Furnace Improvements Sales Presentation

Furnace Improvements

Mission: Low cost value added solutions for fired heaters

1600 Hyw 6, Sugar Land TX, 77478Phone: (281) 980-0325

www.heatflux.com

Our Company

• 15+ years • 200+ Completed projects• 40+ Professionals• Combined 300+ years of experience• Offices:

– Sugar Land, TX – New Delhi, India

Challenge us with your project!

Type of Heaters

• Crude heaters• Vacuum heaters• Hydrotreater heaters• Reformer charge

heaters• CO boilers• Coker heaters• Waste heat boilers

Type of Services

Revamping• Capacity increase• Efficiency improvement • NOx reduction

New Heaters• Design & Supply

Trainings • Customize Fired Heater

Trainings

Scope of Services

• Process design– CFD Modeling

• Detailed engineering• Project services• Hardware supply• Fabrication• Erection• Start up assistance

Some of Our Clients

Furnace ImprovementsFurnace Improvements

• Split Flow Technology • Flue Gas Injection • Inclined Firing System

Patented TechnologiesPatented Technologies

Split Flow Technology

• New approach to revamping heaters– Increased capacity– Higher efficiency

• Converting waste heat into process heat

• Lower pressure drop• Lower installation cost

Typical Fired HeaterFluid--- Convection section Radiant section

Conventional revamp Add 2 more passes

Feed In Feed Out

450 °F 600 °F

Radiant SectionConvection Section

1,650 °FFlue gas

500 °FFlue gas

3,200 °FFlue gas

1,650 °FFlue gas

500 °F

Split Flow Fired Heater

Feed In Feed Out

450 °F 600 °FRadiant Section

ConvectionSection - I

1,650 °FFlue gas 3,200 °FFlue gas

1,650 °FFlue gas

500 °F

ConvectionSection- II

900 °FFlue gas

Flue gas

Flue gas

Split Flow in Split Flow out450 °F 600 °F

500 °F

900 °F

FIS-183

www.heatflux.com

Inclined FiringSystem

FIS-Split Flow

Capacity Increased

FIS ClientCapacity (MMBtu/hr) % FIS Client

Capacity (MMBtu/hr) %

Before After Before After

183 Citgo 181 194 10%296 Alon USA 12.4 15 20%

187 Citgo13.7 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 HPCL163 187

15%53 61

255 Valero 54 57 5% 335 Conoco74 83

10%73 81

260 Alon USA 30 37 20% 339 HPCL 135 169 25%

283 Country Mark 8.1 8.35 3%

Efficiency Improvement

FIS ClientEfficiency

% FIS ClientEfficiency

%


183 Citgo 67 86 19% 280 Valero 79 90 11%

187 Citgo74 82 8%

283Country-

Mark65 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%

NOx Reduction

FIS Client TechnologyNOx

Emissions (lb/MMBtu)

FIS Client Technology

NOx Emissions(lb/MMBtu)

208Husky

OilLNB 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 329Alon USA

ULNB <0.03

263 ConocoULNB +

FGR + SI<0.02 335 Conoco ULNB <0.03

266 Conoco ULNB <0.04

New Fired Heaters

FIS Client Service Duty

247 CITGOCombine

Feed Heater47 MMBtu/hr

269 ConocoVacuum Heater

42 MMBtu/hr

279 DevonHot Oil Heater

25 MMBtu/hr

286 Conoco BEU Heater 165 MMBtu/hr

Other Services


CFD Modeling for Heaters & Boilers

Vertical Cylindrical Heater Riley Stoker CO Boiler

Fired Heaters and Boiler Tuning

– Visual Inspection– Work with operators and

refinery personnel– Do require adjustments

to improve performance

• Tuning, Troubleshooting and Optimization– Measure and recollection of important

parameters (Fuel gas flow, draft, etc.)

FIS Training Programs

FIS offers training of :– Refinery Fired Heaters– Fired Heater Operating School– Fired Heater Engineering School– NOx Reduction– Customize trainings… and many

others.

“Get your technical personnel trained and start getting the benefit of having excellent heater performance”

FISTraining Clients

Draft Control System

• Improved Heater Efficiency

• Decreased NOx Emissions

• Optimized Combustion• Reduced Fuel

Consumption• Payback less than a

year

Heater

Process FluidInlet

BurnersFuel gas

PIC

Process FluidOutlet

PT

PT

I/P

ZSL

ExistingDCS / PLC

ControlO2

CO

PPT

FI

Heater Performance Index Software

• Analyzes the performance of Fired Heater 24/7

• Built into DCS

• Generates guidelines

• Built in intelligence

• Customized modeling

– Thermal Efficiency

– Fuel gas rate,

– Draft,

– Excess O2,

– Tube skin temperatures,

– Feed flow rate,

– Pressure drop,

– Coking rate,

– Air preheater performance

DescriptionFlow

(BPM)

Inlet Pressure

(PSIG)Crossover Temp (°F)

Outlet Temp (°F) TMT (°F)

Pass #1 709.5 278.92 585.1 686.78 960.7 / 969.4Pass #2 676.52 295.97 589.75 678.62 965.1 / 994.5Pass #3 670.8 275.85 592.02 680.15 895.8 / 927.1Pass #4 729.08 285.95 597.14 678.49 907 / 1034.4Pass #5 729.1 281.66 594.54 683.37 930.6 / 1041.67Pass #6 695.13 283.84 590.9 670.14 887.6 / 845.62Pass #7 737.39 298.2 594.39 682.95 959.9 / 863.41Pass #8 653.35 275.73 583.27 679.04 964 / 1048.68

Individual pass flow above minimum acceptable

Radiant coil metal temperature is OKBurners are OKOxygen in firebox OKDraft in the firebox is OKNumber of burners in operation is OK

No. of burners in operation 24Heater Performance Index 0.56Thermal Efficiency 90.25Fuel Saving Potential 3.08

Heat pickup in convection section is high – Afterburning Suspected

Air Flow reported appears erroneous. Check the meter calibration.

Heater Performance IndexHeater Performance Index

Performance Monitors

Thank you very much

Give us a chance to improve the performance of your fired heaters

Furnace Improvements ServicesLow Cost Solutions for Fired Heaters and Boilers

1600 Hyw 6, Sugar Land, TX(281)980-0325

www.heatflux.com

AUSTRALIA, INDONESIA,

MALAYSIA, NEW

ZEALAND & SINGAPORE

Kate GimblettTel: +61 (0) 7 5435 2205

Mobile: +61(0)417 087 129

www.energysystem.com.a

u

INDIA Ajai Agarwal Tel: +9111-4214-3751

Mobile:+9198-1015-9901

[email protected]

TAIWAN

Douglas Chang Tel: +8862-2706-1544

Mobile: +8869-2106-9827

[email protected]

LOUISIANA, USA

Charles H. Thatcher Tel: 985-892-4224

Mobile: 985-966-5513

[email protected]

BRAZIL

Jose Fleischmann Tel: (+55) 11-5641-4361

Fax: (+55) 11-5641-4361

[email protected]

KUWAIT

Alex Ambi Tel: +965-2482-9160 ext.126

Mobile: +965-3384-1712

[email protected]

U.A.E., OMAN, QATAR

Sarwar Ali Tel: +971-6742-5035

Mobile: +9715-0631-7452

[email protected]

SOUTHEAST, USA

David Gangle Tel: +20-5437-1702

Mobile:+20-5542-7006

[email protected]

CANADA

Paul Henry Tel: +450-676-3222

Fax: +450-676-5997

[email protected]

MEXICO

Lorena Nieto G.Cel: (04455)43493284

[email protected]

VENEZUELA,

COLUMBIA,

ARUBA & ARGENTINA

Carlos Alarcon Tel: +58-441-6609-3444

Fax: +58-441-4366-8406

[email protected]

TEXAS, USA

Stan McHugh Tel: +713-839-8788

Mobile:+713-703-8907

[email protected]

INDIA

R. RajamaniTel: + 91 94483 79108

Tel: +91 80 65971113

[email protected]

SAUDI ARABIA

Azfar Mahmood Tel: +966-3899-6333

Mobile: +9665-3451-2635

[email protected]

CALIFORNIA, USA

David P. Diggins Tel: +94-9497-6551

Mobile:+94-9463-8591

[email protected]

UTAH, WYOMING, IDAHO,

MONTANA & NEVADA

Allan Woodbury Tel: +801-274-3333

Mobile: +801 918-4826

[email protected]

We have an Agent near You

Projects


CITGO - Corpus ChristiNo. 4 Platformer Heater Revamp

• Objective:• Improve Efficiency

– Stack temperature was 1100° F

• Reduce NOx • Our cost was 1/2 of

the conventional revamp cost

Disadvantages:•High Pressure Drop•Large process piping•New Stack• $ 6 MM

StackStackStack

#1 In

#1 Out

In

#2 In

#2 Out

#3 InOut

In Out

#4 Out

#4 In

#3 Out

Conventional Series Flow Design

FIS Split Flow Scheme

StackStackStack

Burners

#1 In

#1 Out

In

#2 In

#2 Out

#3 In

#3 Out

#4 In

#4 Out

In

Out

Out

Advantages:•Lower Pressure Drop•Small process piping•Reuse of Stack•$ 3 MM

#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

#4 Platformer Heater Before and After Revamp

Before AfterCapacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater

CITGO Corpus ChristyReboiler Trim Heaters

Trim Heaters Parameters (Stripper / Stabilizer)

Parameter UnitsBefore

RevampAfter

RevampParameter Units

BeforeRevamp

AfterRevamp

Heat DutyMMBtu/

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

StackTemp.

°F 813 572StackTemp.

°F 832 575

Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater

ConocoPhillips WRRFCC- CO Boiler

• Re-design of CO FCC Convection section for:– Increase Feed Flow– Improve Efficiency– Prevent Could end

Corrosion of economizer

– Eliminate Flow Distribution Problems

CO Boiler Convection Section Replacement

Item UnitsBefore

RevampAfter

RevampProcess 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]


Premcor Lima RefineryCrude Heater NOx Reduction

• Balanced draft

• 420 MMBtu/hr duty

• 84 burners

• Problems in convection section and radiant section

Premcor Lima RefineryCrude Heater – After RevampNOx Reduction < 0.05

lb/MMBtu

Increased to 460 MMBtu/hr duty

Low Coking Rate

Low APH Temperature

Design, Engineering, Erection/Start up and Supervision


ConocoPhillips- Ponca CityCrude Heater NOx Reduction

• Multi-cell heater– 160.6 MMBtu/hr– 87% Efficiency– 62 Burners

• Installation of 66 ULNB’s

• NOx Emissions <0.03 Lb/MMBtu


Valero Texas City Refinery#2 Platformer

• Common Convection section with H-18/H-19 and H-23

• Process heating-all Radiant

• Steam Generation in Convection

• Common Stack• Natural Draft

37

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

38

Convection Section

• Steam Generator Bank• Steam Superheater

Bank• BFW Preheater Bank• Steam Generation:

73,669 lbs/hr@464 psig

• 14 tubes per row• Eighteen rows• Two future rows

39

NHT Heaters

H-18- Hydrotreater Charge Heater

• Duty-11.97 MMBtu/hrH-19 Hydrotreater

Stripper Reboiler• Duty-18.45 MMBtu/hrH-23 Depropanizer

Reboiler• Duty- 15.15 MMBtu/hr

• All Radiant• Efficiency -52-55%

40

Performance Problems

Convection section was in bad stateFins are burnt out / fouledSteam superheater temperature 40 °F

lower Thermal Efficiency is 78% vs. 88% design. Stack temperature higher by almost 375

°F.Stack temperature ~ 775 °F

41

Split Flow Scheme

H-20/H-21/H-22Limit radiant heat flux to 15,000 Btu/hr ft²Shift the balance duty to convection section

H-18/H-19/H-23Limit heat flux to 8,000-9,000 Btu/hr ft²Limit the firing to design rateLimit the volumetric heat release to 10000

Btu/ft2

Shift the balance duty to convection section42

Valero Proposed Revamp – Split Flow Scheme

43

Split flow Convection SectionHeat Recovery

SequenceH-20; H-21; H-18 /

H-19 / H-23SSH; SG; BFW

Total rows – 20Conv. section

dimension unchanged

Retubed the conv. section

44

Platform and NHT Heaters

After FIS Revamp

• Increased Capacity of platformer heater and NHT heaters from 12 to 18 MBPD

• Split flow increased heat duty by ≈ 25% in Platform and Naphtha Hydrotreater Heaters.

• Improved efficiency from 80 % to 89%


CITGOCorpus Christi - TX

• 4 MMBtu/hr Combined Feed Heater

• Natural Draft

• Design, Engineering & Supply

• Commissioned 2005Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater

Valero Wilmington Refinery Platformer Heater

• Capacity Improved from 12 MBPD to 18 MBPD

• Used Split Flow Technology

• Improved efficiency by 10%

• Completed in January 2008


ConocoPhillips Alliance RefineryNOx Reduction–Crude Heater

• Biggest heater ~ 750 MMBtu/hr

• SCR unit• FIS Novel Concept saved

$ 5 Million• New WHR section • Modify ID & FD fans• Efficiency Improved by 3.5%• Fuel Saving of $1.5 MM /

year

ConocoPhillips Alliance RefinerySCR Scheme

Overall hardware savings: USD 5 Million

No ID Fan Require Smaller Flue Gas Duct No Stack Modifications Require


Premcor Port Arthur RefineryReactor Charge Heater

• Rerate heater to minimize pressure drop

• 8 pass heater was converted to 4 pass

• Tube size increased from 4” to 8”

• Burners were relocated

• New tight shut off stack damper was installed


AlonUSA Big Spring RefineryReactor Feed Heater (080-H-001)

• Vertical Cylindrical Heater • Increase heat duty by 20%• Split Flow Scheme

– Originally single pass heater

– Revamped to 2 pass heater- one in conv, one in radiant

• New Convection Section• Increased efficiency by 8%• 10 ft additional stack


ConocoPhillips Borger RefineryNOx Reduction – CO Boiler

• Conversion from CO Boiler to NG Boiler

• NOx (<0.02 lb/MMBtu)• 450K lbs/hr Boiler• Installation of Ultra Low

NOx Burners• Flue gas recirculation with

steam injection• New economizer section

(4% efficiency improvement)


ConocoPhillips WRREfficiency Improvement- Alky Heater

• 65 MMBtu/hr Heater• New Ultra Low NOx

Burners• Efficiency Improved by 20%• New convection section,

new stack and damper• Stack temperature reduced

by 300 °F• Excess air reduced by 50%• Fuel savings of $800,000

per year


ConocoPhillipsWood River Refinery• New Wider Heater on existing

foundation• 42.82 MMBtu/hr Vacuum heater• Complete Modularization• Turn key supply • Erection completed in 10 days• Commissioned in 2009

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!!!”


Devon EnergyRiverton - WY• 25 MMBTU/hr Hot Oil

Heater

• Design, engineering, supply, erection and commissioning

• Piping, Instrumentation & Foundation

• Commissioned 2007


Valero Texas CityEfficiency Imp.- CDHDS Reboiler• 82 MMBtu/hr, VC, Natural

Draft Heater– Addition of 6 rows for SG in

Conv. Sec.– Larger stack

• 12% Increase Duty• Efficiency Improved to 90%• Fuel savings of $590,550 /

year• Payback less than 1 ½ years


CountryMark CO-OPVacuum Heater• 8.35 MMBtu/hr Cabin

Heater• Revamp:

– Radiant Section Coils– New Burners– New Stack

• Capacity Increased to 8,200 to 9,500 BPD

• Improved Efficiency by 10%


ConocoPhillipsWood River Refinery• 165 MMBtu/hr hot oil

heater

• Modular Construction

• Design, engineering and supply

• 9 months delivery

• Commissioned 2009


ConocoPhillips WRRCCU-1 CO Boilers

• Modeling CO Boilers for correct temperature window for SCR Installation

• Making changes in the coils to ensure correct temperature

• Eliminate CO Slippage – CFD Modeling

• Structural analysis of boiler for higher pressure

• One boiler running for 6 months after modifications

AUXILARY FUEL GAS


Lion Oil El Dorado RefineryNOx Reduction Project

• NOx Reduction– NOx emissions <

0.025lb/MMBtu– Using Ultra Low NOx

burners

• Vacuum Heater (H-1)• Cat Craker Heater (H-

3)• Charge Heater (H-2)

Lion Oil El Dorado Refinery NOx Reduction Project

• Preflash Boiler (H-4)• Stripper Reboiler (H-5)• Reformer Heater (H-6)


AlonUSA Big Spring RefineryHydrogen Heater (77-H-001)• Revamp for Capacity

Increase• Convection Section in

bad Shape• Convectional Revamp

resulted in high pressure drop

• Split Flow technology– Increase duty from 11.6

– 14.77 MMBtu/hr– Improved Efficiency

from 78 – 86%Capacity Increased Efficiency Improvement Split Flow Low NOx Reduction New Heater

ConocoPhillips WRRCCU-2 CO Boilers• Modeling CO Boilers for

correct temperature window for SCR Installation

• Making changes in the coils to ensure correct temperature

• Structural analysis of boiler for higher pressure

• Successfully commissioned October 2009


AlonUSA Big Spring RefineryNaphtha Stabilizer Reboiler (77-H-002)

• Existing duty: 8.68 MMBtu/hr

• New duty: 10.8 MMBtu/hr

• Efficiency Improvement: 4.5%

• Fuel Savings/yr: $270,000

• New Convection Section, Stack & Radiant Coils

• Heater Delivery – 5 Months


CountryMark CO-OPNaphtha Splitter Reboiler

• Naphtha Service– Naphtha Splitter Reboiler

(8.38 MMbtu/hr)

– Platform Coils (3.36 MMBtu/hr)

• Increase capacity not feasible

• FIS Revamped an abandoned platform heater

• Capacity Increase from 8.36 to 20 MMBtu/hr


AlonUSA Big Spring RefineryDepentanizer Reboilers (H-102; H-205)• Natural Draft VC Heaters

• 46 & 34 MMBtu/hr

• Fouling Convection Section

• High NOx Emission

• Installation of ULNB’s with “Inclined Firing System”– NOx emissions <0.03

lb/MMbtu

• Increase Capacity by 10% with “Split Flow”

H-102 Convection Section

Existing Revamped

H-205 has a very similar convection section revamp.

Inclined Firing System

Revamp Results

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


HPCL, Vizag Refinery, IndiaCrude Heater

• Capacity Increase by 15%

• Heat duty Increase by 15%

• Efficiency Improve by 4%

• New Convection section

• New 20 Low NOx Burners

• Stack Temperature reduced by ≈ 200°F

HPCL, Vizag Refinery, IndiaVacuum Heater

• Capacity Increase by 15%

• Heat duty Increase by 15%

• Efficiency Improve by 6%

• New Convection section

• New 16 Low NOx Burners

• Stack Temperature reduced by ≈ 200°F


ConocoPhillips Wood River RefineryNOx Reduction of CR-3 Unit heaters

• Replacement of Burners with ULNB’s

• New Convection Section with patented Split Flow Technology

• Increase capacity from 32 MBPD to 40 MBPD

• Increase Efficiency by 10%• NOx emission ≤ 0.04

lb/MMBtu

ConocoPhillips WRRExisting Heaters

• VC Heaters• Build as ND in ’59

– Revamped for FD in ‘77• Radiant Section

– Process Feed• 12 Burners

– 10.95 MMBtu/hr/burner• Convection Section H-4 / H-5

– BFW, SSG / SG• Heat Duty H-4 / H-5 (Total/Process)

– 110 MMBtu/hr / 103 MMBtu/hr– 74 MMBtu/hr / 73 MMBtu/hr

H-4 & H-5 Heaters Problems

• Radiant Tubes were scaled

• Convection Section surface was less than 50% effective

• High Flue Gas Temperature leaving CS

• Low Efficiency– Design ≈ 92 (FD)– Operating ≈ 82 (FD)

Split Flow H-5 Heater

Convection Section Revamp with FIS Split Flow Technology (H-5)

Existing Revamped

Revamp Results

ParameterH4 H-5


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


HPCL, Mumbai Refinery, India Crude HeaterAdditional Convection Section

on top of ExistingIncreasing the number of

burners from 12 to 17Addition of FRE APS and FRE

VPS coilsReduction of flue gas temp.

to APH15% Additional Capacity for

Crude and Vacuum heaterIncreased Efficiency to 90%


Date post:	25-May-2015
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Furnace Improvements Sales Presentation

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