NPRA Q&A 1990

We are reproducing following questions and answers concerning process heaters from the NPRA Q&A session that
took place in 1990. We hope the information will be useful to you. If you have any comments on these topics, please
let us know or send us an email and we will post it on our website.

Question 1
Have refiners experienced naphthenic acid corrosion in crude and vacuum units when processing crudes with acid
numbers less than 1 mg KOH/gram...

Question 2
What criteria are used to determine the necessity of decoking crude and vacuum heaters? Which criteria and/or
parameters are monitored during heater decoking operations?

Question 3
What type of heater tube skin thermocouples are most successful for a vertical heater operating near 1400 °F in the
radiant section?

Question 4
What types of continuous or portable analyzers are used to monitor SOx, NOx, O2 and CO in the flue gas from FCC
units? What has been the relative reliability of these analyzers in this service?

Question 5
Is there an established level of sodium content in resid feed that is acceptable when feeding to a delayed coking
unit?

Question 6
Is there a trend to move away from steam/air decoking of furnaces in view of environmental constraints? If so, what
alternatives are considered efficient for thermal cracking units? If not, what is used to clean up steam/air decoking
waste gases?

Question 7
What is the panel’s experience with staggered tubes versus single row tubes in a reformer (Foster Wheeler heaters)...

Question 8
What is the maximum tube skin temperature that can be used for 25-35-Nb (HP modified) reformer tubes? What is
the latest type of tube material used for high severity operation of a reformer furnace?

Question 9
What on-line analyzers are used to monitor methane slip from reformers or CO slip from shift reactors?

Question 10
In a hydrocracker reactor feed heater, a 200 psi steam superheat coil made of lncoloy 800 was installed as the first
coil in the bottom of the convection section...

Question 11
What levels of NOx, in pounds/MMBTU are achievable using Low NOx, burners when firing either oil or gas or a
combination?

QUESTION 1:
Have refiners experienced naphthenic acid corrosion in crude and vacuum units when processing crudes with
acid numbers less than 1 mg KOH/gram? For any level of acid number, what alloys have you found to
satisfactorily resist naphthenic acid attack in heaters, transfer lines, and towers? Has there been any stress
corrosion cracking associated with the use of these alloys?

RATERMAN:
We believe that we have experienced some corrosion on 5 and 9 chrome steels when processing low neutralization
number crudes. The main factors influencing corrosion by naphthenic acid attack are the acid strength (the
neutralization number), temperature, velocity or turbulence, and whether or not a liquid or vapor phase is present.
Most articles warn that corrosion can become significant at neutralization numbers above 0.5 mg KOH/gram and at
temperatures between 445 - 790 °F. Condensation of hydrocarbons at these temperatures can lead to a particularly
bad situation due to the acid concentrating in the condensing liquid phase. The lower molecular weight Naphthenic
acids are much stronger acids than the higher ones. For all purpose protection against naphthenic acid corrosion, the
high molybdenum containing austenitic stainless steels, type 316 and 317, are usually recommended.
Two good reference papers on naphthenic acid attack and control are Paper 99 in the International Corrosion Forum
sponsored by the NACE group in April of 1983, and a paper by J. Gutzeit presented at the March 1976 International
Corrosion Forum.

CARON:
Our customary target for a blended crude maximum acid number is 0.5 mg KOH/gram. Depending upon crude
inventories, deliveries, etc., we may exceed this target for short time periods. We monitor our crude unit side
streams for iron once a week and we use this data to evaluate limits on high acid number crudes. We have not seen
any excessive corrosion when using these guidelines. When high acid number crudes are going to be processed, 5 to
12 chrome steels are usually used.

KENNEDY:
We have experienced metal loss in the piping and exchangers of our vacuum tower wash oil section which we
believe is naphthenic acid corrosion. We do not measure the acid number of our crudes, but we do measure the acid
number of our wash oil which ranges from 0.3 to 1 mg KOH/gram. We have experienced a corrosion rate of about
10 mils/year in our wash oil exchanger tubes which are 1.25 chrome. We have had varying degrees of satisfactory
service out of 316L, 5 chrome, and 304 stainless steel in areas where naphthenic acid corrosion could occur. We
have not encountered any stress corrosion cracking problems.

MORGAN:
We feel that the acid number corrosion threshold is typically between 0.5 and 1.5. But, as previously mentioned, the
corrosion will also depend on other factors like velocity, temperature, and phase. We have had good experience with
317L stainless steel in vacuum unit transfer lines and the hot section of the vacuum tower. We do not do anything in
particular to protect against polythionic stress corrosion cracking on lines in heavy oil service. However, we will
take preventive steps on unit shutdowns if chloride stress corrosion potential exists. To date we have not had any
problems with either type of cracking in our vacuum units.

back to the top

QUESTION 2:
What criteria are used to determine the necessity of decoking crude and vacuum heaters? Which criteria
and/or parameters are monitored during heater decoking operations?

UTLEY:
In our case we watch a couple of different parameters to determine coking: pressure drop, fuel gas consumption,
visual inspection on-stream, and time in service. However in most cases we decoke during plant turnarounds. It is
easy to do, cost very little, and we feel it is good insurance.
We generally go two years between turnarounds on our catalytic cracking unit and 4 to 5 years on our crude unit.
We did have some problems a few years ago when we had a coke buildup around the outlet thermocouple on our
catalytic cracking heater because of some bare piping. We estimate the readings were 50 to 60 °F low. We generally
run about 810 °F on a combined outlet. We coked up in about three days going from a normal pressure drop of 30
psi to about an 80 or 90 psi drop. During decoking operations we monitor firebox temperatures at around 1200 °F,
coil outlet temperatures at 1,000 °F, steam rate, air rate, and visually monitor the color of the tubes and solids output
during spalling operations.
RATERMAN:
The main parameters that we use to determine when the crude or vacuum heater needs to be decoked are pressure
drop across the coil, or an increase in the skin temperature of the tubes at a constant process duty. In addition to
these, heater efficiency may be tracked by performing simple heat balance on the process side and comparing it to
the fuel consumption. This method, however, cannot easily distinguish between process side or firebox side fouling.
To decoke the furnace we first attempt to remove loose coke by spalling it off followed by steam air decoking.
During the latter process we closely monitor the steam-to-air ratio, the velocity through the tubes, and the skin
temperature to avoid hot spots and possible tube damage.
We usually try to keep between 1 to 2% oxygen at the inlet of the tube and set steam rate to give us about 18 lbs/foot
sq sec. Firebox temperatures are maintained at 1050 to 1150 °F and the air rate is used to control the burn front
temperature and speed.

STEGELMAN:
We decoke our crude furnaces each scheduled turnaround. Presently, that is 18 months. We watch the furnace
temperatures, both the firebox and tube skin, and also the stack temperature for signs of coking. In Borger in two of
our more sensitive furnaces, which happen to be tall, thin furnaces, bowing of the tubes during operation is an
indication that we see. We have had to do some middle-of-the-run decokings on these furnaces. We have gone to a
mild burnout to dry out the deposits. We limit to about 800 °F on the tube outlet temperature and then use sand jet
cleaning to assure we will have clean tubes and to assure that we will not have any over-heated sections due to the
burnout. We have had very good luck in getting clean tubes this way.

BRANHAM:
Basically, we monitor the flow control valve position on-line and x-ray tubes during the turnaround. X-rays are
made of the inlet, middle and outlet of the heater passes. I believe that the decoking operation has been described
thoroughly.

CARON:
During normal crude still run, we monitor many variables on the heaters including pass pressure drop, pass flow
rates, pass inlet and outlet temperatures, and bridge wall temperatures. These give us a good indication of heater
performance and potential coking. As we reach various heater limits, throughput or firing rate reductions are taken
to remain within the limits. When the economics dictate that increased crude run/product value can overcome the
downtime days and costs, we decoke. For good measure, like everybody else, when we have a turnaround, we
decoke.
Our decoking procedures call for spalling and then burning the coke from the tubes. We spall as long as we see coke
in our quench box. In addition to the items we normally monitor on our heater, we pay special attention to the air
flow rate, the steam flow rate, and the pass outlet temperatures during the decoking. We also observe our heater
tubes for any color changes. Every half hour we check the effluent for carbon dioxide and oxygen. Once the
decoking is complete, we perform a delta P test on each pass with steam.

GESICK:
The only thing that I want to add to what has already been said is that even if the general performance of the heater
is satisfactory, localized hot spots on individual passes or sections of individual tubes can require a decoking of the
heater, even if the rest of the heater is performing adequately.

KENNEDY:
We use five major criteria in deciding if and when a crude or vacuum heater needs decoking. Both our crude and
vacuum heaters have four passes. Each pass is monitored using an outlet temperature and flow. We try to balance
the pass flows to keep the outlet temperatures within a range of 30 °F If the flow through a pass appears to be
declining, then this is an indication of coke buildup in that pass. We also visually check the heater tubes and look for
hot spots and tube deformation, which may indicate the need for decoking. A fourth consideration is the operating
history of the heater. Have there been any problems which could cause flow to the passes to be lost and coke up the
heater?
Another parameter to check is the heater delta P, as a gradual increase in the pump discharge pressure could also
indicate coke buildup. During the decoking procedure, the parameters we check are the decoking quench water color
(especially during spalling), the amount of steam and air used, the tube skin temperatures, and the tube skin color in
the burn wave.

MORGAN:
We concur with everything that has been said, and we do the same. I have one additional note. We have occasionally
tried to x-ray furnace tubes on shutdown to try to look for coke. This procedure has only been marginally successful.
In fact, most times we are more confused after we look at the films than before.

ROBERT GOMBAS (Amoco Oil Company):

On two different occasions, we had tube leaks while steam-air decoking a coking furnace. We did not meter the flow
of air or steam and only used firebox and tube effluent temperatures along with the visual color of the tubes to
control the decoking. We found later from metallurgical examination that the tubes failed from having
reached/exceeded the temperature where carburization and metallurgical changes occur. For better control, we have
recommended metering both steam and air, and monitoring the CO2 during the decoking. In addition we have
recommended the use of infrared guns to watch for localized hot spots during the burn. How many of the panel have
at least steam and air meters in their decoking facilities?

HIGGINS:
A show of hands reveals that many of them do have meters .

J. A. GEARHART (J. A. Gearhart Enterprises, Inc.):

Another clue to look for, which would indicate that the vacuum heater tubes are coking, is the increased make of
gas. This puts an extra load on the ejectors which may result in a rise in the vacuum tower pressure. The gas odor
can also be detected above the hot well. A recommended practice to minimize coking in the vacuum furnace tubes is
the injection of steam into the tubes at the outlet of the convection section. Additionally, the diameter of the furnace
tubes should be enlarged to allow for increased volume of steam and oil vaporization as the mixed flow continues
toward the outlet furnace tube or tubes. This procedure also has the effect of lowering partial pressure and increasing
the amount of vaporization in the furnace rather than superheating the oil sufficiently to cause it to vaporize entirely
in the flash zone of the vacuum tower.

back to the top

QUESTION 3:
What type of heater tube skin thermocouples are most successful for a vertical heater operating near 1400 °F
in the radiant section?

MACKEY:
The most accurate thermocouples we have found are called Refracto-pads. The thermocouple elements are factory
bent to conform to the furnace tube diameter. A 310 stainless steel shield is also fabricated to conform. This shield
filled with castable insulation just prior to welding the shield to the tube protects the thermocouple pad, tip and
portion of the sheathed thermocouple from direct furnace radiation. The company that makes ours is Gay
Engineering of Pasadena, Texas.

BRANHAM:
We also use the Refracto-Pads. Some have been in service with firebox temperatures around 1500 ºF with good
success since 1986. Some of the earlier failures of skin thermocouples were more related to the thermocouple lead
failure and how that is installed as opposed to the pad itself.

RATERMAN:
Our recommended type of thermocouple for the described application is a knife-edged TC. These couples are
manufactured by Thermocouple Products Company of Winfield, Illinois. They will also supply procedures for
attaching the thermocouple to the heater tube. We have found the reliability of these couples to be very good if the
procedures are carefully followed.

MORGAN:
Our domestic plants have standardized on the V-Pad type skin couple supplied by Sandelius Instruments and Tube-
Temp. The heavy sheath made from type 310 stainless steel has given 6 to 7 years reliable life at temperatures
approaching 1400 °F. Our Humber, England plant has had good luck with an Acramet eccentric thermocouple
attached to the tube with a metal spray process.

back to the top

QUESTION 4:
What types of continuous or portable analyzers are used to monitor SOx, NOx, O2 and CO in the flue gas
from FCC units? What has been the relative reliability of these analyzers in this service?

MORGAN:
All of our units use Thermox WDG-3 oxygen analyzers. The analyzer itself has proven to be very reliable, but the
sample delivery systems have been a high maintenance area. The best solution we have found is to blowback the
analyzer and sample system for about a minute each day with dry instrument air.
For carbon monoxide we have had good experience with a Land Combustion analyzer. It has been in service since
1986 and usually averages about two failures per year.

BRANHAM:
Ashland monitors NOx and CO on the Catlettsburg RCC CO boiler stack using a Combustion Engineering model
8903. An Applied Automations model 2100 analyzer is used on the regenerator flue gas to measure SO2, CO, and
O2. Reliability has generally been good. To insure reliability, daily and weekly PM is scheduled on these important
analyzers. CO is monitored on the Catlettsburg FCCU using a Contraves model 100R and this is to be replaced with
an Anarad model AR930 as I previously reported. The O2 analyzer used for each cracking unit is different but all
are felt to be okay. We use Westinghouse Model 1500, Thermox model WDG3, Seimens Oxymat 5F, and Servomex
model 1100 with equally good success.

CARON:
A portable analyzer marketed by Land Combustion Inc. can monitor SOx, NOx, O2 and CO in the flue gas. We tried
one and directionly the results went the right way. For SO, determination we have used a Lear-Siegler model 8100
with good results. We have used the Beckman model 865 infrared for CO levels in the stack. To date the analyzer
response has been satisfactory. Oxygen levels have been measured with two analyzers. One is an Ametek while the
other is a Thermox WDG3.
The major problem with reliability is not so much the analyzer but with the sampling system. The service is difficult
and the sample lines are prone to blockage.

MACKEY:
We have continuous NOx, SOx, CO, and O2 analyzers on our unit. The NO, unit we use is a ThermoElectron model
10. The SOx, unit is a Western Research model 722. We use a Beckman model 685 CO analyzer and a Thermox O2
analyzer. I would echo the same comments about the sample conditioning systems. That is really where you want to
put your time and effort. In general these systems are routinely maintained once per week.

RATERMAN:
Our biggest problem is severe fouling of the sensor or sampling system with catalyst dust. Some of the continuous
instruments we use for monitoring the flue gas are, for oxygen we use Westinghouse and Hartmann and Braun; for
opacity we use Lear-Siegler or Dynatron, carbon monoxide — Beckman; SOx, a Lear-Siegler or a DuPont, and for
NO, we have tried a handheld ENERAC, but we are not so sure about the accuracy of that instrument.

back to the top

QUESTION 5:
Is there an established level of sodium content in resid feed that is acceptable when feeding to a delayed
coking unit?

MORGAN:
From a furnace run length standpoint we would like to see less than 8 lbs/l000 bbls in the resid feed. This relates to
less than 2 lbs/l000 bbls in the desalted crude. Of course the lower the better for furnace run lengths. We have seen
significant coker run length improvements when we increased salt removal by converting two of our crude unit
desalters to two stage desalting.

COOPER:
Each major refiner has adopted different specifications based on their experience. Most of the focus is on the sodium
specification for sale of coke. For a given refinery configuration, the concentration of sodium in coker feed can be
predicted by mass balance against the sodium content of desalted crude. Statistical analysis relates sodium in the
desalted crude to furnace fouling rates as well as to product concentration.

RATERMAN:
We generally try to limit the sodium content in the resid feed to our delayed cokers to between 30 and 50 ppm. At
levels above 50 ppm, we tend to experience accelerated coking in the furnace and the transfer lines to the drum. As
the levels of sodium are reduced below 30, the fouling rates tend to reach a minimum with little or no additional
improvement.

SCHAUB:
My comment on this question really relates to a visbreaker unit where we specified a maximum feed sodium
content. On this particular unit, you had tube skin temperatures that you could monitor. Over a course of even one
shift you could detect a permanent. increase in skin temperature on furnace tubes with a 30 to 50 ppm sodium
content in the feed.

JOHN R. WOOD (Petroleum Refining Consultants):

In addition to the panelists comments, sodium in the form of caustic is particularly significant and should be
minimized and preferably eliminated to reduce heater and transfer line coking.

back to the top

QUESTION 6:
Is there a trend to move away from steam/air decoking of furnaces in view of environmental constraints? If
so, what alternatives are considered efficient for thermal cracking units? If not, what is used to clean up
steam/air decoking waste gases?

PAINCHAUD:
We have no plans to move away from the tried and true method of steam/air decoking. Our procedure is to quench
the flue gas with water, separate the water, and discharge the gas at a safe location. We have tried the pipeline
cleaning methods with limited success. We view it as cost prohibitive and only justifiable when quick turnarounds
are required.

RATERMAN:
Offline steam/air decoking is still the most effective way to remove coke from furnaces containing different tube
sizes in a pass. When properly done, the primary products at combustion will be CO2 and water, which may be
safely discharged after scrubbing. If carbon monoxide levels are high, then consideration should be given to routing
the combustion gases to a nearby firebox. As an alternative to steam/air decoking in our coker furnaces, we have
tried a procedure recently where we have thermally cycled the tubes while in service, spalling off coke which is then
collected in the coke drum. The procedure requires careful attention to the way the furnace is fired in order to
remove the coke from the outlet first and then gradually work your way back towards the inlet. To use this technique
in a visbreaker would require addition of a coke removing facility in the quench tower bottom circuit.

JAMES GALLAGHER (ABB Lummus Crest Inc.):

We are currently designing visbreakers with steam/air decoking facilities on the heaters. But one thing we are seeing
is that with soaker visbreaker technology, the frequency of actually decoking the furnace is substantially less than
with a coil visbreaker. Decoking of the soaker drum can be done manually or with hydro-jetting and typically
produces a solid coke product which can be sold as a fuel.
back to the top

QUESTION 7:
What is the panel’s experience with staggered tubes versus single row tubes in a reformer (Foster Wheeler
heaters)? Has experience shown that it is economical to modify staggered tubes to single row? Also, how is
pigtail failure affected by the reformer tube layout?

CARON:
This spring we modified our Foster Wheeler hydrogen plant to a single row design from staggered tube design. The
biggest difference from an operations view point is that the tube bowing common to staggered tube designs is
eliminated. Less bowing gives less rotation at the outlet crossover, yielding lower stresses at this connection. We
expect this to improve reliability. Modification to a single row design resulted in larger diameter tubes and fewer of
them. Fewer tubes make the maintenance department happy because there is less handling, easier catalyst loading,
fewer flanges to remove and replace, fewer pigtails and crossover welds, and it is easier to seal the furnace at the
floor and at the arch. In our case the economic justification was straightforward. Our existing tubes were
approaching the end of their useful life. Our decision was to replace in-kind or switch to the single row design. Our
estimate indicated a 10% lower cost to switch to a single row design. We switched and are pleased with the results.

RATERMAN:
In 1982 we modified the hydrogen reformer furnace tubes in one of our refineries from a staggered tube
arrangement to a single row arrangement with larger tube size to maintain capacity. The reformer furnace was
designed by Foster Wheeler. Prior to the 1982 modification we had many pigtail failures. But since then we have
experienced very good performance. All the newer reformer heaters now have a flexible pigtail design which has
greatly reduced the problems in this area.

JAMES FLESHMAN (Foster Wheeler Corporation):

I definitely agree with the panel’s experience. With the older HK40 tube material, rupture strengths of that material
determined tube size and wall thickness; this resulted in more, smaller tubes. These tubes were arranged in a double
(staggered) row in many cases for economical radiant box design.
It should be noted that a recently released API Recommended Practice suggests even lower rupture strengths for this
alloy than was used in the older designs. With the development and proven operating experience of the niobium-
modified HP alloys, which have higher rupture strengths in the temperature ranges of most steam reformers, larger
diameter tubes could be utilized without excessive tube wall thicknesses. Thus, for a given catalyst volume, fewer
tubes can be installed. The existing radiant boxes have adequate space to permit installing these tubes in an in-line
(single) row arrangement.
The benefits noted above are certainly applicable, and economics for the conversion itself have been confirmed.
Additionally, future savings are realized during subsequent catalyst changeouts (fewer tubes). Also, the simpler seal
arrangements at the arch and the floor are usually more effective since they go together more easily, resulting in less
infiltration and reduced fuel due to the lower infiltration. The tube bowing is eliminated due to the significantly
improved circumferential heat input with the single row; therefore, both sides of the tube are at an even temperature.
The staggered tube has uneven temperatures which imposes differential expansion and resulting bowing. Foster
Wheeler also fully upgrades the unit during a conversion, offering the benefits of more recently developed design
features (including Foster Wheeler’s patented stress collars).

ANDERS NIELSEN (Haldor Topsoe A/S):

Haldor Topsoe has had extensive and successful experience with retubing of staggered row reformers in hydrogen
and ammonia plants of their own design. The retubing has been based on the snake row principle; removing every
third tube. By using the newer, stronger tube materials such as 25-35 chrome, nickel, niobium, instead of the original
HK40 or 24-24 chrome, nickel, niobium and maintaining the original outer tube diameter, the inner diameter can be
substantially increased so that the increase in reformer pressure drop will be negligible. This snake row reformer
tube arrangement has in actual service proven to be capable of meeting the original plant design production rate. For
this type of retubing, it is essential to have the required knowledge of catalyst kinetics and furnace heat transfer. We
at Haldor Topsoe would normally not consider retubing to a single row configuration due to the large decrease in
number of tubes and also due to use the substantial additional modifications required compared to the snake row
layout. For the snake row layout the only modifications required are capping of one third of the inlet and outlet
pigtails and blinding off of the holes in the reformer casing. Going from staggered row to snake row configuration in
Topsoe reformers, pigtail configuration has remained unchanged normally using the original pigtails. We do not
experience pigtail failures in the original or the modified design.

GEORGE TAGGART (TPA, Inc.):

We have been working with Zilberring Engineering of Zurich on a design on which Dr. Zilberring holds patents.
The design effectively eliminates tubes from hydrocarbon steam reformers by an innovative enclosure design
coupled with an innovative design of heat transfer apparatus and catalyst. The system requires some additional
developmental work, but we think it is a very fine system and would be delighted to discuss it with anyone.

back to the top

QUESTION 8:
What is the maximum tube skin temperature that can be used for 25-35-Nb (HP modified) reformer tubes?
What is the latest type of tube material used for high severity operation of a reformer furnace?

RATERMAN:
The maximum operating skin temperature on 25-35 Niobium HP modified tubes is a function of the operating
pressure and the design life of the tubes. For example, in a reformer operating at 312 psig tube inlet pressure, the
maximum skin temperature is about 1,745 ºF for a 10 year life. In an ethylene furnace where the operating pressure
is only 10 to 15 psi, the maximum skin temperature will be about 2,000 °F. Our current metallurgy of choice for
reformer tubes still remains the 25-35 Niobium material.

ANDERS NIELSEN (Haldor Topsoe A/S):

I agree with the answer from the panel. I would like to add a couple of things. In reformers using conventional outlet
systems in Incoloy 8OOH, we do not find it economical to go above 1,560 °F on the reformer outlet temperature.
The tube skin design temperatures for these conditions are usually much lower than the maximum indicated by the
previous speaker. For high severity operations, we specify 25-35 chrome nickel niobium titanium (HP-BST) which
allows us to operate with tube skin temperatures in excess of 1,800 ºF, at operating pressures around 300 psig.

back to the top

QUESTION 9:
What on-line analyzers are used to monitor methane slip from reformers or CO slip from shift reactors?

CARON:
Our Sarnia and Toledo refineries use Applied Automation analyzers in this service. In the Philadelphia refinery we
use a Beckman model 865 for both methane leakage and CO slip.

back to the top

QUESTION 10:
In a hydrocracker reactor feed heater, a 200 psi steam superheat coil made of lncoloy 800 was installed as the
first coil in the bottom of the convection section. This material, which was selected to facilitate “No-flow”
operation for short periods, has developed cracks after 2-3 years operation due to thermal fatigue. Has
anybody experienced a similar problem? What is the panel’s experience on SS 316 material in steam service?

RATERMAN:
We do not have any experience with Incoloy 800 in this service. We have designed some of the steam coils in our
process heaters for the “No-flow” condition. Materials that we choose to use most often are 2¼ and 9 chrome steels,
and stainless steel type 304. Exact choice of material depends on the maximum flue gas temperature that the tube
will see. We have not experienced any failures as of yet that were caused by not having any flow through the tube.

LANCE FRANZ (Koch Refining Company):

When you are using austenitic stainless steels in heaters, you have to be real concerned about firing sulfur bearing
fuel oils, and certainly about polythionic acid cracking. In looking at the question, there may have been an
assumption that it was thermal fatigue, and it may have been some other cracking mechanism that could cause this.

PHILIP G. SNYDER (Chevron Chemical Company):

At the AICHE Ammonia Symposium this last summer at San Diego, there was a report of the catastrophic failure of
a stainless line due to thermal fatigue from a water spray. Several observations were also made outside the meeting
of furnace superheat alloy coils which also failed catastrophically from water being blown onto the hot surface, also,
from thermal fatigue. A couple of coils were old and sigma phase was present in the material, but there was one that
was not very old. That is similar to what we have seen in FCCU’s when you spray water on a regenerator cyclone or
plenum; you get thermal fatigue failures.

back to the top

QUESTION 11:
What levels of NOx, in pounds/MMBTU are achievable using LoNOx, burners when firing either oil or gas or
a combination?

MACKEY:
Again, in southern California, our new requirements for Low NOx, burners are stipulated at 0.03 pounds/MMBTU.
That is our requirement for emissions. We have manufacturers, John Zink in our case, that are claiming that their
newest LoNOx, burners are expected to yield between 0.025 and 0.03 pounds/MMBTU which is somewhere around
25 ppm. For gas fired burners, we are expecting those to get down even lower, down in the 6 to 8 ppm range, at
about 2% oxygen. Oil fired burners may be able to achieve the 15 to 25 ppm NO,, but the results are very dependent
on the nitrogen content in the fuel.
Other factors that affect the NO, generated by burners are the bridgewall temperatures, the oxygen content, the
excess oxygen, the nitrogen content of the fuel, and obviously the tuning of the burners. However, the manufacturers
are claiming that they can get down to 0.03 pounds/MMBTU.

SCHAUB:
Perhaps our figures are dated here, but what we have seen is from 0.1 to 0.2 pounds of NO, per MMBTU of gas, and
0.2 to 0.3 for Low NOx oil burners. Our figures come from power utility boilers because we had some readily
available data in that application. We would expect similar results for process heater applications. For new utility
boilers, I would point out that Low NOx burners were only one major component of the combustion process
modification using overfire air, flue gas recirculation, or stage combustion where we have seen figures in the region
of 0.05 and 0.15 pounds of NO, per MMBTU for gas and oil, respectively.

UTLEY:
We do not have any Low NOx, burners at this time. However, because of some of the things that are going on in
Utah, we have been looking at NOx levels. We agree with what Mr. Mackey said. There are some manufacturers
that we have talked to that report they can get down to around 0.03 to 0.04 pounds NOx/MMBTU on gas.

back to the top