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HEATER DESIGN
FIRED HEATER
DESIGN
TECHNIP 1
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HEATER DESIGN
PROCESS CONSIDERATIONS:
Arch pressure:
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STACK DESIGN
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• Types of drive:
( A) Fixed speed drive (1000 or 1500 rpm ) -
Capacity control by Inlet guide vans/ Inlet damper
(B) Variable speed drive ( Fluid coupling, VFD ) -
Capacity control by varying speed.
Qα n , H α n2 , P α n3
• Care must be taken to avoid flue gas condensation
on the Impeller. Hence the minimum temperature
at ID fan inlet shall be about 25-30 deg C above
dew point.
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TECHNIP 16
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BURNERS
• Types of Burners:
(A) Gas Firing
(B) Oil Firing
(C) Combination Firing
• No. of burners required for a given heat release shall
be optimized based on following criteria:
(A) In normal cases, max heat release per burner shall
not exceed 3.0 MMKCal/Hr.
(B) Turndown requirements
(C) Flame dimension: ( Flame impingement on tubes,
refractory & adjacent burners shall be avoided )
(D) Heat distribution requirements
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BURNERS (cont.)
• Component of Burner:
Main Gas/Oil tips , Pilot tip , Main flame scanner ( IR / UV ) ,
Pilot flame scanner ( Ionization rod ) , Igniter , Sight ports.
• No. of Burners Max./Nor. Heat Release
<5 1.25
6-7 1.20
>8 1.15
• Min Pilot heat release 20000 Kcal/Hr
• Type of Oil atomization:
(A) Pressure atomization = min oil pr. ~ 10 Kg/Cm2g
(B) Steam atomization = steam/oil ~ 0.3 Kg/Kg & Delta P
~2.1 Kg/Cm2
• For Oil fired burners, max. viscosity is 43 CSt.
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BURNERS (cont.)
• Generation of pollutants from Burner:
(A) SOx : Sox (SO2 & SO3 ) generation chiefly depends on the
sulfur content of the fuel.
(B) NOx : NOx (NO & NO2 ) is generated thermally by the
reaction occurring above 700-800 deg C. Methods of NOx
reduction are:
Splitting fuel within burner
Splitting combustion air within burner
Diluting air-fuel mixture by flue gas mixing.
Normal limit is 50-125 ppmv for gas firing & 200-250 ppmv for
oil firing.
(C) Unburnt hydrocarbon: Result of improper mixing of fuel
with air.
(D) SPM: Soot, ash etc. Refraction method is used to monitor
the SPM content in flue gas.
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BURNERS (cont.)
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AIR PREHEATER
• Advantages of APH :
(A) Enhance efficiency ( up 92-93 %).
(B) To enhance air-fuel mixing ( High air velocity ).
(C) Reduce oil burner fouling
(D) More complete combustion of difficult fuels.
• Disadvantages of APH:
(A) Increases potential of SO3 & NOx generation as
adiabatic flame temperature is high.
(B) Reduces the stack temp., so either ID fan or
taller stack will be required.
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TECHNIP 22
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TECHNIP 23
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SOOTBLOWERS
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DAMPERS
• Type of Dampers:
(A) Control damper: It controls the draft in the heater. It can be
either manual or automatic in operation. It always has some
leakage ( ~3%). It can be single blade ( like butterfly damper ) or
multiple blade ( like louver damper ). Multiple blade damper can
have parallel blade opening or opposed blade opening ( better
control but complex in operation).
No. of Blades ~ inside area of the duct or stack (M2) / 1.2
Control damper is normally use in stack, FD/ID fan and
combustion air bypass around the APH.
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DAMPERS (cont.)
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INSTRUMENTATIONS
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INSTRUMENTATIONS (cont.)
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REFRACTORIES
• Type of refractories:
(A) High Density Fire Bricks(HDFB): These are normally placed on
the floor to protect the mechanically weak castables / bricks. They
have excellent mechanical strength but very poor thermal insulation
properties.They are laid loose on the floor. Exp. AC30 etc.
(B) Insulating Fire Bricks(IFB): These are normally placed on
radiant floor (below HDFB), radiant wall and sometimes in vertical flue
gas ducts. They are lighter than HDFB and hence mechanically poor.
Application of IFB requires more time than castables / ceramic fibres.
They are laid with mortar and expansion gaps are provided to
accommodate the thermal expansion of the bricks. Exp. JM 23, JM 26
etc.
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REFRACTORIES (cont.)
(C) Castables: Castable are placed in all parts of fired heater. They
can be mechanically very strong ( as Insulyte 15Li ) or thermally
very superior ( like Firelite 124). They are applied on the surface by
pouring or gunning. Anchors (CS or SS-304, depending on the tip
temperature) are used to hold the castable with the casing.
Normally V, Y or chain link type anchors are used.
Castable can be applied in dual layer also. In dual layer
construction, a mechanically superior castable is used on hot face &
thermally superior castable on cold surface.
Sometimes ceramic blocks are used in place of castables. Exp.
Cerablok-800 etc.
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REFRACTORIES (cont.)
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METALLURGY
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METALLURGY (cont.)
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METALLURGY (cont.)
TECHNIP 36