Furnace Improvement Services (FIS) is an engineering consulting company that specializes in CO boiler design, revamp, and troubleshooting. The document provides an overview of CO boilers and case studies of FIS projects involving CO boiler revamps, efficiency improvements, capacity increases, and NOx reduction. Key projects included replacing the convection section of a CO boiler to increase capacity and efficiency, and modifying a combustion chamber and burners to ensure complete combustion and reduce CO emissions. FIS has experience with over 300 projects and aims to provide low-cost solutions to improve CO boiler performance and compliance.
.Coker heaters are one of the most critical heaters in the refineries. The feed is heated to a very high temperature. Run length is one of the important factors for coker heaters. We have worked recently worked on a conventional Coker heater and implemented several improvements while retubing the radiant section.
Fired Equipment presentation on Types, Classification and governing Equations...Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Fired Equipment. This is an introduction to understand more about their:-
-Types
-Basic Principles and equations
-Worked Example
You can find also more at:
http://hassanelbanhawi.com/staticequipment/firedequipment/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Furnaces in Refinery and Petrochemicals
Process furnaces
Crude distillation unit
Reaction Heaters
Reformer Heater
Heater Performance objectives
Reasons to save Energy
Heater Types
Radiant section
Convection section
Crossover section
Burners
Line Sizing presentation on Types and governing Equations.Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Pipeline Sizing. This is an introduction to understand more about their:-
-The basic idea.
-Simplified method for calculations.
-Equations.
-Data Tables.
-Worked Examples.
-Excel Sheets for Calculation.
-Links to other topics which may be interesting.
You can find also more at:
http://hassanelbanhawi.com/staticequipment/linesizing/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
.Coker heaters are one of the most critical heaters in the refineries. The feed is heated to a very high temperature. Run length is one of the important factors for coker heaters. We have worked recently worked on a conventional Coker heater and implemented several improvements while retubing the radiant section.
Fired Equipment presentation on Types, Classification and governing Equations...Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Fired Equipment. This is an introduction to understand more about their:-
-Types
-Basic Principles and equations
-Worked Example
You can find also more at:
http://hassanelbanhawi.com/staticequipment/firedequipment/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Furnaces in Refinery and Petrochemicals
Process furnaces
Crude distillation unit
Reaction Heaters
Reformer Heater
Heater Performance objectives
Reasons to save Energy
Heater Types
Radiant section
Convection section
Crossover section
Burners
Line Sizing presentation on Types and governing Equations.Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Pipeline Sizing. This is an introduction to understand more about their:-
-The basic idea.
-Simplified method for calculations.
-Equations.
-Data Tables.
-Worked Examples.
-Excel Sheets for Calculation.
-Links to other topics which may be interesting.
You can find also more at:
http://hassanelbanhawi.com/staticequipment/linesizing/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Design Calculations of Venting in Atmospheric and Low-pressure Storage Tanks ...Pradeep Dhondi
hi
i have made an excel base software base on API st.2000 "Design Calculations of Venting in Atmospheric and Low-pressure Storage Tanks" to make calculation easy and accurate , i have take many case study and verified my software got positive result.
if you think you need this software for design the vent , please go to "rajiravi.ml" website there you can find complete information base on software and information based on contact etc...
Pumps presentation on Types, Classification and governing EquationsHassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Pumps. This is an introduction to understand more about their:-
-Types
-Selection
-Basic Principles and equations
-Pump System
-Pump Curve
-Worked Example
-Very useful Excel sheets for pumps calculation
You can find also more at:
http://hassanelbanhawi.com/rotatingequipment/pumps/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Fired Heaters-Key to Efficient Operation of Refineries and PetrochemicalsAshutosh Garg
Fired Heaters are a critical to successful operation of refineries and petrochemical plants. They are a major energy consumer as well as a major source of air pollution. There are also concerns about the run length of the heaters as well safety issues.
Brief introduction to Fired Heaters operation and design. Definition of the different Heaters in the industry and brief strategy how to operate them safely.
This presentation is a brief descriptive procedure of simulating in aspen flare system analyser (otherwise called as flarenet). It gives a step by step instructions to develop a flare network scheme in the simulator
The discussion on "Handling of Turbines During Emergencies" has been detailed in the ppt. Some case studies are also discussed in the session where the course participants express their difficulties while coming across the emergencies in handling the turbines at their locations.
Fired heaters are used for heating hydrocarbons fluids in the refineries and petrochemical plants. They are used for high temperature heat transfer. In most fired heaters, we are burning fuel gas as source of heat . There are many heaters in the world where liquid fuel is also burnt in the fired heaters to provide the energy, but their number is decreasing due to tighter pollution laws. Heaters that are processing hydrocarbons services are prone to coking and cracking depending upon the nature of the hydrocarbons being processed. Typically heaters may run length of anywhere from 3 months for coking service to 6 years for different services. Heater designers and operators are always faced with the challenge of providing uniform heat transfer to all the tubes. Engineers use equations that assume uniform heat transfer to heater tubes When designing fired heaters. However, in reality, most fired heaters do not experience uniform heat transfer, and as a result, hot spots develop on the tubes. These hot spots cause coking inside the tubes which requires the heater be shutdown periodically to remove the coke and clean the tubes. Any shutdown to clean the tubes in a fired heater causes a substantial production loss. The owners want to extend the run length of fired heaters. Furnace Improvements has developed a new patented firing technology that provides uniform heat transfer to heater tubes. This technology can be applied to most fired heaters. Our patented technology reorients the burners at a slight angle away from the tubes. We are able to direct the hottest part of the flames and flue gases away from the tubes without affecting the heat transfer in any way. FIS has installed this in 5 heaters ranging from 14 MMBtu/hr. to 280 MMBtu/hr. The clients are experiencing significant reduction in tube metal temperatures. This is translating into lower coking rates and higher tube life. We have been able to increase the capacity of the heaters in most of the cases. In one of the case study that has been presented in this heater, the heater duty was increased from 14 MMBtu/hr. to 21 MMBtu/hr. Inclined firing improves the heat transfer to the tubes and makes in uniform.
This material provides the basic of design, operation and maintenance so that you can use this as guide line to operation, to inspect your boiler. Hope this will be benefit you.
Distillation Towers (Columns) presentation on Types, governing Equations and ...Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Columns. This is an introduction to understand more about their:-
-Types
-Basic Principles and equations
-Distillation System
-P&ID Symbols
-Worked Example
You can find also more at:
http://hassanelbanhawi.com/staticequipment/columns/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Smart Stack Damper is one of the patented technologies of Furnace Improvements. It offers an innovative way to control drat in fired heaters. Smart Stack Damper consists of multiple pneumatic operators for controlling the damper. It is possible to save substantial amount of energy by proper training and installing smart stack dampers in your fired heaters.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
Design Calculations of Venting in Atmospheric and Low-pressure Storage Tanks ...Pradeep Dhondi
hi
i have made an excel base software base on API st.2000 "Design Calculations of Venting in Atmospheric and Low-pressure Storage Tanks" to make calculation easy and accurate , i have take many case study and verified my software got positive result.
if you think you need this software for design the vent , please go to "rajiravi.ml" website there you can find complete information base on software and information based on contact etc...
Pumps presentation on Types, Classification and governing EquationsHassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Pumps. This is an introduction to understand more about their:-
-Types
-Selection
-Basic Principles and equations
-Pump System
-Pump Curve
-Worked Example
-Very useful Excel sheets for pumps calculation
You can find also more at:
http://hassanelbanhawi.com/rotatingequipment/pumps/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Fired Heaters-Key to Efficient Operation of Refineries and PetrochemicalsAshutosh Garg
Fired Heaters are a critical to successful operation of refineries and petrochemical plants. They are a major energy consumer as well as a major source of air pollution. There are also concerns about the run length of the heaters as well safety issues.
Brief introduction to Fired Heaters operation and design. Definition of the different Heaters in the industry and brief strategy how to operate them safely.
This presentation is a brief descriptive procedure of simulating in aspen flare system analyser (otherwise called as flarenet). It gives a step by step instructions to develop a flare network scheme in the simulator
The discussion on "Handling of Turbines During Emergencies" has been detailed in the ppt. Some case studies are also discussed in the session where the course participants express their difficulties while coming across the emergencies in handling the turbines at their locations.
Fired heaters are used for heating hydrocarbons fluids in the refineries and petrochemical plants. They are used for high temperature heat transfer. In most fired heaters, we are burning fuel gas as source of heat . There are many heaters in the world where liquid fuel is also burnt in the fired heaters to provide the energy, but their number is decreasing due to tighter pollution laws. Heaters that are processing hydrocarbons services are prone to coking and cracking depending upon the nature of the hydrocarbons being processed. Typically heaters may run length of anywhere from 3 months for coking service to 6 years for different services. Heater designers and operators are always faced with the challenge of providing uniform heat transfer to all the tubes. Engineers use equations that assume uniform heat transfer to heater tubes When designing fired heaters. However, in reality, most fired heaters do not experience uniform heat transfer, and as a result, hot spots develop on the tubes. These hot spots cause coking inside the tubes which requires the heater be shutdown periodically to remove the coke and clean the tubes. Any shutdown to clean the tubes in a fired heater causes a substantial production loss. The owners want to extend the run length of fired heaters. Furnace Improvements has developed a new patented firing technology that provides uniform heat transfer to heater tubes. This technology can be applied to most fired heaters. Our patented technology reorients the burners at a slight angle away from the tubes. We are able to direct the hottest part of the flames and flue gases away from the tubes without affecting the heat transfer in any way. FIS has installed this in 5 heaters ranging from 14 MMBtu/hr. to 280 MMBtu/hr. The clients are experiencing significant reduction in tube metal temperatures. This is translating into lower coking rates and higher tube life. We have been able to increase the capacity of the heaters in most of the cases. In one of the case study that has been presented in this heater, the heater duty was increased from 14 MMBtu/hr. to 21 MMBtu/hr. Inclined firing improves the heat transfer to the tubes and makes in uniform.
This material provides the basic of design, operation and maintenance so that you can use this as guide line to operation, to inspect your boiler. Hope this will be benefit you.
Distillation Towers (Columns) presentation on Types, governing Equations and ...Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Columns. This is an introduction to understand more about their:-
-Types
-Basic Principles and equations
-Distillation System
-P&ID Symbols
-Worked Example
You can find also more at:
http://hassanelbanhawi.com/staticequipment/columns/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Smart Stack Damper is one of the patented technologies of Furnace Improvements. It offers an innovative way to control drat in fired heaters. Smart Stack Damper consists of multiple pneumatic operators for controlling the damper. It is possible to save substantial amount of energy by proper training and installing smart stack dampers in your fired heaters.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
Minimising emissions, maximising alternative fuelsA TEC Group
Dr. Stefan Kern, A TEC Production and Services GmbH, details the conversion of the kiln at Lafarge Retznei and shows how an optimised calciner design allowed for 100% alternative fuel usage.
"Minimising emissions, maximising alternative fuels". Article published on World Cement Magazine, edition June 2022.
Summary of changes in burner specificationsKapil Batra
Our team at Furnace Improvement Services, New Delhi has compiled an interesting comparison of the changes in Burner Specifications in API-560 Fired Heaters for General Refinery Service over the years. Burner design has evolved a lot due to increasing restriction on NOx emissions. Because of the changes in burner design a lot of additions, modification and deletions have been made in the API 560 standard. We have covered from the 1st API edition made in 1986 to the latest 5th edition published in 2016. We intend to publish more such comparisons from API 560 standard. Please feel free to provide your feedback and comments.
Cokemaking in an Integrated Steel Works - Technology, Location and Greenhouse...Smithers Apex
- Impact of cokemaking technology on costs and greenhouse gas emissions for different steel works configurations
- Regional implications that drive cokemaking technology selection
- Identifying implementation niches for the available cokemaking technologies
Author:
Ian Cameron, Senior Director - Iron & Steel, HATCH, Canada
Calciner modification including a new hot gas chamber by Buzzi Cement HraniceA TEC Group
In June 2013, Buzzi Cement Hranice a.s., Czech Republic,
awarded a contract to A TEC for an upgrade of the preheater
and calciner of the clinker production line. The contract
covered engineering, supply of equipment, steel structure,
erection and civil works.
[First published on Cement International in January 2015]
Effect of Combustion Air Pre-Heating In Carbon Monoxide Emission in Diesel Fi...IJERA Editor
This paper describes the effect of combustion air pre- heating in Diesel fired heat Treatment Furnace. The main
heat treatment processes are Normalizing, Tempering, Hardening, Annealing, Solution Annealing and Stress
Relieving. The emission of carbon monoxide is measured with combustion air pre-heating and without preheating.
The results are then compared and it is found that the emission of CO is reduced by 29.12%. With the
Combustion air pre-heating a considerable reduction in Specific Furnace Fuel Consumption (SFFC) is obtained.
The test was caaried out at Peekay Steels Casting (P) ltd, Nallalam, Calicut.
General Terms: Heat Treatment Furnace
This is a presentation on the design of plant for producing 20 million standard cubic feet per day (0.555 × 106 standard m3/day) of hydrogen (H2) of at least 95% purity from heavy fuel oil (HFO) with an upstream time of 7680 hours/year applying the process of partial oxidation of the heavy oil feedstock.
Fluidized bed combustor design and features, Fluidized-bed combustion is a process in which solid particles are made to exhibit fluid-like properties by suspending these particles in an upwardly flowing evenly distributed fluid (air or gas) stream.
Combustion takes place in the bed with high heat transfer to the furnace and low combustion temperatures.
Fluidized-bed combustion is a process in which solid particles are made to exhibit fluid-like properties by suspending these particles in an upwardly flowing evenly distributed fluid (air or gas) stream.
Combustion takes place in the bed with high heat transfer to the furnace and low combustion temperatures.
Kubernetes & AI - Beauty and the Beast !?! @KCD Istanbul 2024Tobias Schneck
As AI technology is pushing into IT I was wondering myself, as an “infrastructure container kubernetes guy”, how get this fancy AI technology get managed from an infrastructure operational view? Is it possible to apply our lovely cloud native principals as well? What benefit’s both technologies could bring to each other?
Let me take this questions and provide you a short journey through existing deployment models and use cases for AI software. On practical examples, we discuss what cloud/on-premise strategy we may need for applying it to our own infrastructure to get it to work from an enterprise perspective. I want to give an overview about infrastructure requirements and technologies, what could be beneficial or limiting your AI use cases in an enterprise environment. An interactive Demo will give you some insides, what approaches I got already working for real.
JMeter webinar - integration with InfluxDB and GrafanaRTTS
Watch this recorded webinar about real-time monitoring of application performance. See how to integrate Apache JMeter, the open-source leader in performance testing, with InfluxDB, the open-source time-series database, and Grafana, the open-source analytics and visualization application.
In this webinar, we will review the benefits of leveraging InfluxDB and Grafana when executing load tests and demonstrate how these tools are used to visualize performance metrics.
Length: 30 minutes
Session Overview
-------------------------------------------
During this webinar, we will cover the following topics while demonstrating the integrations of JMeter, InfluxDB and Grafana:
- What out-of-the-box solutions are available for real-time monitoring JMeter tests?
- What are the benefits of integrating InfluxDB and Grafana into the load testing stack?
- Which features are provided by Grafana?
- Demonstration of InfluxDB and Grafana using a practice web application
To view the webinar recording, go to:
https://www.rttsweb.com/jmeter-integration-webinar
Transcript: Selling digital books in 2024: Insights from industry leaders - T...BookNet Canada
The publishing industry has been selling digital audiobooks and ebooks for over a decade and has found its groove. What’s changed? What has stayed the same? Where do we go from here? Join a group of leading sales peers from across the industry for a conversation about the lessons learned since the popularization of digital books, best practices, digital book supply chain management, and more.
Link to video recording: https://bnctechforum.ca/sessions/selling-digital-books-in-2024-insights-from-industry-leaders/
Presented by BookNet Canada on May 28, 2024, with support from the Department of Canadian Heritage.
State of ICS and IoT Cyber Threat Landscape Report 2024 previewPrayukth K V
The IoT and OT threat landscape report has been prepared by the Threat Research Team at Sectrio using data from Sectrio, cyber threat intelligence farming facilities spread across over 85 cities around the world. In addition, Sectrio also runs AI-based advanced threat and payload engagement facilities that serve as sinks to attract and engage sophisticated threat actors, and newer malware including new variants and latent threats that are at an earlier stage of development.
The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties – USA
Expansion of bot farms – how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
Why are attacks on smart factories rising?
Cyber risk predictions
Axis of attacks – Europe
Systemic attacks in the Middle East
Download the full report from here:
https://sectrio.com/resources/ot-threat-landscape-reports/sectrio-releases-ot-ics-and-iot-security-threat-landscape-report-2024/
UiPath Test Automation using UiPath Test Suite series, part 3DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 3. In this session, we will cover desktop automation along with UI automation.
Topics covered:
UI automation Introduction,
UI automation Sample
Desktop automation flow
Pradeep Chinnala, Senior Consultant Automation Developer @WonderBotz and UiPath MVP
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
GraphRAG is All You need? LLM & Knowledge GraphGuy Korland
Guy Korland, CEO and Co-founder of FalkorDB, will review two articles on the integration of language models with knowledge graphs.
1. Unifying Large Language Models and Knowledge Graphs: A Roadmap.
https://arxiv.org/abs/2306.08302
2. Microsoft Research's GraphRAG paper and a review paper on various uses of knowledge graphs:
https://www.microsoft.com/en-us/research/blog/graphrag-unlocking-llm-discovery-on-narrative-private-data/
Epistemic Interaction - tuning interfaces to provide information for AI supportAlan Dix
Paper presented at SYNERGY workshop at AVI 2024, Genoa, Italy. 3rd June 2024
https://alandix.com/academic/papers/synergy2024-epistemic/
As machine learning integrates deeper into human-computer interactions, the concept of epistemic interaction emerges, aiming to refine these interactions to enhance system adaptability. This approach encourages minor, intentional adjustments in user behaviour to enrich the data available for system learning. This paper introduces epistemic interaction within the context of human-system communication, illustrating how deliberate interaction design can improve system understanding and adaptation. Through concrete examples, we demonstrate the potential of epistemic interaction to significantly advance human-computer interaction by leveraging intuitive human communication strategies to inform system design and functionality, offering a novel pathway for enriching user-system engagements.
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 4. In this session, we will cover Test Manager overview along with SAP heatmap.
The UiPath Test Manager overview with SAP heatmap webinar offers a concise yet comprehensive exploration of the role of a Test Manager within SAP environments, coupled with the utilization of heatmaps for effective testing strategies.
Participants will gain insights into the responsibilities, challenges, and best practices associated with test management in SAP projects. Additionally, the webinar delves into the significance of heatmaps as a visual aid for identifying testing priorities, areas of risk, and resource allocation within SAP landscapes. Through this session, attendees can expect to enhance their understanding of test management principles while learning practical approaches to optimize testing processes in SAP environments using heatmap visualization techniques
What will you get from this session?
1. Insights into SAP testing best practices
2. Heatmap utilization for testing
3. Optimization of testing processes
4. Demo
Topics covered:
Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
Encryption in Microsoft 365 - ExpertsLive Netherlands 2024Albert Hoitingh
In this session I delve into the encryption technology used in Microsoft 365 and Microsoft Purview. Including the concepts of Customer Key and Double Key Encryption.
2. CO Boilers
Furnace Improvement Services (FIS) is a full service engineering and consulting
company, having completed over 300 engineering studies and projects. FIS currently has a
team of 40 skilled engineers on board with offices in Sugar Land, TX and in New Delhi, India.
We have experience in design and revamp of all types of CO boilers
CO Boilers
Most of the fluid catalytic cracking (FCC) units produce gases rich in carbon monoxide (CO).
This gas is burnt in a CO boiler to recover heat and produce steam.
The supply of CO gas is normally not sufficient to ensure destruction of CO. Supplementary
fuel raises the temperature of the CO gases to the ignition point and assures the complete burn-
ing of the combustibles in the CO gas stream . There are two types of CO boilers prevalent in
the industry. One design has a separate combustion chamber for CO burning and is followed by
a convection section for heat recovery. The other type is a water wall type boiler which is modi-
fied to burn CO gas.
Our Expertise
Furnace Improvements has worked on several CO Boilers in the past 15 years.
Scope of Services include:
♦ Increasing Capacity
♦ Improving Boiler efficiency
♦ Eliminate flow distribution problems
♦ Tube Failure analysis
♦ CFD Modeling
♦ NOx Reduction
Revamping - Training - Troubleshooting
www.heatflux.com
3. CO Boilers
Case Study - CO Boiler Revamp
An Illinois refinery had a carbon monoxide (CO) boiler in their Fluid Catalytic Cracking (FCC)
Unit. The CO boiler was more than 40 years old. The CO boiler’s convection section is used to
preheat the FCC charge and also generate superheated steam at 600 psig/710°F.
The boiler had three main problems:
♦ low economizer tube metal temperatures were reaching dew point levels
♦ high super heated steam temperature
♦ problems with tube supports in the hottest zones
The refinery approached FIS to provide thermal design for replacing the convection section of
the CO boiler. Furnace Improvements carried out the engineering study for replacing the con-
vection section. We conducted a detailed operation analysis of the existing CO boiler and built
a model of the existing design. With the model built, we were able to simulate the current oper-
ating conditions and predict the heater performance for the future operating conditions.
The convection section was redesigned to: Item Units Before Revamp After Revamp
Heat Duty
♦ Increase FCC feed flow rate MMBtu/hr 182.45 220.83
Total
Process Heat
MMBtu/hr 81.55 104.91
♦ Improve CO Boiler efficiency Duty
Process Flow BPD 41,995 48,000
♦ Prevent cold end corrosion of economizer
Process ∆T °F 674 - 459 694 – 459
♦ Eliminate flow distribution problems Steam Heat
MMBtu/hr 100.90 115.92
Duty
Steam Flow lb/hr 155,170 190,000
The new design was developed retaining the ex- Steam Outlet
°F 765 714
Temp.
isting soot blower locations, same platform eleva-
Economizer
tions, and without any additional firing require- TMT
°F 301 318
ment. The detailed engineering drawings of the Stack Temp. °F 636 577
convection section vendor were also reviewed. Efficiency % 68.0 72.6
0.55 Million*
Fuel Savings $ / annum
* Based on $3.0 / MM Btu
Savings
The proposed revamp took care of all the operating issues with the existing CO boiler. It was
estimated to save the client almost $550,000 per year. The boiler was commissioned in March
2003.
Revamping - Training - Troubleshooting
www.heatflux.com
4. CO Boilers
Case Study - NOx Reduction
A Texas refinery’s CO boiler was originally designed to generate 450,000 lb/hr steam @ 600
psig / 750°F by firing a combination of CO gas and refinery fuel gas.
Furnace Improvements (FIS) was approached to convert the CO boiler to a refinery fuel gas
fired boiler only and reduce the NOx emissions to 0.02 lb/MMBtu (15 ppm).
Case Study Results
FIS conducted a study and provided the client with various options for NOx reduction. Conoco-
Phillips selected the option of Ultra Low NOx Burners with flue gas recirculation for detail en-
gineering. FIS’ scope of services was comprised of the following:
♦ Ultra Low NOx Burners with steam injection
♦ Flue gas Recirculation
♦ New economizer to increase the efficiency by 3%
♦ Design of additional rows of super heater coil
♦ Remove CO burners from firebox and seal the CO ports with additional heat transfer
surface
♦ Computational fluid dynamics (CFD) modeling of the existing and new burners to pre-
dict the combustion scenario
The project was completed and commissioned successfully in December 2007 by FIS
Revamping - Training - Troubleshooting
www.heatflux.com
5. CO Boilers
Case Study - CO Slippage
ConocoPhillips Wood River Refinery has a CO heater (CCU-1) in their FCC unit. It is used to
combust the FCC off gas (mainly CO gas) from the spent catalyst regenerator unit. The hot flue
gases generated from combustion of FCC off gas are used to preheat the oil and generate super
heated steam @ 600 psig / 700ºF.
ConocoPhillips was installing a new SCR unit downstream of the CO
Heater as a part of the consent decree agreement to reduce the NOx
emissions. The new SCR requires a flue gas inlet temperature in the
range of 680-700 °F, which required reconfiguring the heat transfer
surface in the convection section. FIS modeled the convection section
for 5 proposed cases and provided a revised design.
FIS developed a CFD model of the existing combustion chamber and
found out that mixing of FCC off gas and air was very poor in the
combustion chamber leading to incomplete combustion in the firebox
and post combustion in the convection section. FIS also found out
that the burners were oversized and they were operating at a very low
fuel gas pressure.
CFD Models
FIG. 1 FIG. 2
Contour of CO Mass Fraction Contour of Temperature Distribution
FIS proposed modifications to the combustion chamber and verified the modifications with the
CFD. As shown in figure 2, CO is burned completely compared to the existing case. The flue
gas temperature pattern inside the combustion chamber is uniform compared to the existing
case.
Revamping - Training - Troubleshooting
www.heatflux.com
6. CO Boilers
Case Study Cont.
The CFD model predicted the following:
♦ Mixing of the FCC off gas and air in the combustion chamber is very poor. The CO enter-
ing the chamber sweeps along the floor and exit, which results in incomplete combustion
of CO. The flue gas temperature distribution is not uniform.
♦ FIS observed misdistribution of FCC off gas to the nine burners.
FIS proposed modifications to the CO plenum, the misdistribution is calculated via CFD model.
As shown in figure 3, the proposed modification ensured uniform distribution of FCC off gas to
all the burners. This coupled with the modifications made to the combustion chamber ensured
complete combustion of CO gas and reduced the CO emissions.
FIG.3
After FIS developed a CFD model of the proposed design and the model suggested a marked
improvement in the combustion of CO. Some of the modifications FIS suggested are as fol-
lows:
♦ Install correct size burners
♦ Install a baffle wall in the combustion chamber
♦ Inject FCC off gas in the flame zone.
♦ Increase the air velocity through over fire air port
All modifications to CO Heater (CCU-1) have been completed and it has been in
operation since February 2008.
Revamping - Training - Troubleshooting
www.heatflux.com
7. CO Boilers
Project Reference List
Mobil - (FIS 152) ConocoPhillips - (FIS 188)
Location: Beaumont, TX Location: Roxana, IL
Scope of Work: Rating of a CO Boiler Scope of Work: Performance improvement
study on CO Heater Convection Section
Citgo - (FIS 207) Citgo - (FIS 214)
Location: Corpus Christi, TX Location: Corpus Christi, TX
Scope Of Work: Performance Improvement Scope Of Work: CO Boiler Burner Inspection
Study for CO Boiler
ConocoPhillips - (FIS 243) ConocoPhillips - (FIS 263)
Location: Corpus Christi, TX Location: Borger,TX
Scope Of Work: CFD Modeling of BFW Dis- Scope Of Work: Design, Engineering and
tribution in CO Boiler Economizer Coils supply and erection services for conversion of
Unit No. 40 CO Boiler to Fuel Gas Fired
Boiler.
Citgo - (FIS 267) ConocoPhillips - (FIS 276)
Location: Corpus Christi, TX Location: Roxana, IL
Scope Of Work: CO Boiler Re-rating report Scope Of Work: CO Boiler Engineering
as a Flue gas cooler Study, Tuning and CFD modeling
ConocoPhillips - (FIS 299) Citgo - (FIS 349)
Location: Roxana, IL Location: Lemont, IL
Scope Of Work: CCU -2 CO Boiler H -2 Scope Of Work: Engineering Study for in-
Modification Re-rating study creasing steam production in CO Boiler
Revamping - Training - Troubleshooting
www.heatflux.com
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Email: info@heatflux.com
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