Low Cost Value Added Solutions for Fired Heaters NOx Reduction
Do it Once, Do it RightFurnace Improvements Services (FIS) is a full service engineering and consulting company. Forover 14 years, we have been helping end users and owners providing design and engineering services toreduce their NOx emissions, improve the efficiency and capacity of their fired heaters, boilers andwaste heat recovery units.FIS have completed over 300 engineering studies and projects. We currently have a team of 45 skilledengineers on board with offices in Sugar Land, TX and in New Delhi, India. We have experience in de-sign and revamp all types of refinery fired heaters.NOx EmissionsPollutant-emission laws governing combustion equipment are increasing every year. One of the environ-mental regulations now affecting the Chemical Process Industries (CPI) are the laws covering NitrogenOxides (NOx) emissions.Finding the means for limiting NOx from fired heaters has become a major thrust of many sectors in theCPI.Reducing NOx Emissions in Fired HeatersThe following options are use in the Chemical and Petrochemical companies to reduce NOx emissions.Flue gas recirculation (FGR). Extracts a portion of the flue gas from the stack and returns it to the fur-nace along with combustion air. This lowers the peak flame temperature, and cuts thermal-NOx forma-tion. The addition of flue gas also reduces the Oxygen available to react with the Nitrogen.Selective Catalytic Reduction (SCR) involves injecting ammonia into the flue gas upstream of a cata-lyst bed. The chemical reaction involved is: O2 + 4NO + 4NH3 → 4N2 + 6H2ONOx and NH3 combine on the catalyst’s surface, forming anammonium salt intermediate that subsequently decomposes toproduce elemental Nitrogen and Water. The catalyst lowersthe activation energy of the NOx decomposition reaction,thereby enabling use of this technology at lower flue gas tem-peratures. The optimum temp. range for SCR is 600° to 700°F.Ultra Low NOx Burners, Several designs are available todaythat combine two NOx reduction steps into one burner withoutany external equipment. These burners typically incorporatestaged air with internal FGR or staged fuel with internal FGR.Choosing the Best Option for YouFIS has executed several projects regarding low NOx emission. We have the experience and the knowl-edge to customize the best option for you.
High Quality Technical WorkCase StudyAn USA company approach FIS looking for a practical solutionto reduce the NOx in their Crude Heater. This crude heater is thebiggest heater within the clients system, with a heat duty of 750MMBtu/hr.The scope was to install a selective catalytic reduction unit, toreduce NOx emissions to less than 0.01lb/MMBtu. The convec-tion section was split to get the correct flue gas temperature win-dow for the SCR. A novel scheme was implemented by FIS thatsaved 5 million dollars to the client.FIS option didn’t require installing new ID fans or duct work.The ID/FD fans were upgraded. FIS performed the CFD analysisto ensure there is proper mixing of Ammonia with the flue gasesin the SCR unit and there is uniform distribution of flue gasesover the catalyst bed.FIS reduced the flue gas temperature leaving stack from 420 deg F to 300 deg F, thus improving the effi-ciency by 3.5%. The annual fuel savings are approximately 1.5 million dollars.As you can see, this picture shows the conventional scheme versus FIS scheme. The alternative is toroute the cold and hot flue gas ducting into convection section instead of the stack. The convection sec-tion is split into two parts by installing a blanking plate. This eliminates the need to install new ID fansand stack and saves on duct work. CONVENTIONAL SCR SCHEME FIS SCR SCHEMEThis heater was commissioned in February 2009 and is running successfully ever since.
Low Cost Value Added Solutions for Fired Heaters Some of our clients We have an agent near you. BRAZIL TAIWAN Jose Fleischmann Douglas Chang Tel: (+55) 11-5641-4361 Tel: +8862-2706-1544 Fax: (+55) 11-5641-4361 Mobile: +8869-2106-9827 email@example.com firstname.lastname@example.org CANADA U.A.E., OMAN, QATAR Paul Henry Sarwar Ali Tel: +450-676-3222 Tel: +971-6742-5035 Fax: +450-676-5997 Mobile: +9715-0631-7452 email@example.com firstname.lastname@example.org VENEZUELA, COLUMBIA, INDIA ARGENTINA & ARUBA R. Rajamani Carlos Alarcon Tel: + 91 94483 79108 Tel: +58-441-6609-3444 Tel: +91 80 65971113 Fax: +58-441-4366-8406 email@example.com firstname.lastname@example.org INDIA CALIFORNIA, USA Ajai Agarwal David P. Diggins Tel: +9111-4214-3751 Tel: +94-9497-6551 Mobile:+9198-1015-9901 Mobile:+94-9463-8591 email@example.com firstname.lastname@example.org KUWAIT LOUISIANA, USA Alex Ambi Charles H. Thatcher Tel: +965-2482-9160 ext.126 Tel: 985-892-4224 Mobile: +965-3384-1712 Mobile: 985-966-5513 email@example.com firstname.lastname@example.org SOUTHEAST, USA MEXICO David Gangle Lorena Nieto G. Tel: +20-5437-1702 Mobile: (04455)43493284 Mobile:+20-5542-7006 email@example.com firstname.lastname@example.org SAUDI ARABIA TEXAS, USA Azfar Mahmood Stan McHugh Tel: +966-3899-6333 Tel: +713-839-8788 Mobile: +9665-3451-2635 Mobile:+713-703-8907 email@example.com firstname.lastname@example.org FURNACE IMPROVEMENTS SERVICES Furnace Improvements Services Inc. A.G. Furnace Improvements Pvt. Ltd. 1600 Highway 6 South, Suite 480 K-33, Ground Floor Sugar Land, Texas 77478 USA Opp. Balaji Estate, Kalkaji Tel: (281) 980-0325 New Delhi, India 110019 Fax: (832) 886-1665 Tel: 91-11-405-8-8696 Tel 2: 91-11-262-8-6775 Email: email@example.com www.heatflux.com