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Fired heater simulation

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Fired heater simulation

  1. 1. weyer special | fired heater simulation weyer group allround. smart.FIRED HEATERSIMULATION www.weyer-group.com
  2. 2. weyer special | fired heater simulationFired heater simulationDirect fired heaters are generally used in processes where the process temperature required is greater than 300 °C. A dis-tinction is made here between process heaters and refinery heaters. The most widely used refinery heaters are those whichare used for heating or evaporating hydrocarbons. There can be 20 different heaters in a typical refinery. For this commontype of furnace, a range of different validated simulation tools are available on the market. The weyer group uses Xfh deve-loped by HTRI, the tool widely used in the refinery industry for the modeling of furnaces. The following describes the scopeof a simulation such as this, as well as the use of the simulation results.Our services: 1 What is simulated? Properly characterizing the actual func- tion of the furnace is essential to achie- The weyer group has extensive experi-  Furnace recalculations ving a result that is useful and accurate. ence in the rigorous thermodynamic si-  Recalculations in the weyer group employees have in-depth mulation of these types of process knowledge of the refinery and petroche- event of a product heaters. mical industries, which allows us to change First, sophisticated software is used to create a simulation based on the proper  Burner optimisation map out the complete geometry of the design and operating conditions. We furnace. The arrangement of the pipe- can import chemical property data from  Design of new pipe- work and headers, of both the convec- process simulators (Pro/II and Aspen work tion and radiation zones, are faithfully Hysis) used by the weyer group or data reproduced from customer documentation. supplied by the customer. The use of  Furnace documen- The geometry of the firebox and the ar- boiling point analyses according to tation rangement of the burners, including the ASTM D86 or true boiling point is also type of burner, can be modeled in exac- possible. ting detail using our system. And of course air preheaters and natural 2 How are the results used? draught furnaces can also be modeled. The applications for this type of furnace simulation are wide and varied:weyer special | fired heater simulation | page 2
  3. 3. weyer group allround. smart. conditions thanks to rigorous heater simu- synthesis gas. These furnaces are often  Life Cycle Analysis lation. The following results from the si- specially designed for their particular ap-Information on the lifespan of the tubes mulation can then be used to define the plication. There is, for example, a signifi-can be produced from the simulation best “operating window” for the case at cant difference between cracking furna-results according to API 530. The hand: ces for the production of ethylene, whichMaximum Tube Metal Temperature use naphtha and those which use LPG. • Tube wall temperatures(MTMT) can be predicted from the opera- Semi-empirical simulation tools are used to • Burner flame lengthsting point of the furnace, and is used as model furnaces such as these, which have • Film temperaturesthe basis of strength calculations. The ope- been designed specifically for the applica- • Pressure profile in the piperation of the fired heater can also be eva- tion. The weyer group employees, who • Fired heater internal pressure profileluated retrospectively on the basis of TRD are experienced in process simulation, are • Flow regimes in the pipes508 and information can be provided familiar with a number of these tools, such (one- / two-phase flows)about the current state of the furnace. as Spyro manufactured by KTI for ethylene The operating window forms the basis forThe operation of a furnace is more reliable plants. So, weyer offers the capability not fired heater automation, the safetywith furnace simulations: Potential tube only to simulate general service refinery concept and a corresponding operatingfailures which could lead to the release of heater applications, but also process fired manual. It can allow you to avoid opera-hydrocarbons into the combustion heaters as well. ting conditions which could result inchamber, can be identified at an early damage to the furnace.stage. Repair measures can be plannedinto normal maintenance turnarounds,avoiding an unplanned outage.  Fired heater optimisation A rigorous fired heater simulation provides valuable information regarding expected throughputs, energy consumption and ef- ficiency. You can also examine the effects of modifications or retrofits of existing fur- naces before they are put into service. This can significantly reduce re-commissioning times. It is possible, for example, to examine the effects of • new pipe geometries • fin tubes versus smooth-bore Your benefit: pipes • alternative burner arrangements  Enhanced process reliability with life or the cycle analysis • refitting of fans  ptimised fired heater operating point O  Identifying the ”operating window” As mentioned at the outset, so-calledProcess furnaces very rarely only have one process fired heaters are used in the basic  Pre-planning ofspecific use. It is far more likely in practice chemical industry, much like they are in • Revampsthat the uses, throughputs and also refinery operations. However, chemical re- • Recoilingproduct temperatures to be achieved actions take place in these furnaces during • Product changeschange frequently. Optimum operating the flow of reactants through the heatedwindows for a process fired heater can be zones. These furnaces are used, for  Standardised documentation indepen- identified for many different operating example, for the production of ethylene or dent of the fired heater manufacturer weyer special | fired heater simulation | page 3
  4. 4. weyer group allround. smart.Your Contact www.weyer-group.comThe weyer group is an independent association of engineering and consulting companies based in Germany, Austria and Switzerland.Starting with the expectations and wishes of its customers, the weyer group has developed a wide range of skills and expertise since it was founded over 30 years ago. www.weyer-group.com

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