Tugas 1 No.

2
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PIC Flue gas pipa dan dipanaskan dengan
1
pembakaran bahan bakar
AT PI
1 4

FT
1 TI
PI
1
5
TI
feed TI
5

TI
6
PT
1

TI
product
3
TI
7 TI TI
TI 9 10
4

FT TI
FI
2 8 TI
3
11

fuel
udara PI
2
PI
3
PI
6
Process Control Object in Fired Heater
1. Safety
2. Environmental protection
3. Device/Equipment protection
4. Smooth operation
5. Quality product
6. Profit
7. Monitoring and diagnosing
 Questions on Fired Heater Process Principles
1. Describe two applications for a fired heater.
2. Why/when is a fired heater used rather than a steam heat exchanger?
3. Why does the pipe (coil) enter the heater above the radiant section?
4. Define energy efficiency and describe how it is calculated using process measurements.
5. The pressure inside the firebox is lower than outside; why does flue gas exit without compression?
6. How is the best value of the air flow rate determined?
7. Describe potential unsafe operating situations and how they are avoided.
8. A fired heater may have more than one burner. Discuss why.
9. A coil in a fired heater may be split into several pipes that pass through the heater and are combined at the exit of the
heater. Discuss why this design might be used. Do you expect challenges with this design?
10. Flue gas exits to the environment via the stack at a high temperature. How might more energy be recovered from the
flue gas by heat transfer, with the effect of reducing fuel consumption?
11. Discuss factors that determine the minimum allowable temperature of the flue gas as it leaves the fired heater
convection section.
Application of Fired Heaters
• Fired heater is usually used for process that required heating above high pressure steam temperature
(>480°C).
• Several industry that usually utilized fired heater are refinery , petrochemical, gas plants,and fertilizer plant.

• Operations that required heating from this unit are

• Reboiler for Distillation Column
• A process of separation based in boiling point of liquid
[Operation temperature: can reach 600°C)
Application of Fired Heaters
• Catalytic reforming
• A process to convert naphta to high octane liquid product
called reformate. This is an energy intensive process
• Operating temperature range from 400°C to more than
500°C
Other application:
• Fluidized Catalytic Cracking(FCC)
• Alkylation
• Catalytic Reforming
• Continuous Catalyst Regeneration (CCR)
• Thermal Cracking
• Coking
• Hydrocracking
• Direct-fired reactors, for example, the pyrolysis of
dichloroethane to form vinyl
• chloride;
• Reformers for hydrogen production, giving outlet
temperatures of 800°–900°C;
Why/when is a fired heater used rather than a steam heat exchanger?

• It is usually prefered if the duty of heating is high.

• According to Synnot(2008), modern fired heater has thermal efficiency of 80%-90%
• it can yield high temperature in shorter amount of time(it has high heat transfer flow rate)
Why does the pipe (coil) enter the heater above the radiant section?

• Primary use of coil above the radiant section is to increase

heat recovery.
• There are two sections in most fired heater: the radiant that
constitutes most of heat transfer and convection section,
which is usually above the radiant with lower heat transfer
• The radiant section gas temperature depend on amount of
fuel used and excess of air
• The inlet gas enter from below to radiant heater and exit as
flue gas at above. Sometimes, the inlet gas is in excess and
the flue gas temperature is too high, resulting overheating
and lower thermal efficiency.
• This excess heat in flue gas can be used to preheat reactant
before exit the furnace.
• So the coil is designed to enter above the radiant section to
receive excess heat from flue gas
Define energy efficiency and describe how it is calculated using
process measurements.

• Energy efficiency can be expressed in term of thermal efficiency. Technically it is a ratio of heat absorbed by
reactant divided by total heat input.
• If heat absorbed isdefined as heat input minus heat losses, the overall equation become

• The measurement of its efficiency can be evaluated in several terms:

• In terms of temperature. The temperature indicator 8 can be used as benchmark to evaluate energy input as thermal energy relates closesly
to temperature of inlet. In that case we can obtain the energy absorbed by measuring temperature of the reactant at various point. Initially
reactant is at temperature indicated by TI-1, then the temperature elevation can be measured from TI-5, TI-2, TI-3, TI-7, TI-4, TI-9 and TI-10.
• In terms of composition and pressure. Pressure can indicate the amount of air and fuel(gas) that entering the furnace in compare to the flue
gas that exit the furnace. These parameter can be interpreted as energy input by analyzing pressure and composition of fuel and gas. While,
flue gas composition or pressure can be analyzed to obtain energy loss data.
 PIC
1

AT PI
1 4

FT
1 TI
PI
1
5
TI
5
TI
2

TI
6
PT
1

TI
3
TI
7 TI TI
TI 9 10
4

FT TI
FI
2 8 TI
3
11

PI PI PI
2 3 6
Define energy efficiency and describe how it
is calculated using process measurements.
• One example scheme to
increase efficiency using
process measurement and
control is as followed:
• The temperature indicator
detect gas temperature
limit
• It will reduce maximum
firing limit to decrease gas
temperature.
• In some cases, the burner
need to be shut down via
heater shutdown control.
• Then cooling fluid is flowed
to remove excessive heat
source :Campbell,John. Gas conditioning and Processing
The pressure inside the firebox is lower than outside; why does flue
gas exit without compression?

• The flue gas is high in temperature and have high kinetic energy. according to Bernoulli equation, the fluid
flows because of several type energy contribution, pressure, kinetic, and potential. If one energy is
dominating enough, the fluid will flow in such direction
How is the best value of the air flow rate determined?