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Furnace Improvements Sales Presentation

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Furnace Improvements Sales Presentation

  1. 1. Furnace Improvements Mission: Low cost value added solutions for fired heaters 1600 Hyw 6, Sugar Land TX, 77478 Phone: (281) 980-0325 www.heatflux.com
  2. 2. Our Company <ul><li>15+ years </li></ul><ul><li>200+ Completed projects </li></ul><ul><li>40+ Professionals </li></ul><ul><li>Combined 300+ years of experience </li></ul><ul><li>Offices: </li></ul><ul><ul><li>Sugar Land, TX </li></ul></ul><ul><ul><li>New Delhi, India </li></ul></ul>Challenge us with your project!
  3. 3. Type of Heaters <ul><li>Crude heaters </li></ul><ul><li>Vacuum heaters </li></ul><ul><li>Hydrotreater heaters </li></ul><ul><li>Reformer charge heaters </li></ul><ul><li>CO boilers </li></ul><ul><li>Coker heaters </li></ul><ul><li>Waste heat boilers </li></ul>
  4. 4. Type of Services <ul><li>Revamping </li></ul><ul><li>Capacity increase </li></ul><ul><li>Efficiency improvement </li></ul><ul><li>NOx reduction </li></ul><ul><li>New Heaters </li></ul><ul><li>Design & Supply </li></ul><ul><li>Trainings </li></ul><ul><li>Customize Fired Heater Trainings </li></ul>
  5. 5. Scope of Services <ul><li>Process design </li></ul><ul><ul><li>CFD Modeling </li></ul></ul><ul><li>Detailed engineering </li></ul><ul><li>Project services </li></ul><ul><li>Hardware supply </li></ul><ul><li>Fabrication </li></ul><ul><li>Erection </li></ul><ul><li>Start up assistance </li></ul>
  6. 6. Some of Our Clients
  7. 7. Patented Technologies Furnace Improvements <ul><li>Split Flow Technology </li></ul><ul><li>Flue Gas Injection </li></ul><ul><li>Inclined Firing System </li></ul>
  8. 8. Split Flow Technology <ul><li>New approach to revamping heaters </li></ul><ul><ul><li>Increased capacity </li></ul></ul><ul><ul><li>Higher efficiency </li></ul></ul><ul><li>Converting waste heat into process heat </li></ul><ul><li>Lower pressure drop </li></ul><ul><li>Lower installation cost </li></ul>
  9. 9. Typical Fired Heater Fluid---  Convection section  Radiant section Conventional revamp  Add 2 more passes
  10. 10. Split Flow Fired Heater FIS-183
  11. 11. Inclined Firing System www.heatflux.com
  12. 12. FIS-Split Flow
  13. 13. Capacity Increased FIS Client Capacity (MMBtu/hr) % FIS Client Capacity (MMBtu/hr) % Before After Before After 183 Citgo 181 194 10% 296 Alon USA 12.4 15 20% 187 Citgo 13.7 15.1 10% 12 13.2 303 Alon USA 9 11 20% 242 Valero 120 151 25% 314 CountryMark 12 20 70% 248 Valero 135 186 35% 333 HPCL 163 187 15% 53 61 255 Valero 54 57 5% 335 Conoco 74 83 10% 73 81 260 Alon USA 30 37 20% 339 HPCL 135 169 25% 283 Country Mark 8.1 8.35 3%
  14. 14. Efficiency Improvement FIS Client Efficiency % FIS Client Efficiency % Before After Before After 183 Citgo 67 86 19% 280 Valero 79 90 11% 187 Citgo 74 82 8% 283 Country-Mark 65 75 10% 188 Conoco 68 73 5% 296 Alon USA 74 86 12% 242 Valero 80 89 9% 303 Alon USA 83 88 5% 248 Valero 80 89 9% 333 HPCL 82 90 8% 266 Conoco 66 86 20%
  15. 15. NOx Reduction FIS Client Technology NOx Emissions (lb/MMBtu) FIS Client Technology NOx Emissions (lb/MMBtu) 208 Husky Oil LNB 0.05 287 Conoco SCR - 210 Conoco ULNB < 0.03 290 Lion Oil ULNB 0.025 242 Valero ULNB - 299 Conoco SCR - 254 Conoco SCR <0.01 329 Alon USA ULNB <0.03 263 Conoco ULNB + FGR + SI <0.02 335 Conoco ULNB <0.03 266 Conoco ULNB <0.04
  16. 16. New Fired Heaters FIS Client Service Duty 247 CITGO Combine Feed Heater 47 MMBtu/hr 269 Conoco Vacuum Heater 42 MMBtu/hr 279 Devon Hot Oil Heater 25 MMBtu/hr 286 Conoco BEU Heater 165 MMBtu/hr
  17. 17. Other Services Furnace Improvements
  18. 18. CFD Modeling for Heaters & Boilers Vertical Cylindrical Heater Riley Stoker CO Boiler
  19. 19. Fired Heaters and Boiler Tuning <ul><ul><li>Visual Inspection </li></ul></ul><ul><ul><li>Work with operators and refinery personnel </li></ul></ul><ul><ul><li>Do require adjustments to improve performance </li></ul></ul><ul><ul><li>Tuning, Troubleshooting and Optimization </li></ul></ul><ul><ul><li>Measure and recollection of important parameters (Fuel gas flow, draft, etc.) </li></ul></ul>
  20. 20. FIS Training Programs <ul><li>FIS offers training of : </li></ul><ul><ul><li>Refinery Fired Heaters </li></ul></ul><ul><ul><li>Fired Heater Operating School </li></ul></ul><ul><ul><li>Fired Heater Engineering School </li></ul></ul><ul><ul><li>NOx Reduction </li></ul></ul><ul><ul><li>Customize trainings… and many others. </li></ul></ul><ul><li>“ Get your technical personnel trained and start getting the benefit of having excellent heater performance” </li></ul>FIS Training Clients
  21. 21. Draft Control System <ul><li>Improved Heater Efficiency </li></ul><ul><li>Decreased NO x Emissions </li></ul><ul><li>Optimized Combustion </li></ul><ul><li>Reduced Fuel Consumption </li></ul><ul><li>Payback less than a year  </li></ul>
  22. 22. Heater Performance Index Software <ul><li>Analyzes the performance of Fired Heater 24/7 </li></ul><ul><li>Built into DCS </li></ul><ul><li>Generates guidelines </li></ul><ul><li>Built in intelligence </li></ul><ul><li>Customized modeling </li></ul><ul><ul><li>Thermal Efficiency </li></ul></ul><ul><ul><li>Fuel gas rate, </li></ul></ul><ul><ul><li>Draft, </li></ul></ul><ul><ul><li>Excess O 2 , </li></ul></ul><ul><ul><li>Tube skin temperatures, </li></ul></ul><ul><ul><li>Feed flow rate, </li></ul></ul><ul><ul><li>Pressure drop, </li></ul></ul><ul><ul><li>Coking rate, </li></ul></ul><ul><ul><li>Air preheater performance </li></ul></ul>
  23. 23. Heat pickup in convection section is high – Afterburning Suspected Air Flow reported appears erroneous. Check the meter calibration. Heater Performance Index Performance Monitors Description Flow (BPM) Inlet Pressure (PSIG) Crossover Temp (°F) Outlet Temp (°F) TMT (°F) Pass #1 709.5 278.92 585.1 686.78 960.7 / 969.4 Pass #2 676.52 295.97 589.75 678.62 965.1 / 994.5 Pass #3 670.8 275.85 592.02 680.15 895.8 / 927.1 Pass #4 729.08 285.95 597.14 678.49 907 / 1034.4 Pass #5 729.1 281.66 594.54 683.37 930.6 / 1041.67 Pass #6 695.13 283.84 590.9 670.14 887.6 / 845.62 Pass #7 737.39 298.2 594.39 682.95 959.9 / 863.41 Pass #8 653.35 275.73 583.27 679.04 964 / 1048.68 Individual pass flow above minimum acceptable Radiant coil metal temperature is OK Burners are OK Oxygen in firebox OK Draft in the firebox is OK Number of burners in operation is OK No. of burners in operation 24 Heater Performance Index 0.56 Thermal Efficiency 90.25 Fuel Saving Potential 3.08
  24. 24. Thank you very much <ul><li>Give us a chance to improve the performance of your fired heaters </li></ul>Furnace Improvements Services Low Cost Solutions for Fired Heaters and Boilers 1600 Hyw 6, Sugar Land, TX (281)980-0325 www.heatflux.com
  25. 25. We have an Agent near You   AUSTRALIA, INDONESIA, MALAYSIA, NEW ZEALAND & SINGAPORE Kate Gimblett Tel:  +61 (0) 7 5435 2205 Mobile: +61(0)417 087 129 www.energysystem.com.au INDIA Ajai Agarwal Tel: +9111-4214-3751 Mobile:+9198-1015-9901 aqology@gmail.com TAIWAN Douglas Chang Tel: +8862-2706-1544 Mobile: +8869-2106-9827 china.abc@msa.hinet.net LOUISIANA, USA Charles H. Thatcher Tel: 985-892-4224 Mobile: 985-966-5513 cht@bellsouth.net BRAZIL Jose Fleischmann Tel: (+55) 11-5641-4361 Fax: (+55) 11-5641-4361 jofleis@attglobal.net KUWAIT Alex Ambi Tel: +965-2482-9160 ext.126 Mobile: +965-3384-1712 alex@alzahemgroup.com U.A.E., OMAN, QATAR Sarwar Ali Tel: +971-6742-5035 Mobile: +9715-0631-7452 mists@emirates.net.ae SOUTHEAST, USA David Gangle Tel: +20-5437-1702 Mobile:+20-5542-7006 dgangle@gancoheat.com CANADA Paul Henry Tel: +450-676-3222 Fax: +450-676-5997 bjuren@bellnet.ca MEXICO Lorena Nieto G. Cel: (04455)43493284 lorenanietogarfias@gmail.com VENEZUELA, COLUMBIA, ARUBA & ARGENTINA Carlos Alarcon Tel: +58-441-6609-3444 Fax: +58-441-4366-8406 caav-ramasco@cantv.net TEXAS, USA Stan McHugh Tel: +713-839-8788 Mobile:+713-703-8907 sam.co@sbcglobal.net INDIA R. Rajamani Tel: + 91 94483 79108 Tel: +91 80 65971113 [email_address] SAUDI ARABIA Azfar Mahmood Tel: +966-3899-6333 Mobile: +9665-3451-2635 azfar@smartbde.com CALIFORNIA, USA David P. Diggins Tel: +94-9497-6551 Mobile:+94-9463-8591 digginsinc@cox.net UTAH, WYOMING, IDAHO, MONTANA & NEVADA Allan Woodbury Tel: +801-274-3333 Mobile: +801 918-4826 [email_address]
  26. 26. Projects Furnace Improvements
  27. 27. CITGO - Corpus Christi No. 4 Platformer Heater Revamp <ul><li>Objective: </li></ul><ul><li>Improve Efficiency </li></ul><ul><ul><li>Stack temperature was 1100° F </li></ul></ul><ul><li>Reduce NOx </li></ul><ul><li>Our cost was 1/2 of the conventional revamp cost </li></ul>
  28. 28. Conventional Series Flow Design <ul><li>Disadvantages: </li></ul><ul><li>High Pressure Drop </li></ul><ul><li>Large process piping </li></ul><ul><li>New Stack </li></ul><ul><li>$ 6 MM </li></ul>
  29. 29. FIS Split Flow Scheme <ul><li>Advantages: </li></ul><ul><li>Lower Pressure Drop </li></ul><ul><li>Small process piping </li></ul><ul><li>Reuse of Stack </li></ul><ul><li>$ 3 MM </li></ul>
  30. 30. #4 Platformer Heater Data Comparison Item Units Before Revamp After Revamp Capacity BPD 18,500 24,000 Heat Duty MM Btu/hr 158.0 194.5 Heat Release MM Btu/hr 234 225 Efficiency % 67.50 86.60 Stack Temp. °F 1,092 478 Fuel MSCFH 244 242.8 Fuel Savings $/annum 5.8 Million* *Based on $6.0 / MM Btu
  31. 31. #4 Platformer Heater Before and After Revamp Before After Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  32. 32. CITGO Corpus Christy Reboiler Trim Heaters Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater Trim Heaters Parameters (Stripper / Stabilizer) Parameter Units Before Revamp After Revamp Parameter Units Before Revamp After Revamp Heat Duty MMBtu/hr 13.78 15.14 Heat Duty MMBtu/hr 12.0 13.20 Heat Release MMBtu/hr 18.06 18.29 Heat Release MMBtu/hr 16.13 16.10 Efficiency % 76.4 83.2 Efficiency % 74.4 82.0 Stack Temp. °F 813 572 Stack Temp. °F 832 575
  33. 33. ConocoPhillips WRR FCC- CO Boiler <ul><li>Re-design of CO FCC Convection section for: </li></ul><ul><ul><li>Increase Feed Flow </li></ul></ul><ul><ul><li>Improve Efficiency </li></ul></ul><ul><ul><li>Prevent Could end Corrosion of economizer </li></ul></ul><ul><ul><li>Eliminate Flow Distribution Problems </li></ul></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater CO Boiler Convection Section Replacement Item Units Before Revamp After Revamp Process Heat Duty MMBtu/hr 81.55 104.91 Steam Heat Duty MMBtu/hr 100.90 115.92 Process Flow BPD 41,995 48,000 Stack Temp. °F 636 577 Efficiency % 68.0 72.6 Fuel Savings $ / annum 0.55 Million* [ $3.0/MM Btu]
  34. 34. Premcor Lima Refinery Crude Heater NOx Reduction <ul><li>Balanced draft </li></ul><ul><li>420 MMBtu/hr duty </li></ul><ul><li>84 burners </li></ul><ul><li>Problems in convection section and radiant section </li></ul>
  35. 35. Premcor Lima Refinery Crude Heater – After Revamp <ul><li>NOx Reduction < 0.05 lb/MMBtu </li></ul><ul><li>Increased to 460 MMBtu/hr duty </li></ul><ul><li>Low Coking Rate </li></ul><ul><li>Low APH Temperature </li></ul><ul><li>Design, Engineering, Erection/Start up and Supervision </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  36. 36. ConocoPhillips- Ponca City Crude Heater NOx Reduction <ul><li>Multi-cell heater </li></ul><ul><ul><li>160.6 MMBtu/hr </li></ul></ul><ul><ul><li>87% Efficiency </li></ul></ul><ul><ul><li>62 Burners </li></ul></ul><ul><li>Installation of 66 ULNB’s </li></ul><ul><li>NOx Emissions <0.03 Lb/MMBtu </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  37. 37. Valero Texas City Refinery #2 Platformer <ul><li>Common Convection section with H-18/H-19 and H-23 </li></ul><ul><li>Process heating-all Radiant </li></ul><ul><li>Steam Generation in Convection </li></ul><ul><li>Common Stack </li></ul><ul><li>Natural Draft </li></ul>
  38. 38. Platformer Heaters (H-20/21/22) Parameter Units Original Design Total Heater Duty MMBtu/hr 155.98 Radiant Heat Duty MMBtu/hr 74.09 Convection Heat Duty MMBtu/hr 81.89
  39. 39. Convection Section <ul><li>Steam Generator Bank </li></ul><ul><li>Steam Superheater Bank </li></ul><ul><li>BFW Preheater Bank </li></ul><ul><li>Steam Generation: 73,669 lbs/hr@464 psig </li></ul><ul><li>14 tubes per row </li></ul><ul><li>Eighteen rows </li></ul><ul><li>Two future rows </li></ul>
  40. 40. NHT Heaters <ul><li>H-18- Hydrotreater Charge Heater </li></ul><ul><li>Duty-11.97 MMBtu/hr </li></ul><ul><li>H-19 Hydrotreater Stripper Reboiler </li></ul><ul><li>Duty-18.45 MMBtu/hr </li></ul><ul><li>H-23 Depropanizer Reboiler </li></ul><ul><li>Duty- 15.15 MMBtu/hr </li></ul><ul><li>All Radiant </li></ul><ul><li>Efficiency -52-55% </li></ul>
  41. 41. Performance Problems <ul><ul><ul><li>Convection section was in bad state </li></ul></ul></ul><ul><ul><ul><li>Fins are burnt out / fouled </li></ul></ul></ul><ul><ul><ul><li>Steam superheater temperature 40 °F lower </li></ul></ul></ul><ul><ul><ul><li>Thermal Efficiency is 78% vs. 88% design. </li></ul></ul></ul><ul><ul><ul><li>Stack temperature higher by almost 375 °F. </li></ul></ul></ul><ul><ul><ul><li>Stack temperature ~ 775 °F </li></ul></ul></ul>
  42. 42. Split Flow Scheme <ul><ul><li>H-20/H-21/H-22 </li></ul></ul><ul><ul><ul><li>Limit radiant heat flux to 15,000 Btu/hr ft² </li></ul></ul></ul><ul><ul><ul><li>Shift the balance duty to convection section </li></ul></ul></ul><ul><ul><li>H-18/H-19/H-23 </li></ul></ul><ul><ul><ul><li>Limit heat flux to 8,000-9,000 Btu/hr ft² </li></ul></ul></ul><ul><ul><ul><li>Limit the firing to design rate </li></ul></ul></ul><ul><ul><ul><li>Limit the volumetric heat release to 10000 Btu/ft 2 </li></ul></ul></ul><ul><ul><ul><li>Shift the balance duty to convection section </li></ul></ul></ul>
  43. 43. Valero Proposed Revamp – Split Flow Scheme
  44. 44. Split flow Convection Section <ul><li>Heat Recovery Sequence </li></ul><ul><ul><li>H-20; H-21; H-18 / H-19 / H-23 </li></ul></ul><ul><ul><li>SSH; SG; BFW </li></ul></ul><ul><li>Total rows – 20 </li></ul><ul><li>Conv. section dimension unchanged </li></ul><ul><li>Retubed the conv. section </li></ul>
  45. 45. Platform and NHT Heaters <ul><li>After FIS Revamp </li></ul><ul><li>Increased Capacity of platformer heater and NHT heaters from 12 to 18 MBPD </li></ul><ul><li>Split flow increased heat duty by ≈ 25% in Platform and Naphtha Hydrotreater Heaters. </li></ul><ul><li>Improved efficiency from 80 % to 89% </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  46. 46. CITGO Corpus Christi - TX <ul><li>4 MMBtu/hr Combined Feed Heater </li></ul><ul><li>Natural Draft </li></ul><ul><li>Design, Engineering & Supply </li></ul><ul><li>Commissioned 2005 </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  47. 47. Valero Wilmington Refinery Platformer Heater <ul><li>Capacity Improved from 12 MBPD to 18 MBPD </li></ul><ul><li>Used Split Flow Technology </li></ul><ul><li>Improved efficiency by 10% </li></ul><ul><li>Completed in January 2008 </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  48. 48. ConocoPhillips Alliance Refinery NOx Reduction–Crude Heater <ul><li>Biggest heater ~ 750 MMBtu/hr </li></ul><ul><li>SCR unit </li></ul><ul><li>FIS Novel Concept saved </li></ul><ul><li>$ 5 Million </li></ul><ul><li>New WHR section </li></ul><ul><li>Modify ID & FD fans </li></ul><ul><li>Efficiency Improved by 3.5% </li></ul><ul><li>Fuel Saving of $1.5 MM / year </li></ul>
  49. 49. ConocoPhillips Alliance Refinery SCR Scheme Overall hardware savings: USD 5 Million <ul><li>No ID Fan Require </li></ul><ul><li>Smaller Flue Gas Duct </li></ul><ul><li>No Stack Modifications Require </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  50. 50. Premcor Port Arthur Refinery Reactor Charge Heater <ul><li>Rerate heater to minimize pressure drop </li></ul><ul><li>8 pass heater was converted to 4 pass </li></ul><ul><li>Tube size increased from 4” to 8” </li></ul><ul><li>Burners were relocated </li></ul><ul><li>New tight shut off stack damper was installed </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  51. 51. AlonUSA Big Spring Refinery Reactor Feed Heater (080-H-001) <ul><li>Vertical Cylindrical Heater </li></ul><ul><li>Increase heat duty by 20% </li></ul><ul><li>Split Flow Scheme </li></ul><ul><ul><li>Originally single pass heater </li></ul></ul><ul><ul><li>Revamped to 2 pass heater- one in conv, one in radiant </li></ul></ul><ul><li>New Convection Section </li></ul><ul><li>Increased efficiency by 8% </li></ul><ul><li>10 ft additional stack </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  52. 52. ConocoPhillips Borger Refinery NOx Reduction – CO Boiler <ul><li>Conversion from CO Boiler to NG Boiler </li></ul><ul><li>NOx (<0.02 lb/MMBtu) </li></ul><ul><li>450K lbs/hr Boiler </li></ul><ul><li>Installation of Ultra Low NOx Burners </li></ul><ul><li>Flue gas recirculation with steam injection </li></ul><ul><li>New economizer section (4% efficiency improvement) </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  53. 53. ConocoPhillips WRR Efficiency Improvement- Alky Heater <ul><li>65 MMBtu/hr Heater </li></ul><ul><li>New Ultra Low NOx Burners </li></ul><ul><li>Efficiency Improved by 20% </li></ul><ul><li>New convection section, new stack and damper </li></ul><ul><li>Stack temperature reduced by 300 °F </li></ul><ul><li>Excess air reduced by 50% </li></ul><ul><li>Fuel savings of $800,000 per year </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  54. 54. ConocoPhillips Wood River Refinery <ul><li>New Wider Heater on existing foundation </li></ul><ul><li>42.82 MMBtu/hr Vacuum heater </li></ul><ul><li>Complete Modularization </li></ul><ul><li>Turn key supply </li></ul><ul><li>Erection completed in 10 days </li></ul><ul><li>Commissioned in 2009 </li></ul>Technical Manager Comment: “… we talked about the performance of the heater since startup.  It has been fantastic! This is one of the most efficient heaters in the refinery.  It's a lot different when you have a tight firebox.  Great job!!!” Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  55. 55. Devon Energy Riverton - WY <ul><li>25 MMBTU/hr Hot Oil Heater </li></ul><ul><li>Design, engineering, supply, erection and commissioning </li></ul><ul><li>Piping, Instrumentation & Foundation </li></ul><ul><li>Commissioned 2007 </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  56. 56. Valero Texas City Efficiency Imp.- CDHDS Reboiler <ul><li>82 MMBtu/hr, VC, Natural Draft Heater </li></ul><ul><ul><li>Addition of 6 rows for SG in Conv. Sec. </li></ul></ul><ul><ul><li>Larger stack </li></ul></ul><ul><li>12% Increase Duty </li></ul><ul><li>Efficiency Improved to 90% </li></ul><ul><li>Fuel savings of $590,550 / year </li></ul><ul><li>Payback less than 1 ½ years </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  57. 57. CountryMark CO-OP Vacuum Heater <ul><li>8.35 MMBtu/hr Cabin Heater </li></ul><ul><li>Revamp: </li></ul><ul><ul><li>Radiant Section Coils </li></ul></ul><ul><ul><li>New Burners </li></ul></ul><ul><ul><li>New Stack </li></ul></ul><ul><li>Capacity Increased to 8,200 to 9,500 BPD </li></ul><ul><li>Improved Efficiency by 10% </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  58. 58. ConocoPhillips Wood River Refinery <ul><li>165 MMBtu/hr hot oil heater </li></ul><ul><li>Modular Construction </li></ul><ul><li>Design, engineering and supply </li></ul><ul><li>9 months delivery </li></ul><ul><li>Commissioned 2009 </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  59. 59. ConocoPhillips WRR CCU-1 CO Boilers <ul><li>Modeling CO Boilers for correct temperature window for SCR Installation </li></ul><ul><li>Making changes in the coils to ensure correct temperature </li></ul><ul><li>Eliminate CO Slippage </li></ul><ul><ul><li>CFD Modeling </li></ul></ul><ul><li>Structural analysis of boiler for higher pressure </li></ul><ul><li>One boiler running for 6 months after modifications </li></ul>AUXILARY FUEL GAS Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  60. 60. Lion Oil El Dorado Refinery NOx Reduction Project <ul><li>NOx Reduction </li></ul><ul><ul><li>NOx emissions < 0.025lb/MMBtu </li></ul></ul><ul><ul><li>Using Ultra Low NOx burners </li></ul></ul><ul><ul><li>Vacuum Heater (H-1) </li></ul></ul><ul><ul><li>Cat Craker Heater (H-3) </li></ul></ul><ul><ul><li>Charge Heater (H-2) </li></ul></ul>
  61. 61. Lion Oil El Dorado Refinery NOx Reduction Project <ul><ul><li>Preflash Boiler (H-4) </li></ul></ul><ul><ul><li>Stripper Reboiler (H-5) </li></ul></ul><ul><ul><li>Reformer Heater (H-6) </li></ul></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  62. 62. AlonUSA Big Spring Refinery Hydrogen Heater (77-H-001) <ul><li>Revamp for Capacity Increase </li></ul><ul><li>Convection Section in bad Shape </li></ul><ul><li>Convectional Revamp resulted in high pressure drop </li></ul><ul><li>Split Flow technology </li></ul><ul><ul><li>Increase duty from 11.6 – 14.77 MMBtu/hr </li></ul></ul><ul><ul><li>Improved Efficiency from 78 – 86% </li></ul></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  63. 63. ConocoPhillips WRR CCU-2 CO Boilers <ul><li>Modeling CO Boilers for correct temperature window for SCR Installation </li></ul><ul><li>Making changes in the coils to ensure correct temperature </li></ul><ul><li>Structural analysis of boiler for higher pressure </li></ul><ul><li>Successfully commissioned October 2009 </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  64. 64. AlonUSA Big Spring Refinery Naphtha Stabilizer Reboiler (77-H-002) <ul><li>Existing duty: 8.68 MMBtu/hr </li></ul><ul><li>New duty: 10.8 MMBtu/hr </li></ul><ul><li>Efficiency Improvement: 4.5% </li></ul><ul><li>Fuel Savings/yr: $270,000 </li></ul><ul><li>New Convection Section, Stack & Radiant Coils </li></ul><ul><li>Heater Delivery – 5 Months </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  65. 65. CountryMark CO-OP Naphtha Splitter Reboiler <ul><li>Naphtha Service </li></ul><ul><ul><li>Naphtha Splitter Reboiler (8.38 MMbtu/hr) </li></ul></ul><ul><ul><li>Platform Coils (3.36 MMBtu/hr) </li></ul></ul><ul><li>Increase capacity not feasible </li></ul><ul><li>FIS Revamped an abandoned platform heater </li></ul><ul><li>Capacity Increase from 8.36 to 20 MMBtu/hr </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  66. 66. AlonUSA Big Spring Refinery Depentanizer Reboilers (H-102; H-205) <ul><li>Natural Draft VC Heaters </li></ul><ul><li>46 & 34 MMBtu/hr </li></ul><ul><li>Fouling Convection Section </li></ul><ul><li>High NOx Emission </li></ul><ul><li>Installation of ULNB’s with “ Inclined Firing System ” </li></ul><ul><ul><li>NOx emissions <0.03 lb/MMbtu </li></ul></ul><ul><li>Increase Capacity by 10% with “ Split Flow” </li></ul>
  67. 67. H-102 Convection Section <ul><li>Existing </li></ul><ul><li>Revamped </li></ul>H-205 has a very similar convection section revamp.
  68. 68. Inclined Firing System
  69. 69. Revamp Results Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater H-102 H-205 Design Operating After Revamp Design Operating After Revamp Efficiency % 85 83 86 84 81 86 Capacity MMBtu/hr 46 30.1 51.15 33.7 20.1 37.07 NOx Emission Lb/MM btu - - < 0.03 - - < 0.03 No. of Burners - 8 8 8 6 6 6 Heat release / Burner MMBtu/hr 8.51 - 8.65 8.35 - 8.36
  70. 70. HPCL, Vizag Refinery, India Crude Heater <ul><li>Capacity Increase by 15% </li></ul><ul><li>Heat duty Increase by 15% </li></ul><ul><li>Efficiency Improve by 4% </li></ul><ul><li>New Convection section </li></ul><ul><li>New 20 Low NOx Burners </li></ul><ul><li>Stack Temperature reduced by ≈ 200°F </li></ul>
  71. 71. HPCL, Vizag Refinery, India Vacuum Heater <ul><li>Capacity Increase by 15% </li></ul><ul><li>Heat duty Increase by 15% </li></ul><ul><li>Efficiency Improve by 6% </li></ul><ul><li>New Convection section </li></ul><ul><li>New 16 Low NOx Burners </li></ul><ul><li>Stack Temperature reduced by ≈ 200°F </li></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater
  72. 72. ConocoPhillips Wood River Refinery NOx Reduction of CR-3 Unit heaters <ul><li>Replacement of Burners with ULNB’s </li></ul><ul><li>New Convection Section with patented Split Flow Technology </li></ul><ul><li>Increase capacity from 32 MBPD to 40 MBPD </li></ul><ul><li>Increase Efficiency by 10% </li></ul><ul><li>NOx emission ≤ 0.04 lb/MMBtu </li></ul>
  73. 73. ConocoPhillips WRR Existing Heaters <ul><li>VC Heaters </li></ul><ul><li>Build as ND in ’59 </li></ul><ul><ul><li>Revamped for FD in ‘77 </li></ul></ul><ul><li>Radiant Section </li></ul><ul><ul><li>Process Feed </li></ul></ul><ul><li>12 Burners </li></ul><ul><ul><li>10.95 MMBtu/hr/burner </li></ul></ul><ul><li>Convection Section H-4 / H-5 </li></ul><ul><ul><li>BFW, SSG / SG </li></ul></ul><ul><li>Heat Duty H-4 / H-5 (Total/Process) </li></ul><ul><ul><li>110 MMBtu/hr / 103 MMBtu/hr </li></ul></ul><ul><ul><li>74 MMBtu/hr / 73 MMBtu/hr </li></ul></ul>
  74. 74. H-4 & H-5 Heaters Problems <ul><li>Radiant Tubes were scaled </li></ul><ul><li>Convection Section surface was less than 50% effective </li></ul><ul><li>High Flue Gas Temperature leaving CS </li></ul><ul><li>Low Efficiency </li></ul><ul><ul><li>Design ≈ 92 (FD) </li></ul></ul><ul><ul><li>Operating ≈ 82 (FD) </li></ul></ul>
  75. 75. Split Flow H-5 Heater
  76. 76. Convection Section Revamp with FIS Split Flow Technology (H-5) <ul><li>Existing </li></ul><ul><li>Revamped </li></ul>
  77. 77. Revamp Results Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater Parameter H4 H-5 Before After Before After Total Heat Duty (MMBtu/hr) 110 103 103 98 Process Heat Duty (MMBtu/hr) 74 83 73 81 Efficiency ND/FD (%) 82 / - 88 / 95 79 / 88 90 / 92 # Burners 12 12 12 12 Heat Release per Burner 10.95 10.12 10.95 9.8 NOx Emissions (lb/MMBtu) - < 0.03 - < 0.03
  78. 78. HPCL, Mumbai Refinery, India Crude Heater <ul><ul><li>Additional Convection Section on top of Existing </li></ul></ul><ul><ul><li>Increasing the number of burners from 12 to 17 </li></ul></ul><ul><ul><li>Addition of FRE APS and FRE VPS coils </li></ul></ul><ul><ul><li>Reduction of flue gas temp. to APH </li></ul></ul><ul><ul><li>15% Additional Capacity for Crude and Vacuum heater </li></ul></ul><ul><ul><li>Increased Efficiency to 90% </li></ul></ul>Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater

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