RRTC Sept.05 G Caronno Fired Heaters PresentationJH Final 1 Animated
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Transcript of RRTC Sept.05 G Caronno Fired Heaters PresentationJH Final 1 Animated
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Giampiero CaronnoSales Manager, Equipment DivisionFoster Wheeler Italiana Spa
RRTC 22 & 23 September 2005
Fired HeatersEnhancing Refinery Profitability
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Fired Heaters – Enhancing Refinery Profitability
Contents
• How a fired heater works
• Fired heater design basis – the importance of the ‘heart’ of the unit
• Parameters influencing fired heater operation
• Maximization of process unit profitability
• Improper operation
• Example of revamping – case studies
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Fired Heaters – Enhancing Refinery Profitability
How a fired heater works
Balanced (forced) draft
Natural draft
Stac
kC
onve
ctio
nR
adia
nt s
ectio
n
sect
ion
Damper
Stack exit loss
Stack effect in stack
Stack effect in convection section
Burners
0.05” –0.1” W.G. draft.Draft at radiant section outlet, R0
Negative pressure 0.05” – 0.1” W.G. at top of radiant section
Stack effect in radiant section
Negative pressure Positive pressure0
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Fired Heaters – Enhancing Refinery Profitability
Design Basis
• Tailored design to meet design requirements
• Main design parameters: efficiency and heat flux
• Optimization between efficiency and cost
• How many fired heaters have a proper design basis ?
• How many fired heaters work in line with the design basis ?
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Fired Heaters – Enhancing Refinery Profitability
Parameters influencing fired heater operation
EFFICIENCY REDUCTIONEFFICIENCY REDUCTION==
Heat LoadHeat Load++
Excess AirExcess Air++ FoulingFouling
++
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Fired Heaters – Enhancing Refinery Profitability
Parameters influencing fired heater operation (*)
• Higher heat flux
• Reduced tube life time
• Reduced efficiency
Heat load
(*) Based on:(*) Based on:
Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil Cost= 0.2 €/KgFuel Oil Cost= 0.2 €/Kg
430400°CStack temperature
62 (+20%)52Gcal/hFired heater duty
77.2
67.36
75.5
82.12
%Fired heater Efficiency
Gcal/hHeat fired
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Fired Heaters – Enhancing Refinery Profitability
Parameters influencing fired heater operation (*)
Excess Air
5252Gcal/hFired heater duty
259,200
65.82
400
20
67.36
400
40
€ Yearly saving
Gcal/hHeat fired
°CStack temperature
%Excess air
33000€Extra Yearly Cost
21Kg/hExtra Fuel
2100Kg/hExtra Air
(*) Based on:(*) Based on:
Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil Cost= 0.2 €/KgFuel Oil Cost= 0.2 €/Kg
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Fired Heaters – Enhancing Refinery Profitability
Parameters influencing fired heater operation (*)
• Clean condition
• Internal fouling
• External fouling
52Gcal/hFired heater duty
€/yearIncremental fuel cost
€/hIncremental fuel cost
7090Kg/hFuel fired
100,000HrsTubelife
448°CMetal temperature
435°CPeak film temperature
400°CStack temperature
77.2%Heater efficiency
Clean condition
52
464,000
58
7380
20,000
524
438
450
74.2
Internal fouling
52
944,000
118
7680
100,000
456
441
500
71.3
External Fouling
Fouling of exchange surface
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Fired Heaters – Enhancing Refinery Profitability
Maximization of process unit profitability
Reduce utilityReduce utilityconsumptionconsumption
Maximization unit profitability
Minimize Minimize operatingoperating
costcost
OptimizeOptimizefired heatersfired heatersperformanceperformance
Reduce Reduce emissionsemissions
IncreaseIncreasecapacitycapacity
MaximizeMaximizeonon--stream timestream time
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Fired Heaters – Enhancing Refinery Profitability
Maximization of process unit profitability
OptimizeOptimizefired heatersfired heatersperformanceperformanceUniform conditionsUniform conditions
Optimize firingOptimize firing
Reduce Reduce emissionsemissionsReduce firing rateReduce firing rate
Replace burnersReplace burnersIncreaseIncreasecapacitycapacity
Limited firing capacityLimited firing capacity
Limited heat transfer surfaceLimited heat transfer surface
Draft shortageDraft shortage
Flame impingementFlame impingementHigh tube metal temperatureHigh tube metal temperature
Firing control difficultiesFiring control difficultiesCoke formation inside tubesCoke formation inside tubes
Reduce utilityReduce utilityconsumptionconsumption
Add extra surfaceAdd extra surface
APH installationAPH installation
Cleaning surfacesCleaning surfaces
MaximizeMaximizeonon--stream timestream time
Proper operationProper operation
Maintenance scheduleMaintenance schedule
Fired Heater componentsFired Heater components
Minimize Minimize operatingoperating
costcostInternal tube cleaningInternal tube cleaning
Fire cheap fuelsFire cheap fuels
Automatic devicesAutomatic devices
Instrumentation improvementInstrumentation improvement
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Fired Heaters – Enhancing Refinery Profitability
Maximization of process unit profitability (*)
• Higher efficiency• Milder conditions at constant load• Possible increased fired heater load
IncreaseIncreasecapacitycapacity
Reduce utilityReduce utilityconsumptionconsumption24,40028,000Kcal/h m2Heat flux
8370%Fired heater efficiency
N.A.
393
33
46,000
1,243,000
387
33
46,000
€/yearSaving
°CPeak film temperature
Gcal/hFired heater duty
BPSDTopping capacity
Increase of convection surface
(*) Based on:(*) Based on:
Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil Cost= 0.2 €/KgFuel Oil Cost= 0.2 €/Kg
30,900
81
387
43
60,000
Increase of radiant surface
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Fired Heaters – Enhancing Refinery Profitability
Maximization of process unit profitability (*)
Installation of air preheating system
6,0807,090Kg/hFuel fired
70,00070,000BPSDTopping capacity
9077%Fired heater efficiency
N.A.
40
52
1,620,000
20
52
€/yearSaving
%Excess air
Gcal/hFired heater duty
IncreaseIncreasecapacitycapacity
Reduce utilityReduce utilityconsumptionconsumption
(*) Based on:(*) Based on:
Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil LHV= 9500 Kcal/Kg Fuel Oil Cost= 0.2 €/KgFuel Oil Cost= 0.2 €/Kg
• Higher efficiency• Short payout period
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Fired Heaters – Enhancing Refinery Profitability
Maximization of process unit profitability
Reduce Reduce emissionsemissions
184t on/yNox outlet (**)
250mg/Nm3Nox emissions (**)
442t on/yNox outlet (*)
600mg/Nm3Nox emissions (*)
40%Excess air
77.2%Heater efficiency
H.I. burners low eff.
54
75
252
350
20
79
Low Noxburners
56
90
253
400
20
90
Low Nox
w/APH
(*) Fuel oil firing(**) Fuel gas firing
Emission reductions
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Fired Heaters – Enhancing Refinery Profitability
Improper fired heater operation
Original fired heater
design
Currentfired heaterconditionsDamper design
Low velocityinside tubes
Old typeburners
Positive pressure
Uneven flow distribution
Fouling on heat transfer
surfaces
Air infiltration
High excess air
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Fired Heaters – Enhancing Refinery Profitability
Case 1 Atmospheric distillation fired heater
• Installation of a fix type air preheating system (APH) on a twenty-five year crude heater
• APH Installation was carried out during scheduled turnaround
• Forced and induced draft system installed
• Fired heater control was upgraded
Fired heater duty, Gcal/h 52 52
Net efficiency, % 72 90
Heat fired, Gcal/h 72.2 57.8
Fuel oil saving, Kg/h 1,520
Annual saving, Euros (*) 1,216,000
(*) Euros equivalent / F.O. Cost : 0.1 €/ Kg equivalent
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Fired Heaters – Enhancing Refinery Profitability
Case 2 Refinery fired heaters
• Firing optimization and emission reduction program for most of refinery process heaters
• Burners of significant fired heaters were replaced during phasedturnarounds; minor modifications on fired heater floors required
• Refinery fuel balance re-arranged to have most effective FO / FG ratio
• Refinery global flue gas emissions were reduced to 65%
Overall fired heaters duty, Gcal/h 1,039.4
Ave. NOx emissions, mg/Nm3 455.5 296.3
Total NOx outlet, Kg/h 425.6 276.8
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Fired Heaters – Enhancing Refinery Profitability
Case 3 Vacuum Distillation fired heater
• Improved operating conditions of vacuum distillation fired heater
• Replaced burners with state-of-the-art type to solve tube bending due to flame impingement problems and to reduce flue gas emissions
• Convection section and stack were modified and replaced
Fired heater duty, Gcal/h 20 20
Net efficiency, % 74 80
Heat fired, Gcal/h 27 25
Fuel oil saving, Kg/h 214
Annual fuel saving, Euros(*) 342,000(*) Not considering improvement in operating conditions
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Fired Heaters – Enhancing Refinery Profitability
Case 4 Atmospheric Distillation fired heater
• Increase unit capacity from 30,000 to 42,000 BPSD
• Improved fired heater efficiency (+40% capacity with only 11% additional heat fired)
• Added radiant surface in available space
• Replaced bare tubes with finned tubes in convection section
Unit capacity, BPSD 30 42
Fired heater duty, Gcal/h 25 35
Net efficiency, % 65 82
Heat fired, Gcal/h 38.5 42.7
Heat flux, Kcal/h m2 27,000 28,500
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Fired Heaters – Enhancing Refinery Profitability
Case 5 Steam reformer revamping in a middle east refinery
• Identified a need of additional hydrogen production capacity of 12’000 Nm3/h
• Revamped an existing steam reformer; the upgrading project included the catalyst tubes replacement with new ones with new material (lower thickness)
• The increased catalyst volume, the higher catalyst performances and the convection review allowed to target a production increase of 20%
Hydrogen capacity, Nm3/h 60,000 72,000
Fuel+feed consumption, Gcal/h 247 298
Overall steam production, t/h 120 158
Export steam, t/h 63 93
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Fired Heaters – Enhancing Refinery Profitability
The importance of the fired heater specialist
360° vision on fired heaters
Dampers & stackDampers & stack
Fans and Fans and blowersblowers
Pressure profilePressure profile
Heat recovery Heat recovery sectionsection
Pressure partsPressure parts
Tube supports & tube Tube supports & tube sheetssheets
Burners operationBurners operation
Emission Emission reductionsreductions
MechanicalMechanical
ReRe--ratingrating
ProcessProcess
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Giampiero CaronnoSales Manager, Equipment DivisionFoster Wheeler Italiana Spa
[email protected] www.fwc.com
Thank you