Furnaces and fired heaters

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This technical document were prepared by self during my tenure with Essar Oil Limited-Jamnagar, INDIA where I ahve preapred lots of this type of training manual and will provide you for your enhancement of technical knowledge!

A process heater is a direct-fired heat exchanger that uses the hot gases of combustion to raise the temperature of a feed owing through coils of tubes aligned throughout the heater. Depending on the use, these are also called furnaces or red heaters. Some heaters simply deliver the feed at a predetermined temperature to the next stage of the reaction process; others perform reactions on the feed while it travels through the tubes.

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Fired heaters are often suffering from high tube metal temperatures and short run lengths. Operators are always worried about hot spots in the furnace. While refineries want to push the heaters hard, the heater starts coking up and very soon, the heater tubes have to be cleaned. FIS has done extensive research and CFD modelling of heaters in the recent time and has concluded that localized burner flame and hot flue gas currents are responsible for the hot spots on the tubes. FIS has now developed a new patented technology for solving hot spot problems. This technology called Inclined Firing Technology involves orienting the burners at an angle on the floor / wall/ roof to direct the flame away from the tubes. The results of this technology have been extremely good and with a very low investment, the reliability and run length of the heater is improved significantly.

Uniform heat transfer in fired heaters

Ashutosh Garg

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.

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As part of the Human Connectome Project (HCP), which includes high-quality fMRI, anatomical MRI, DTi and genetic data from 1200 subjects, we have scanned and investigated a subset of 100 subjects (mostly comprised of pairs of twins) using MEG. The raw data acquired in the HCP has been analyzed using standard pipelines [ref1] and both raw and results at various levels of processing have been shared though the ConnectomeDB [ref2]. Throughout the process of the HCP we have not only analyzed (resting state) MEG data, but also have developed the data analysis protocols, the software and the strategies to achieve reproducible MEG connectivity results. The MEG data analysis software is based on FieldTrip, an open source toolbox [ref3], and is shared alongside the data to allow the analyses to be repeated on independent data. In this presentation I will outline what the HCP MEG team has learned along the way and I will provide recommendations on what to do and what to avoid in making MEG studies on (resting state) connectivity more reproducible. 1. Larson-Prior LJ, Oostenveld R, Della Penna S, Michalareas G, Prior F, Babajani-Feremi A, Schoffelen JM, Marzetti L, de Pasquale F, Di Pompeo F, Stout J, Woolrich M, Luo Q, Bucholz R, Fries P, Pizzella V, Romani GL, Corbetta M, Snyder AZ; WU-Minn HCP Consortium. Adding dynamics to the Human Connectome Project with MEG. Neuroimage, 2013. doi:10.1016/j.neuroimage.2013.05.056 2. Hodge MR, Horton W, Brown T, Herrick R, Olsen T, Hileman ME, McKay M, Archie KA, Cler E, Harms MP, Burgess GC, Glasser MF, Elam JS, Curtiss SW, Barch DM, Oostenveld R, Larson-Prior LJ, Ugurbil K, Van Essen DC, Marcus DS. ConnectomeDB-Sharing human brain connectivity data. Neuroimage, 2016. doi:10.1016/j.neuroimage.2015.04.046 3. Oostenveld R, Fries P, Maris E, Schoffelen JM. FieldTrip: Open Source Software for Advanced Analysis of MEG, EEG, and Invasive Electrophysiological Data. Comput Intell Neurosci. 2011. doi:10.1155/2011/156869

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