A new approach to improving heater efficiency
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The document describes improvements to heater efficiency using a split flow approach. In a typical implementation, the process stream is split, with the main flow heated through the radiant section and a split flow heated in the convection section before being recombined. Case studies at Citgo and Valero refineries achieved significant efficiency gains through split flow designs, reducing pressure drops, heat fluxes, and costs compared to conventional approaches.
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A new approach to improving heater efficiency
- 2. Typical Fired Heater Fluid------ Convection section Radiant section www.heatflux.com
- 3. Conventional Approach to Efficiency Improvement www.heatflux.com Additional Heat Transfer Surface in Convection Section
- 4. Split flow Fired Heater www.heatflux.com
- 9. Current Heater Operation www.heatflux.com Parameter Units Operating Value Total Heater Duty MMBtu/hr 158.10 Radiant Heat Duty MMBtu/hr 120.19 Convection Heat Duty MMBtu/hr 37.91 Firing Rate MMBtu/hr 229.20 Efficiency % 68.98
- 10. Flow Scheme - Before Revamp #4 Platformer Heater www.heatflux.com
- 11. Existing #4 Platformer Heater www.heatflux.com
- 12. Proposed Conventional Design High Pressure Drop www.heatflux.com
- 13. Conventional Design with Series Flow www.heatflux.com
- 14. Comparison of Pressure Drop at 22,000 BPD www.heatflux.com Pressure Drop, psi Original Design Series flow Design Cell 1 3.1 4.5 Cell 2 3.3 4.6 Cell 3 1.2 2.5 Cell 4 1.1 2.3 Total 8.7 13.9
- 16. FIS Split Flow* Scheme * Split flow - US Patent www.heatflux.com
- 17. FIS Split flow * design - Proposed * Patented. www.heatflux.com
- 18. Comparison (Cell 1) Parameters at 22,000 BPD www.heatflux.com Parameter Original Design Split flow Design Pressure Drop, psi 3.1 2.1 Firebox temperature, F 1,615 1,551 Radiant flux, Btu/hr ft2 19,823 15,047 Radiant tube metal temp, F 1,151 1,120 Firing rate, MMBtu/hr 116.35 82.65
- 19. #4 Platformer Heater Data Comparison www.heatflux.com 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
- 20. #4 Platformer Heater Before and After Revamp www.heatflux.com
- 21. Case Study-2
- 23. Platformer Heaters (H-20/21/22) www.heatflux.com 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 Radiant Fuel Efficiency % 54.2
- 24. Plan View of heater www.heatflux.com
- 33. Valero Proposed Revamp – Split Flow Scheme www.heatflux.com
- 37. Valero Proposed Revamp – Split Flow Scheme www.heatflux.com
Editor's Notes
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Reliance Refinery, Jaam Nagar India February 24, 2007 What is this Novel Approach? Typically in a fired heater, the feed is preheated in the convection section and further heated in the radiant section.
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Reliance Refinery, Jaam Nagar India February 24, 2007
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Flint Hills - Corpus Christi, TX 12/01/11
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Valero, Texas City Refinery,TX 12/01/11
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters
- Premcor Refinining Energy Managers Conference February 9, 2005 Furnace Improvements, Low cost solutions for fired heaters