Improving Fired Heaters Reliability using Inclined Firing Technology

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Louise Rogers
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1 Improving Fired Heaters Reliability using Inclined Firing Technology 1

2 Operating 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 2

3 Benefits 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 3

4 Inclined Firing System OUTLET 12'-9" TCD 12'-9" TCD 4'-4 ½ 4' 12'-9" 6' 5' 2'-7" Burners are inclined at 5-10 deg. INLET 2'-7" 4' BCD 4' 9/11/ BCD

5 5' 5' 4'-6" 5' 5' 6' 5' 5' 4'-6" 35'-6" 35'-6" 5-10deg. INTERHEATER -2 INTERHEATER -1 CHARGE HEATER

6 Inclined Firing System 8 burner system TCD of '-4 1/2" 57'-10" WELD TO WELD LENGTH 45'-8 5/8" 10'-5" I/S INS. Φ20'-8" TCD Φ21' -9 1/2" I/S INS. 3'-7 1/2" 4'-6" 5'-4 1/2" 6'-3" 7'-1 1/2" B.C.D. 2'-7" 5'-0" 10'-0" 15'-0" 20'-0" 25'-0" Height in Elevation BCD Φ8'-0" B.C.D. 6

7 Case 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 7

8 CFD Modeling Start CAD Geometry CAD Geometry & Meshing Boundary Conditions Diverge Computational Fluid Dynamics Uses numerical methods and algorithms to study fluid flow Solver Converged Solution Post Processor CFD Optimization Flow patterns in fired heaters, burners, fireboxes 3D models of fired equipment are created Analysis End 8

9 Gladieux Processing Hot oil heater being built with 6 inclined burners,commissioned in July

10 FIS-392B Client-GLADIEUX PROCESSING Location-HUNTINGTON, INDIANA

11 Flue Gas Velocity Contours Y-Plane [ft/s]

12 Flue Gas Vector Plot Y-Plane [ft/s] Long recirculation is observed.

13 Flame Contours (CO >2000 ppm) Colored by Temperature ( o F) Flame shapes are separate from each other. [ F] [ F]

14 Flame Contours (CO >2000 ppm) Colored by height (ft) [ft] [ft]

15 Tube Metal Temperature Contours Wall Tubes [ F] Tube Metal Temperatures [ F] Flue Gas Temperatures near Tubes

16 Wall Tubes Heat Flux Contours Average Heat Flux on the Tubes: 10,482 Btu/hr ft 2 [Btu/hr ft 2 ]

17 Phillips 66 Billings, MT Down Fired Steam Reformer PROPOSED INCLINED BURNER PROPOSED INCLINED BURN C L BURNER C L BURNER C L BURNER C L BURNER C L BURNER 4'-0" 4'-0" 3.5 o 3.5 o 2'-8 1/2" 4'-0" 2'-8 1/2" 4'-0" 3.5 o 2'-8 1/2" 2'-8 1/2" 2'-8 1/2" 2'-8 1/2" 2'-8 1/2" 5'-5" 5'-5" 5'-5" 5'-5" 5'-5" 5'-5" 20'-0 7/8" (SHELL WIDTH) EXISTING 20'-0 7/8" (SHELL WIDTH) PROPOSED 20'-0 7/8" (SHELL WIDTH) 20'-0 7/8" (SHELL WIDTH)

clearly show improvement in the flue gas flow pattern

18 Velocity Vectors on Center Plane Base Case Proposed Case [ft/s] 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.

High flue gas temperature going away from the tubes.

19 Temperature Contours on Center Plane Base Case Proposed Case [ F] High flue gas temperature going towards the tubes. High flue gas temperature going away from the tubes. In the proposed case, temperature contours clearly show the reduction in the flue gas temperature around the radiant tubes.

20 Husky Lima, Ohio Charge Heater with 6 Burners

21 Flue Gas Temperature Contours Central Plane [ F] Existing Case Temperature near the tube is high. Proposed Modification Flame angled towards the center of the furnace / away from tubes.

22 Flue Gas Temperature Contours Temperature near the tube is high. Plane Location [ F] Existing Case Proposed Modification

23 Fluid Path Lines: from Fuel Inlet Outer recirculation pattern [ft/s] Existing Case Proposed Modification

24 Flame Contours (CO >2000ppm) Colored by Temperature [ F] [F] Existing Case Proposed Modification

25 Flame Contours (CO >2000ppm) Colored by Height Flame height is14 ft. Flame height is reduce to 9 ft. [ft] [ft] Existing Case Proposed Modification

26 Flame Contours (5% O2) Colored by Height Flame height is16 ft. Flame height is reduce to 9.8 ft. [ft] [ft] Existing Case Proposed Modification

27 Flame Contours (3% O2) Colored by Height Flame height is 15.2 ft at 3% O 2. [ft] [ft]

28 Tube Metal Temperatures Hot spots due to flame impingement. TMTs more uniform. [ F] Existing Case Proposed Modification

29 Tube Heat Flux High heat flux distribution at bottom of the tubes [Btu/hr ft 2 ] Existing Case [Btu/hr ft 2 ] Proposed Modification

30 Phillips 66 Sweeny - Coker Heater High tube metal temperature issues Fuel gas fired low NOx burners 30

31 Coker Heater Geometry Burners are inclined by 7.5 towards the walls. Existing Proposed 31

32 Velocity Vectors Plane at primary tip [ft/s] Expanded View 32

33 Velocity Vectors by Temperature [ F] Plane at primary tip 33

34 Tube Metal Temperature Contours [ F] 34

35 Refractory Temperature Contours [ F] 35

36 Flame Shapes (Iso-Surface of CO 2000 ppm) [ F] B-1 B-2 B-3 Colored by Temperature B-4 36

37 Flow Profiles - Vertical Up Firing vs Inclined Firing [ft/s] Inclined Firing Vertical Up Firing 37

38 Flue Gas Temperature Profiles Vertical Up Firing vs Inclined Firing [ F] Inclined Firing Vertical Up Firing 38

39 Flame Profiles - Vertical Up Firing vs Inclined Firing Inclined Firing Vertical Up Firing 39

40 Phillips 66 Sweeny - Crude Heater Cabin heater suffering from high tube metal temperatures at arch Originally 6 large burners-30 MMBtu/hr each Proposed 36 burners-5 MMBtu/hr each with inclined firing mode

41 Flames Colored by Height CO 2000 PPM [ft] Base Case Proposed Design

42 Velocity Vectors - Z-1 Section Z-1 Z-2 Z-2 Z-1 [ft/s] Base Case Proposed Design

43 Temperature Contours at Z Sections [ F] Base Case Proposed Design

44 Radiant Tube Temperature Contours [ F] Base Case Proposed Design

to eliminate flame impingement Carried out CFD modeling of the burners and radiant

45 Citgo Corpus Christi - Crude Heater Client facing flame impingement and high tube metal temperatures in radiant section FIS recommended inclined burner firing system to eliminate flame impingement Carried out CFD modeling of the burners and radiant section to demonstrate the benefit of the inclined burner firing system 45

46 Existing Burner Arrangement EXISTING FLOOR & PLENUM ARRANGEMENT 46

47 Inclined Firing System Burner Arrangement 47

48 FIS-356D Client-CITGO Location-CORPUS CHRISTI, TEXAS

49 FIS-356D Client-CITGO Location-CORPUS CHRISTI, TEXAS

50 Velocity Vectors Base Case vs Inclined Firing System 50 ft 36 ft 19 ft [ft/sec] Existing Case with Vertically Fired Burners 0 ft Height in Feet Proposed Case with Inclined Firing System 50

51 Temperature Contours Base vs Inclined Firing System [ F] Base Case Inclined Firing System 51

52 Temperature Contours at 10ft Base Case vs Inclined Firing System At 10 ft Base Case At 10 ft Inclined Firing System [ F] 52

53 Temperature Contours at 15 ft - Base Case vs Inclined Firing System 1 At 15 ft Base Case At 15 ft Inclined Firing System [ F] 53

54 CO Mass Fraction Contours at 10 ft Base Case vs Inclined Firing System 1 [ppm] At 10 ft Base Case At 10 ft Inclined Firing System 54

55 CO Mass Fraction Contours at 15 ft Base Case vs Inclined Firing System 1 At 15 Ft Base Case At 15 Ft. Inclined Firing System [ppm] 55

56 Iso Surface of CO MF 2000 PPM Colored by Temperatures Base Case vs Inclined Firing System [ F] Base Case [ F] Inclined Firing System Top View 56

57 Iso Surface of CO Mass Fraction 2000 ppm Colored by Flame Height [ft] Base Case Inclined Firing System 57

58 Radiant Wall Temperatures For h =100 Btu/ft 2 h and T= 800 F [ F] Base Design Proposed Design 58

59 Summary Citgo reported almost 250 F reduction in tube metal temperatures after the revamp. Inclined Firing is proven in solving high tube metal temperatures problems CFD modeling demonstrated the ability of IFS to improve performance FIS is ready to evaluate your heater to determine whether it is a suitable candidate for Inclined Firing at no cost. 59

60 CountryMark Refining Installation of 4 burners in inclined firing pattern 60

61 FIS-367C Client-COUNTRYMARK Location-MT. VERNON, IN

62 HPCL Mumbai SEU Units 3200 (P.C.D.) 3962 (P.C.D.) F-4202 F (TYP.) 5.5 (TYP.) C L BURNER B.C.D. B.C.D. C L BURNER C L BURNER C L BURNER 1650 FLOOR PLT FLOOR PLT. 62

63 Alon Refining - Big Spring, TX Two vertical cylindrical heaters working for almost 3 years with Inclined Firing System Reduced fouling and hot spots Provided 10% extra capacity with Inclined Firing Technology

64 ALON USA LP BIG SPRING, TEXAS

65 We hope you found our presentation helpful and informative. 65

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