2 bare rows called shock or shield.
Basically cross/counter flow heat exchanger.
Extended surface used to enhance heat transfer.
5.14
RADIANT/CONVECTION SECTIONS
MAJOR ELEMENTS
Insulation system
Generally internal.
Castable refractory, ceramic fiber, maintain casing <82C,
(Design Basis)
5.15
CONVECTION SECTION
EXTENDED SURFACE
SURFACE
CYLINDRICAL STUD
EXTENDED SURFACE
5.16
STACKS
Types
Fired heater supported, ground supported
Internally lined, externally lined, unlined
Design considerations/procedures contained in DP VIIIC.
5.17
STACKS
5.18
5.19
5.20
5.21
Combustion System
Components
Burners, Pilots
Fuel system
Protective/Control systems
Flame Detection
Air flow protection (Forced draft)
Process flow protection
5.22
Combustion System
Combustion Theory
Definition: Chemical Combination Of Fuel With Oxygen In Air
Which Releases Heat
CxHy + (x+y/4) O2
5.23
5.24
COMBUSTION SYSTEM
Fuel System
5.25
COMBUSTION SYSTEM
Air Supply System
Components include:
Air distribution plenum or header
Flow Control Device (damper or guide vanes)
Noise reduction device or silencer
Flow modeling often performed to verify flow distribution
5.26
5.27
COMBUSTION SYSTEM
Basic Control
Requirements in IP15-1-1
5.28
COMBUSTION SYSTEM
Protective Systems - Flame Monitoring
5.29
COMBUSTION SYSTEM
Protective Instrumentation
Details in IP 15-1-1
5.30
5.31
Additional
Instruments
Required for Forced
Draft Process Fired
Heaters
5.32
Additional
Instruments
Required for
Fired Heaters
with Flue
Gas/Air Preheaters
5.33
5.34
5.35
FURNACE EFFICIENCY
DEFINITION OF TERMS
Low/High Heating Value (LHV/HHV)
Excess Air
Heat Absorbed
Heat Fired
5.36
FURNACE EFFICIENCY
CALCULATIONS
Efficiency =
x 100
Heat Fired
Three Methods
Input/Output
Stack Loss Method
EMS or Simplified Method
5.37
FURNACE EFFICIENCY
INPUT/OUTPUT METHOD
Calculate Efficiency
5.38
FURNACE EFFICIENCY
STACK LOSS METHOD
5.39
260oC
5.40
EA
111.4 x %0
EA
20.95 %0
91.2 x %0
2
20.95 %0
2
5.41
Dry Analysis of O2
91.2 x3.8
Excess Air
20.2
20.95 3.8
Say 20%
5.42
FURNACE EFFICIENCY
2. Calculate Heat Absorbed by Process
0%
40
E xc
20
e ss
Air
% Heat
5.43
kJ/kg Fuel
3. Efficiency
Eff =
Qa
LHV
x 100 =
39,200
45,400
x 100
5.44
5.45
EMS Efficiency
(Simplified Method)
Efficiency, %
Eff = {100 - [0.0427 + 0.00034 * XSA] * [Ts - Tair]} * [100/(100 + Loss)]
5.46
EMS Efficiency
CLOSE ENOUGH!!!!
5.47
AIR PREHEATER
5.48
AIR PREHEATERS
Consider When:
Stack Temperature > 644F (340C)
Fuel Value is High
Heat Absorbed is Large, >100 MBTU/hr (30 MW)
Forced Draft Burners are Used
Can Combine Flue Gases of More than One Furnace
5.49
PRINCIPLE TYPES
Rotary
Regenerative Air
Preheater
Typical Installation
5.50
5.51
5.52
5.53
5.54
Definition
Filling of the combustion zone with fuel that has
insufficient air for stable combustion
In this situation, the coil outlet temperature may drop,
triggering the temperature controller to increase fuel
flow to the burners. However, because there is
insufficient air for combustion and the fuel is not
burned, more and more unburnt fuel will build-up inside
the furnace, creating the risk of an explosion.
5.55
5.56
5.57
Combating Flooding
air dampers
5.58
Consequences of Flooding
5.59
Consequences of Flooding
5.60
FURNACE DEFINITIONS
Air Pre-heater.
A heat exchanger that heats the air required for combustion by
exchanging heat with the flue gases leaving the convection section.
Arch.
above.
The overhead (usually flat) portion of the radiant section, supported from
Box.
The burners and tubes are enclosed in the fire-box, which consists of a
structure, refractory lining and tube supports.
Breeching.
The hood that collects the flue gas at the convection section exit,
for transmission to the stack.
Bridgewall Temperature.
The temperature of the flue gas leaving the radiant
section. The term comes from the old horizontal box heaters, where a bridge-wall
physically separated the radiant and convection sections.
Burner.
Casing. A steel sheathing which encloses the heater box and makes it essentially
air tight.
Cell.
A portion of the radiant section, separated from other cells by tubes or a
refractory wall. Also called a "zone".
5.61
FURNACE DEFINITIONS
Center Wall.
separate cells.
Coil.
A series of straight tube lengths connected by 180 return bends, forming a
continuous path through which the process fluid passes and is heated.
Convection Section.
The portion of a heater, consisting of a bank of tubes,
which receives heat from the hot flue gases, mainly by convection.
Corbelling.
Narrow ledges, or baffles, extending from the convection section
side walls to prevent gas from flowing preferentially up the side of the convection
section, between the wall and the nearest tubes, thereby bypassing the tube bank.
Critical Velocity.
A fluid velocity equal to the velocity of sound through the fluid at
its temperature and pressure. Also called sonic velocity.
Crossover.
Piping which transfers the process fluid either externally or
internally from one section of the heater to another.
Damper. A device to regulate the flow of gas through a stack or duct and to control
draft in a heater. A typical device consists of a flat plate connected to a shaft that
can be rotated, similar to a butterfly valve.
5.62
FURNACE DEFINITIONS
Draft.
The negative pressure (vacuum) at a given point inside the heater, usually
expressed in inches of water.
Excess Air.
The percentage of air in the heater in excess of the stoichiometric
amount required for combustion.
Extended Surface. Surface added to the outside of bare tubes in the convection
section to provide more heat transfer area. This may consist of cylindrical studs buttwelded to the tube or fins continuously would and welded to the tube.
Film.
A thin fluid layer adjacent to a pipe wall that remains in laminar flow, even
when the bulk flow is turbulent. The velocity profile in the film is approximately linear,
with zero velocity at the tube wall.
Film Coefficient.
Fire Box. A term used to describe the structure which surrounds the radiant coils and
into which the burners protrude.
Flue Gas.A mixture of gaseous products that result from combustion of the fuels.
Fouling. The building up of a film or dirt, ash, soot or coke on heat transfer surfaces,
resulting in increased resistance to heat flow.
5.63
FURNACE DEFINITIONS
Forced Draft. Use of a fan to supply combustion air to the burners and to overcome
the pressure drop through the burners. This is in contrast to natural draft, where the
buoyancy of the column of hot flue gas in the stack and heater provides the "suction"
to pull combustion air into the burners.
Fired Heater Efficiency.
heating value basis.
Gross Fuel.
The total fuel fired in the heater, including all losses (usually
expressed in kg/h (lbs/hr)).
Gross Heating Value.
Header. The fitting which connects two tubes in a coil. In common usage, "header"
refers to cast or forged 180 U-bends ("return" bends).
Header Box. The compartment at the end of the convection section where the
headers are located. There is no flow gas flow in the header box, since it is
separated from the inside of the heater by an insulated tube sheet. Header boxes
are sometimes also used in the radiant section.
Heat Available. The heat absorbed from the products of combustion (flue gas) as
they are cooled from the flame temperature to a given flue gas temperature.
5.64
FURNACE DEFINITIONS
Heat Density. The rate of heat transfer per unit area to a tube, usually based on
total outside surface area. Typical units are W/m2 (Btu/hr/ft2). Also called "heat
flux".
Heat Duty. The total heat absorbed by the process fluid, usually expressed in MW
(Megawatts) or M Btu/hr (million Btu per hour). Total fired heater duty is the sum of
heat transferred to all process streams, including auxiliary services such as steam
super-heaters and drier coils.
Heat Fired. The total heat released in the heater, equal to gross fuel times lower
heating value (LHV) of the fuel. Usually expressed in MW (MBtu/hr)
Higher Heating Value (HHV). The theoretical heat of combustion of a fuel, when
the water formed is considered as a liquid (credit taken for its heat of combustion).
Also called gross heating value.
Hip Section. The transition zone at the top of the radiant section in cabin type
furnaces. The wall of this section is usually at a 45 degree angle.
Induced Draft. Use of a fan to provide the additional draft required over that
supplied by the stack, to draw the flue gas through the convection section, and any
downstream heat recovery equipment (i.e. air pre-heater).
5.65
FURNACE DEFINITIONS
Inspection Doors. Openings in the convection section side-walls to allow inspection
of tubes, extended surfaces and supports, when the heater is out of service.
NPS. Abbreviation for "Nominal Pipe Size".
Lower Heating Value (LHV). The theoretical heat of combustion of a fuel, when no
credit is taken for the heat of condensation of water in the flue gas. Also called net
heating value. Usually expressed in kJ/kg (Btu/lb)
Manifold. A pipe connected to several parallel passes and used to distribute or
collect fluid from these passes..
Mass Velocity. The mass flow rate per unit of flow area through the coil. Typical
units of measurement are kg/s m2 (lb/sec ft2)
Natural Draft. System in which the draft required to move combustion air into the
heater and flue gas through the heater and out of the stack is provided by stack
effect alone.
Net Fuel. The fuel which would be required in the heater if there were no radiation
losses. Usually expressed in kg/h (lb/hr).
Observation Doors. Openings in the radiant section floor and at selected points
along the walls, to permit viewing of tubes, supports and burners.
5.66
FURNACE DEFINITIONS
One-Sided Fired Tubes. Radiant section tubes located adjacent to a heater wall
have only one side directly exposed to a burner flame. Radiation to the back sides
of the tubes is by reflection/re-radiation from the refractory wall.
Pass. A coil which transports the process fluid from fired heater inlet to outlet.
The total process fluid can be transported through the heater by one or more
parallel passes.
Peepholes. Small observation ports usually placed in the radiant section floor
and/or arch to permit viewing of tubes, supports and burners. They are usually
glass covered.
Radiant Section. The section of the fired heater in which heat is transferred to the
heater tubes primarily by radiation from high temperature flue gas.
Service Factor. A measure of the continuity of operation, generally expressed as
the ratio of total running days for a given time period to the total calendar days in
the period.
Setting. The refractory insulation on the inside of the heater box.
5.67
FURNACE DEFINITIONS
Shield Section. The first two tube rows of the convection section. These tubes are
exposed to direct radiation from the radiant section and usually receive about half
of their heat in this manner. They are usually made of more resistant material than
the rest of the tubes in the convection section. Extended surfaces are not used in
this section.
Sootblower. A steam lance (usually movable) in the convection section for blowing
soot and ash from the tubes using high-pressure steam.
Stack. A cylindrical steel, concrete or brick shell which carries flue gas to the
atmosphere and provides necessary draft.
Stack Effect. The difference (buoyancy) between the weight of a column of high
temperature gases inside the heater and/or stack and the weight of an equivalent
column of external air, usually expressed in inches of water per foot of height.
Stack Temperature. The temperature of the flue gas as it leaves the convection
section, or air pre-heater directly upstream of the stack.
Transfer Line. Piping used to connect the fired heater outlet to downstream
processing equipment (tower, reactor etc.)
Tube Guide. Device used to restrict movement of tubes.
5.68
FURNACE DEFINITIONS
Tube Sheet. A large tube support plate located in the convection section and
supporting a number of tubes. The end supports are usually carbon steel or lowalloy steel and make up one side of the header box. The inside of the end
supports, which is exposed to the flue gas, is insulated. Intermediate supports are
exposed to flue gas on both sides and are fabricated of a suitable alloy material,
usually castings.
Tube Support. A metal part which supports the weight of the tube.
Turndown. Reduced operating conditions compared to design conditions. This
usually refers to reduced heat duty, which may be the result of reduced throughput
and/or reduced enthalpy requirements.
Two-Side Fired Tubes. Radiant tubes which are exposed on both sides to direct
radiation from the burners.
5.69