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Computational Fluid Dynamics (CFD) Modelling for Designing & Troubleshooting Fired Heaters
- 1. CFD Modeling Capability Furnace Improvements Services
- 2. www.heatflux.com Furnace Improvements Services: The Company ❖ Furnace Improvements Services is a reputed engineering and consulting company which provides specialized technological services that integrates mechanical and process engineering with CFD capabilities in order to design or revamp fired heaters and boilers in Oil & Gas industry Company Overview ❖ Offices ▪ Headquarters: Sugar Land, Texas, USA ▪ Process & Mechanical Group: New Delhi, India ▪ CFD & Process Group: Pune, India ❖ Services ▪ Turn-key services for design, engineering and supply of new fired heaters ▪ Revamps of all types of refinery fired heaters ▪ CFD Modeling ▪ Troubleshooting
- 3. www.heatflux.com Typical Project Progress Methodical Approach Mechanical •2D Drawings as per Client Documents •C&I summaries Process •Datasheets: Heater, Burner, Fans, APH, etc. •FRNC Simulations: Operating, Existing, and Proposed cases •Comparison with design parameters and identification of deviating parameters CFD •2D drawings from Mechanical team + FRNC simulations and process calculations from Process team •Evaluation of existing design using CFD Modeling •Validation with operating observations •Confirmation of operating issues •Evaluation of recommendations based on resolution of operating issues •Final proposed design •Detailed proposed design sent to Mechanical and Process team for Drawings and Datasheet Kick-off: ▪Client Drawings and Documents ▪Operating data ▪Field measurements Final report with Existing and Proposed cases: ▪2D drawings ▪Datasheets ▪CFD report
- 4. www.heatflux.com Basis for Study and Resolution Approach Operating Issue: • Operating data • Field measurements • Comparison with design parameters • Identification of deviating parameters Root Cause Analysis: • Evaluation of existing design using CFD Modeling • Validation with operating observations • Confirmation of operating issues Propose modifications: • Various designs and configurations are analysed • Burner tip, perforated plate, and number and location of burners for combustion cases • Vanes, angles, baffles and perforated/corrugated plate designs for flow improvements Final Design: • Best results and least modification • Comparison with existing design to show improvements Issue Identification and Approach
- 5. www.heatflux.com Computational Fluid Dynamics (CFD) ❖ Computational Fluid Dynamics (CFD) is a branch of fluid mechanics, used to solve and analyze problems of fluid flow through numerical analysis of conservation equations for mass, momentum, energy, etc. ❖ Benefits of CFD Modeling ▪ Insight: Gain detailed understanding of the phenomena inside the equipment or system ▪ Foresight: Virtual prototyping and testing to answer many “What If?” ▪ Efficient: Based on the foresight, CFD helps to achieve better design faster and with less cost. CFD helps to reduce the design and development cycle, with rapid prototyping CFD Description
- 6. www.heatflux.com CFD Applications in Fired Heaters CFD Scope Combustion Air Flow Distribution Fan Suction / Discharge Ducts AIG and SCR units Flow Distribution in Manifolds
- 7. www.heatflux.com CFD Modeling Steps Outline General Workflow MODELING MESHING CFD SOLVER PRESENTATION POST- PROCESSING Detailed 3D model of fluid system to accurately represent the domain to be analyzed Setup of models, boundary conditions, computational parameters and convergence goals Combine details from each step to present a simple structure of the methodology and CFD results Meshing of the 3D domain with mesh resolution and refinement Analysis of converged solution with the help of contours, vectors, fluxes, plots and animations
- 8. www.heatflux.com Case Studies ❖ Following slides show the application of CFD for various components of a fired heater system ❖ Typically one example is included for each component ❖ Apart from this, our CFD team is capable to simulate other applications related to refinery operations Sample Case Studies
- 9. www.heatflux.com Outline of Case Studies CFD Analysis Vertical Cylindrical (VC) Heater Cabin/Box Heater Combustion Analysis
- 10. www.heatflux.com Flame Profiles colored by Height Improvement in Flame Profile [ft] Flame Height: 25 ft Flame Height: 11 ft Flame height is reduced by more than 50% for the proposed case Existing Proposed
- 11. www.heatflux.com Maximum TMT: 840 °F Maximum TMT: 800 °F Radiant Tube Metal Temperature Profiles Improvement in TMT Profile Significant reduction in radiant tube metal temperatures. Reducing tube metal temperature increases the heater run length. [°F] Existing Proposed
- 12. www.heatflux.com 0 8 16 24 32 40 0 120 240 360 480 600 720 840 960 1,080 1,200 Radiantsectionheight,ft Mole fraction CO, ppmv Variation of CO mole fraction with height Existing Proposed CO Mole Fraction Profile Decrease in CO levels Average CO levels at each cross-section of the heater has reduced considerably, showing a faster combustion and lower flame heights
- 13. www.heatflux.com Outline of Case Studies CFD Analysis Plenum-mounted Burners Combustion Air Flow
- 14. www.heatflux.com Hot Air Velocity Profile Improved air flow in duct and burners [ft/s] Existing Proposed
- 15. www.heatflux.com Mass flow deviation at burner outlets Substantial Reduction in RMS Deviation -20 -15 -10 -5 0 5 10 15 20 1 2 3 4 5 6 7 8 9 10 11 12 RMSDeviationinMassFlow,% Burner No. Existing Proposed Mass flow deviation for the proposed case is within ± 3% 89 10 11 12 1 2 3 4 5 6 7
- 16. www.heatflux.com Outline of Case Studies CFD Analysis Fan Suction and Discharge
- 17. www.heatflux.com ID Fan Suction Duct Results ❖ Pressure drop was reduced by around 0.5 inches WC on the suction side Better Fan Performance Pressure Profile [inches WC] Existing Proposed Existing Proposed Velocity Profile [ft/s]
- 18. www.heatflux.com ID Fan Discharge Duct Velocity Profile ❖ Pressure drop was reduced by around 0.25 inches WC on the discharge side Uniform flow at stack cross-section [ft/s] ProposedExisting
- 19. www.heatflux.com Outline of Case Studies CFD Analysis Model Geometry AIG Lances AIG - SCR
- 21. www.heatflux.com NOx Distribution at SCR inlet Substantial Improvement in Mixing RMS deviation at SCR inlet is ± 4.56% RMS deviation at SCR inlet is ± 17.25% Existing Proposed [ppmv]
- 22. www.heatflux.com NH3 Distribution at SCR inlet Substantial Improvement in Distribution RMS deviation at SCR inlet is ± 2.87% Existing Proposed [ppmv] RMS deviation at SCR inlet is ± 19.32%
- 23. www.heatflux.com Outline of Case Studies CFD Analysis Fluid Transfer LinesMulti-phase Flow
- 24. www.heatflux.com Liquid volume fraction surface Liquid Fraction in Transfer Line Liquid Volume Fraction Contours Inlet Inlet Surface of liquid volume fraction of 0.5 is created to show the liquid flow in the pipes Existing Proposed
- 25. www.heatflux.com Flow Rate Deviation across Passes (Liquid & Vapor) Comparison: Existing vs. Proposed -25 -20 -15 -10 -5 0 5 10 15 20 A B C D E F G H %DeviationinLiquidFlow Pass Number Existing Proposed -20 -15 -10 -5 0 5 10 15 20 25 A B C D E F G H %DeviationinVaporFlow Pass Number Existing Proposed Deviation in Liquid Flow Deviation in Vapor Flow Improved liquid flow distribution for the proposed case; deviation in liquid flow across all the passes is less than ±10% Improved vapor flow distribution for the proposed case; deviation in vapor flow across all the passes is less than ±5%
- 27. www.heatflux.com Get in Touch ❖ Above case studies highlight FIS capability of carrying out CFD study for diverse applications ❖ Our team will be happy to discuss any specific project requirement Thank You! Furnace Improvements Services Inc. @uniformheattransfer Furnace Improvements Serviceswww.heatflux.com