PROCESS HEATERS ‘Types of Process (Fired) Heater Process heaters (fired heaters or furnaces) are heat transfer units in which heat from fuel combustion is transferred predominantly by radiation and secondarily by convection to fluids contained in tubes. Fired heaters are generally used in heat transfer applications where steam heaters (boilers) are inappropriate. These include applications in which heat must be transferred at temperatures in excess of 200 to 400°F, The process fluid stream to be heated is contained in tubes along the radiant section walls and ceiling, and in tube banks in the conveetion section. This process fluid stream is heated for one of two reasons: (1) to raise the temperature for additional processing (heated feed) or (2) to promote chemical reactions in the tubes (reaction feed). Fired heaters may be designed and constructed in a number of ways, but most fired heaters include burner(s), combustion chamber(s), and tubes that contain process fluids. A heater consists of the following components’ + Main firebox ~a refractory lined steel shell that allows minimum heat loss to the surroundings. + Convective heat transfer tubes - provide initial heat to the crude by transfer from hot flue gases. This section provides about 25 - 35% of the total required duty. Extended surface tubes are frequently used in convection section when gas or clean fuel is fired.» ) wc + Radiant heat transfer tubes - provide about 55 ~ 65% of the total duty by radiation from the flames and the furnace walls. + Additional convection section (e.g. superheater, heat medium, other process duty) tubes - ‘used for convective heat transfer to recover as much heat as possible from the flue gases. + Anumber of burners distribute heat through the furnace. These burners are equipped to use either fuel gas, fuel oil with atomizing steam or air, or multiple fuels (gas, fuel oil, and waste gas). ‘© Damper - controls the pressure in the firebox and thus controls the amount of draft in the unit, The most important part of the fired heater is the heat transfer surface where the hydrocarbon fluid is heated, or where the chemical reaction occurs. In most cases this surface comprises tubes (tube coils) either in a vertical or horizontal array joined at the ends to form continuous coils or as separate reactors. Fired heaters heat fluids or vaporize liquids. Forced circulation of the liquid feed is almost always used. Because radiation is the predominant heat transfer mode that requires the need for equal heating around the tube, tubes are arrayed on wide spacing, Re-radiation from the heater walls often plays a large part in assuring equal radiant heat transfer ‘and temperature control. This requires special consideration for the burner and furnace design. In fired heaters the tubes and the refractory must be supported separately. This results in fired heaters that reflect different approaches to component design. There are several types of process heaters, The common types used in industrial plants (Figure 1) include the vertical cylindrical and the box (cabin) types. The box typ may be end-fired or bottom-fired.T QQ et | inet: oe jonveation it | 1 — st | 4 a ae Figure 1 Schemat c of Types of Fired Heaters Design Guidelines for Fired Heaters Fired heaters may be designed and constructed in a number of ways, but most fired heaters include burner(s), combustion chamber(s), and tubes that contain process fluids. Combustion Chamber Process heaters contain a radiant heat transfer area in the combustion chamber, This area heats the process fluid stream in the tubes by radiation. Equipment found in this area includes the bburner(s) and the combustion chamber(s). Most heat transfer to the process fluid stream occurs here, but these tubes do not necessarily constitute a majority of the tubes in which the process fluid flows. Most fired heaters also use a convective heat transfer section to recover sensible heat from the hot combustion gases by convective heat transfer. This section is located after the radiant heat transfer section and also contains tubes filled with process fluid or fluids from other circuits, The first few rows of tubes in this section are called shield (or shock) tubes and are subject to some radiant heat transfer as well. Typically, the process fluid flows through the convective section prior to entering the radiant section in order to preheat the process fluid stream. In some applications a different stream is heated in the convection section or a part of it The temperature of the flue gas upon entering the convective section usually ranges from 1,500 to 2,000°F. (815 to 1100°C). Preheating in the convective section improves the efficiency of the fired heater, particularly if the tube design includes fins or other extended surface areas. Extended tubes can reduce flue gas temperatures from the 1500-2000°F (815 to 1100°C) range to the 250-500°F range (120 to 260°C).