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Fired Heater Efficiency

Why is the efficiency of my


fired heater important?
Because inefficient heaters cost you money!

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Measuring Fired
Heater Efficiency
This guide will teach you the
process of measuring and
calculating your heaters
efficiency so you can
optimize your plant and
save money.
Based on method outlined in API 560
Annex G
Procedure intended for fired heaters
burning liquid or gaseous fuels. Not
recommended for solid fuels.
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What do we mean by efficiency?

Thermal VS Fuel Efficiency


THERMAL EFFICIENCY
- total heat absorbed divided by total heat input
NOTE: this definition differs from the traditional definition of fired heater efficiency, which generally refers to fuel efficiency

FUEL EFFICIENCY
- total heat absorbed divided by heat input derived
from the combustion of the fuel only
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Equipment Needed
Temperature-measuring devices, such as
thermocouples or thermometers, to
measure the temperature of:

Fuel
Ambient air
Atomizing medium (if applicable)
Flue gas
Thermal fluid

Flue-gas analytical devices to measure


oxygen and combustible gases
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Before the Test


Establish and maintain operating conditions
Perform any re-rating necessary to account for
differences between design and test conditions
Ensure fuel is acceptable for the test
Select and calibrate instrumentation
Ensure heater is operating properly with respect to
the size and shape of flame, excess air & draught
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Testing
Test procedure:
The heater shall be operated at a uniform rate throughout the test
Data shall be taken at the start of the test, and every 2 hours thereafter
The duration of the test shall extend until three consecutive sets of
collected data fall within the prescribed limits

Measurements:
Fuel gas quantity and heating value
Flue-gas temperature and composition analysis
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Example

Hot oil heater for gas plant


Fuel gas composition (vol%):
Nitrogen 1.61
Carbon dioxide 0.15
Methane 98.17
Ethane 0.008

Ambient air temperature: 70F


Relative humidity: 50%

Excess Oxygen: 3% (dry)


Radiation heat loss: 1.5%

Fuel gas LHV


20,814 Btu/lb
Fuel gas HHV
23,115 Btu/lb
Fuel gas temperature
100F
Fuel gas pressure
50 psig
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Thermal Efficiency
=

+ + + ( +
+ + +

Where:

lower heating value of the fuel (Btu/lb)

heat correction due to air (Btu/lb)

heat correction due to fuel (Btu/lb)

heat correction due to atomizing medium (Btu/lb)

assumed radiation heat loss (Btu/lb)

calculated stack heat loss (Btu/lb)


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Need to solve for all variables

Step 1:

solve for heat loss through the stack ( )

Combustion Worksheet
Fuel
Component

Column 1

Volume
fraction
%

Nitrogen

1.61

Carbon
dioxide

0.15

Methane

98.17

Ethane

0.08

TOTAL

Total per
pound of
fuel

Insert fuel composition into


combustion worksheet

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Combustion Worksheet
Fuel
Component

Column 1

Column 2

Volume
fraction
%

Relative
molecular
mass

Column 3
(1x2)

Total
mass
(lb)

Column 4

Net
heating
value

Column 5
(3x4)

Heating
value

(Btu/lb)

(Btu)

Nitrogen

1.61

28.0

0.4508

Carbon
dioxide

0.15

44.0

0.066

Methane

98.17

16.0

15.70

21,500

337,704.80

Ethane

0.08

30.1

0.02

20,420

491.71

TOTAL

16.25

338,196.51

Total per
pound of
fuel

20,814.55

Calculate total mass and


heating value of fuel

(5)

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Calculate products of
combustion for fuel

Combustion Worksheet
Fuel
Component

Column 1

Column 2

Volume
fraction
%

Relative
molecular
mass

Column 3
(1x2)

Total
mass
(lb)

Column 4

Net
heating
value

Column 5
(3x4)

Heating
value

(Btu/lb)

(Btu)

Column 6

Air
required

Column 7
(3x6)

(lb air/lb)

Air
required
(lbs)

Column 8

CO2
formed

Column 9
(3x8)

(lbs CO2/lb)

CO2
formed
(lbs)

Column 10

H2O
formed

Column 11
(3x10)

Column 12

N2
formed

Column 13
(3x12)

(lbs H2O/lb)

H2 O
formed
(lbs)

(lbs N2/lb)

N2
formed
(lbs)

Nitrogen

1.61

28.0

0.4508

Carbon
dioxide

0.15

44.0

0.066

Methane

98.17

16.0

15.70

21,500

337,704.80

17.24

270.79

2.74

43.04

2.25

35.34

13.25

208.12

Ethane

0.08

30.1

0.02

20,420

491.71

16.09

0.39

2.93

0.07

1.80

0.04

12.37

0.30

TOTAL

16.25

338,196.51

271.18

43.11

35.38

208.42

Total per
pound of
fuel

20,814.55

16.69

2.65

2.18

12.83

(5)

(7)

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(9)

(11)

(13)

16

Completed Combustion Worksheet


Fuel
Component

Column 1

Column 2

Volume
fraction
%

Relative
molecular
mass

Column 3
(1x2)

Total
mass

Column 4

Net
heating
value

Column 5
(3x4)

Heating
value

(Btu/lb)

(Btu)

Column 6

Air
required

Column 7
(3x6)

(lb air/lb)

Air
required
(lbs)

Column 8

CO2
formed

Column 9
(3x8)

(lbs CO2/lb)

CO2
formed
(lbs)

Column 10

H2O
formed

Column 11
(3x10)

Column 12

N2
formed

Column 13
(3x12)

(lbs H2O/lb)

H2 O
formed
(lbs)

(lbs N2/lb)

N2
formed
(lbs)

Nitrogen

1.61

28.0

0.4508

Carbon
dioxide

0.15

44.0

0.066

Methane

98.17

16.0

15.70

21,500

337,704.80

17.24

270.79

2.74

43.04

2.25

35.34

13.25

208.12

Ethane

0.08

30.1

0.02

20,420

491.71

16.09

0.39

2.93

0.07

1.80

0.04

12.37

0.30

TOTAL

16.25

338,196.51

271.18

43.11

35.38

208.42

Total per
pound of
fuel

20,814.55

16.69

2.65

2.18

12.83

(5)

(7)

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(9)

(11)

(13)

17

Relative Humidity
Correction for relative humidity:

vapor
18
moisture in air =

air
100 28.85
where:

vapor

vapor pressure of water at ambient temperature


(from steam tables)

air

14.696 psi

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18

0.364
50
18
=

14.696 100 28.85


= 0.0077 lbs of moisture per lb of air

Relative Humidity

(a)

Correction for relative humidity:

vapor
18
moisture in air =

air
100 28.85
where:

vapor

vapor pressure of water at ambient temperature


(from steam tables)

air

14.696 psi

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19

0.364
50
18
=

14.696 100 28.85


= 0.0077 lbs of moisture per lb of air

Relative Humidity
Correction for relative humidity:

(a)

16.69
air required (7)
=
=
1 0.0077
1 moisture in air (a)

vapor
18
moisture in air =

air
100 28.85

= 16.82 lbs of wet air per lb of fuel

(b)

where:

vapor

vapor pressure of water at ambient temperature


(from steam tables)

air

14.696 psi

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20

0.364
50
18
=

14.696 100 28.85


= 0.0077 lbs of moisture per lb of air

Relative Humidity
Correction for relative humidity:

(a)

16.69
air required (7)
=
=
1 0.0077
1 moisture in air (a)

vapor
18
moisture in air =

air
100 28.85

= 16.82 lbs of wet air per lb of fuel

(b)

= lbs wet air per lb of fuel(b) air required(7)


= 16.82 16.69
= 0.1295 lbs of moisture per lb of fuel

(c)

where:

vapor

vapor pressure of water at ambient temperature


(from steam tables)

air

14.696 psi

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21

0.364
50
18
=

14.696 100 28.85


= 0.0077 lbs of moisture per lb of air

Relative Humidity
Correction for relative humidity:

(a)

16.69
air required (7)
=
=
1 0.0077
1 moisture in air (a)

vapor
18
moisture in air =

air
100 28.85

= 16.82 lbs of wet air per lb of fuel

(b)

= lbs wet air per lb of fuel(b) air required(7)


= 16.82 16.69
= 0.1295 lbs of moisture per lb of fuel

(c)

where:

vapor

vapor pressure of water at ambient temperature


(from steam tables)

air

14.696 psi

= H2O formed(11) + lbs of moisture per lb of fuel(c) +


atomizing steam
= 2.17 + 0.1295 + 0
= 2.31 lbs of H2O per lb of fuel
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(d)
22

Excess Air
Correction for excess air:
N2 formed CO2 formed H2 O formed
(28.85

%O
)(
+
+
)
2
lb excess air
28
44
18
=
per lb of fuel
lbs H2 O
20.95 %O2 [ 1.6028
+ 1]
lbs air required

NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.

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(13)

Excess Air

(9)

(d)

N formed CO2 formed H2 O formed


(28.85 %O2 )( 2
+
+
)
28
44
18
=
lbs H2 O (c)
20.95 %O2 [ 1.6028
+ 1]
lbs air required(7)
12.83 2.65 0
(28.85 3)(
+
+ )
28
44
18
=
0
20.95 3[ 1.6028
+ 1]
16.69

Correction for excess air:


N2 formed CO2 formed H2 O formed
(28.85

%O
)(
+
+
)
2
lb excess air
28
44
18
=
per lb of fuel
lbs H2 O
20.95 %O2 [ 1.6028
+ 1]
lbs air required

= 2.50 lbs of excess air per lb of fuel

(e)

NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.

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(13)

Excess Air

(9)

(d)

N formed CO2 formed H2 O formed


(28.85 %O2 )( 2
+
+
)
28
44
18
=
lbs H2 O (c)
20.95 %O2 [ 1.6028
+ 1]
lbs air required(7)
12.83 2.65 0
(28.85 3)(
+
+ )
28
44
18
=
0
20.95 3[ 1.6028
+ 1]
16.69

Correction for excess air:


N2 formed CO2 formed H2 O formed
(28.85

%O
)(
+
+
)
2
lb excess air
28
44
18
=
per lb of fuel
lbs H2 O
20.95 %O2 [ 1.6028
+ 1]
lbs air required

= 2.50 lbs of excess air per lb of fuel

(e)

(e)

lb of excess air per lb of fuel


=
100
air required (7)
=

2.50
100
16.69
(f)

= 14.98 lbs excess air

NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.

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(13)

Excess Air

(9)

(d)

N formed CO2 formed H2 O formed


(28.85 %O2 )( 2
+
+
)
28
44
18
=
lbs H2 O (c)
20.95 %O2 [ 1.6028
+ 1]
lbs air required(7)
12.83 2.65 0
(28.85 3)(
+
+ )
28
44
18
=
0
20.95 3[ 1.6028
+ 1]
16.69

Correction for excess air:


N2 formed CO2 formed H2 O formed
(28.85

%O
)(
+
+
)
2
lb excess air
28
44
18
=
per lb of fuel
lbs H2 O
20.95 %O2 [ 1.6028
+ 1]
lbs air required

= 2.50 lbs of excess air per lb of fuel

(e)

(e)

lb of excess air per lb of fuel


=
100
air required (7)
=

2.50
100
16.69
(f)

= 14.98 lbs excess air

percent excess air (f)


(c)
(d)
=
lbs moisture per lb fuel + lb H2 O per lb fuel
100
NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.

14.98
0.1295 + 2.31
100
= 2.33 total lbs H2O per lb of fuel (corrected for excess air)
=

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(g)

26

Stack Loss
Component

Column 1

Component formed
(lb per lb of fuel)

Carbon dioxide

2.65

(9) from combustion worksheet

Water vapor

2.33

(g) from excess air worksheet

Nitrogen

12.83

(13) from combustion worksheet

Air

2.50

(e) from excess air worksheet

Total

20.31

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Stack Loss
Exit flue-gas temperature, : 500F
Component

Column 1

Column 2

Component formed
(lb per lb of fuel)

Enthalpy at T
(Btu/lb formed)

Carbon dioxide

2.65

100

Water vapor

2.33

192

Nitrogen

12.83

120

Air

2.50

110

Total

20.31

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Values taken from enthalpy


tables in API 560, Figures G.6
and G.7 for each flue-gas
component

28

Stack Loss
Exit flue-gas temperature, : 500F
Component

Column 1

Column 2

Component formed
(lb per lb of fuel)

Column 3

Enthalpy at T

Heat content

(Btu/lb formed)

(Btu/lb of fuel)

Carbon dioxide

2.65

100

265.31

Water vapor

2.33

192

446.72

Nitrogen

12.83

120

1,539.27

Air

2.50

110

274.98

Total

20.31

2,526.28

heat content at = 2,526.28 Btu/lb of fuel

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Step 2:

solve for additional heat losses

Thermal Efficiency
=

+ + + ( +
+ + +

Where:

lower heating value of the fuel (Btu/lb)

heat correction due to air (Btu/lb)

heat correction due to fuel (Btu/lb)

heat correction due to atomizing medium (Btu/lb)

assumed radiation heat loss (Btu/lb)

calculated stack heat loss (Btu/lb)


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Heat Losses
Heat loss due to air:

= a ( ) ( )

= a ( ) ( )

where:

= 0.24 (70 60) (16.81 + 2.50)

specific heat of air

= 46.37 Btu/lb

temperature of air (F)


temperature of design air (F)
the sum of and , expressed as
pounds of air per pound of fuel (from
lines (b) and (e) on the excess air and
relative humidity work sheet)

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Heat Losses
Heat loss due to fuel gas:

= fuel ( )

= fuel ( )

where:

fuel

= 0.587 (100 60)

specific heat of fuel gas

= 23.47 Btu/lb

temperature of fuel gas (F)


temperature of design fuel gas (F)

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Heat Losses
Heat loss due to atomization medium:

= ( )

= 0

where:

No atomization steam in this case.

enthalpy difference
mass of steam (lb)

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Radiation Losses
Heat loss due to radiation:

= %radiation loss

= 20,814 0.015
= 312.24 Btu/lb

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Step 3:

solve for thermal and fuel efficiencies

Thermal Efficiency
=

+ + + ( +
+ + +

Where:

20,814 Btu/lb

46.37 Btu/lb

23.47 Btu/lb

0 Btu/lb

312.24 Btu/lb

2,526.28 Btu/lb
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Thermal Efficiency
=

Where:

20,814 Btu/lb

46.37 Btu/lb

23.47 Btu/lb

0 Btu/lb

312.24 Btu/lb

2,526.28 Btu/lb

+ + + ( +
+ + +

=
=

+ + + ( +
+ + +

, + . + . + (. + , . )

, + . + . +

= 86.4%

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Fuel Efficiency
+ + + ( +
=

Where:

20,814 Btu/lb

46.37 Btu/lb

23.47 Btu/lb

0 Btu/lb

312.24 Btu/lb

2,526.28 Btu/lb
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Fuel Efficiency
+ + + ( +
=

Where:

20,814 Btu/lb

46.37 Btu/lb

23.47 Btu/lb

0 Btu/lb

312.24 Btu/lb

2,526.28 Btu/lb

+ + + ( +
=

, + . + . + (. + , . )
=

,
= 86.7%

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* Based on $2.75/MMBtu gas price

Conclusion
Knowing how to check your heaters efficiency gives you the

knowledge and power to improve your facility and optimize


your heater. As we have seen, improving efficiency can help
save your facility a lot of money.
What are you waiting for? Go check and start saving now!

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