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Energy Consumption
Petroleum Refining 7.5% of the total energy consumption in USA
0.40 MMBtu/ BBL of oil Total Energy consumed in refining- 7.1 Quadrillion BTU/yr Energy cost -$6/MMBtu Total Energy Cost- 42 Billion /yr Fired heaters -40-70% of the energy
Energy Consumption
A Typical refinery process 100,000 BPD Consumption of 0.40 MMBTU/BBL $6 per MMBTU Energy bill of $ 87.6 million per year. Potential Saving
1% Efficiency improve
$876,000/Year
Fired Heaters
Essential component in Petrochemical and Chemical Plants Each refinery has 20-50 fired heaters Design efficiency - 70-90%
Operating efficiency is even less than design.
Fired Heater
Heat liberated by the combustion of fuels is transferred to fluids contained in coils Fired Heater:
Radiant Section Convection Section Stack
www.heatflux.com
Combustion
Combustion Requires
Air ( 0.21O2 + 0.79 N2) Fuel Ignition source
Complete Combustion
Excess air
Incomplete Combustion
Energy Loss CO and H2 are released
Draft
Pressure inside the heater
Combustion air is drawn inside the heater through the burners air register Hot Flue gas flows out of the heater through the stack
Types of Draft
Natural Draft (ND) Forced Draft (FD) Induced Draft (ID) Balanced Draft > 80% < 1% 10% 10%
Draft
Stack Dampers helps control the draft Arch is the highest pressure point in the heater Excess or shortage of draft is not acceptable
STACK EXIT LOSS
STACK ________
CONVECTION SECTION
(SE)c
RADIANT SECTION
Pb
(SE)r Pa
BURNERS
Burner Operation
Correct combustion in firebox include:
The firebox is clear No smoky appearance Burners flames are steady and well-formed
Air Leakages
Air entering in to furnace from a number of places:
Peepholes Header box doors Tube guide opening Feed tubes entering and exits Not pressure tight structure
Heater Optimization
Target set 2-3% O2 in the flue gas. Operating conditions fluctuates :
Manual control /adjustments Operators Number going down Experience going down Need training
Optimisation Approach
Check draft
Adjust using off-take dampers
Check excess O2
Adjust burner register
Check burners
Light up all burners Check Flames/Firebox
Draft
0.7 0.6
Draft , in H2O
12:00
13:12
14:24
Time (7/22/09)
Excess Oxygen
6.0
Excess Oxygen, %
12:00
13:12
14:24
Time (7/22/09)
Stack Temperature
Stack Temperature, F
645 635 625 615 605 595 10:48 Stack Temp. A Stack Temp. B
12:00
13:12
14:24
Time (7/22/09)
Thermal Efficiency
83.0
Thermal Efficiency, %
82.0 81.0
12:00
13:12
14:24
Time (7/22/09)
16 14 12 10
8 6 4 2 0
T Skin, F
Observations in Refineries
Furnace working off design conditions Poor quality of dampers Lower number of operators Operator without sufficient training
Recommendations
Software
Heater Performance Index (HPI)
Hardware
Draft control system Excess O2 control system
Pressure drop,
Coking rate, Air preheater performance
Data 1
Data 2
Data 3
SET POINT
8/15/2009
8/16/2009
8/17/2009
Data 1
Data 2
Data 3
PROCESS 57PI0054.PV 57PI0055.PV 57PI0056.PV 57PI0057.PV 57PI0058.PV 57PI0059.PV 57PI0060.PV Average Crude Inlet Pressure (Pass 1) Crude Inlet Pressure (Pass 2) Crude Inlet Pressure (Pass 3) Crude Inlet Pressure (Pass 4) Crude Inlet Pressure (Pass 5) Crude Inlet Pressure (Pass 6) Crude Inlet Pressure (Pass 7) psig psig psig psig psig psig psig psig 147.9 147.9 147.9 147.9 147.9 147.9 147.9 147.9 278.9 296.0 275.9 286.0 281.7 283.8 298.2 285.7 287.4 309.6 282.8 294.8 290.4 292.4 310.0 295.3 286.0 309.8 284.8 293.0 288.7 290.2 306.8 294.1
SERVICE
UNITS
SET POINT
8/15/2009
8/16/2009
8/17/2009
Data 1
Data 2
Data 3
542
557.2
553.8
555.3
57TI0590
57TI0591 57TI0592 57TI0593 57TI0618 57TI0619 57TI0620
F
F F F F F F F
610
610 610 610 610 610 610 610.0
585.1
589.7 592.0 597.1 594.5 590.9 594.4 590.9
581.9
586.9 589.4 594.2 591.9 588.4 591.1 588.0
583.6
587.9 590.3 595.8 593.2 589.7 593.0 589.4
Data 1
Data 2
Data 3
PROCESS
57TI0633 57TI0634 57TI0635 57TI0636 57TI0629 57TI0630 57TI0631 Coil Outlet Temp. (Pass 1) Coil Outlet Temp. (Pass 2) Coil Outlet Temp. (Pass 3) Coil Outlet Temp. (Pass 4) Coil Outlet Temp. (Pass 5) Coil Outlet Temp. (Pass 6) Coil Outlet Temp. (Pass 7)
o
F F F F F F F F
1200.00
Temperature, Deg F
1100.00
1000.00
900.00
800.00
700.00
PASS1 PASS2 PASS3 PASS4 PASS 5 PASS 6 PASS 7 PASS 8
90.32
90.25
90.20 90.00 89.80 89.60 89.40 89.20 89.00 88.80 88.60 Design Data 1 Data 2 Data 3 Data 4 Data 5 Data 6 Data 7 89.56 89.35 89.26 89.57 89.73 89.69
Stack dampers
Reliable Correctly sized Pneumatically operated Opposed blades
Reliable Dampers
Opposed blades vs. Parallel Blades
Excess O2 Control
Control air supply to burners Pneumatically operated dampers or registers Provide proper control scheme Damper opening is provided based on Draft Excess O2 Firing rate Other parameters Savings realized through out the day
Summary
Manual controls are not adequate Energy prices are high Advanced Controls possible Use DCS based or PLC based Provide adequate safe guards Intelligent analysis of heater parameters Substantial savings can be realized Payout will be less than a year in most cases