Professional Documents
Culture Documents
SCOPE
TYPE OF HEATERS
IN GENERAL IN MRPL
NOMENCLATURE BURNERS
TYPES
REFRACTORIES
TYPES OF HEATERS
Classified on
Draft Fuel used Orientation of burners Orientation of tubes Shape of the heater
DRAFT
Flow of gas/air in the heater As gases become hotter they become lighter, and this makes it to rise up When this is routed through a narrow space, a negative pressure is generated.
Draft
PRESSURE Weight of Air column
P2 = Wt of Cold Air
P2 > P1
DRAFT..
This pressure differential causes air to come into the heater Why Essential?
NATURAL DRAFT
Draft by density difference. The weight of air inside the heater/stack is lesser than the weight outside This forces the air to come rushing in from the outside creating a draft
NSU HEATER NAPTHA VAPOURISER CIRCULAR HEATERS IN HCU KERO HEATER IN CDU2
(EFFICIENCIES OF NAT DRAFT FURNACES ARE VERY LOW. SO NOT GENERALLY PREFERRED)
FORCED DRAFT
Hot air/flue gases goes out by itself thru a stack The heater will be under positive pressure
EXAMPLES OF FD
Boilers in CPP
INDUCED DRAFT
By a fan or blower
The gases so induced are forced into the stack Because of the -ve pressure, cold air comes into the box
EXAMPLES
BALANCED DRAFT
Cool air forced into the heater Flue gases induced out of the heater Forcing & Inducing by Fans Net Negative Pressure inside box
BALANCED DRAFT
Better draft control Smaller heights of chimneys Air-pre heaters increasing efficiency
FUELS
Varied Fuels
Gas Fired Oil Fired Combination Fired Waste Heat (Only Flue Gases) Solid Fuel
FUELS...
SOLID FUEL
Low Cost Large Peripherals (Grate, Mills etc) Precise control Minute Variation Fluctuating Loads
GAS
FUELS...
OIL
High Heat Duty Steady Loads Advantages of Both Higher Heat Duty
COMBINATION
FUELS- IN MRPL
Solid Fuel
None HCU Reactor, H2 Reformer, CCR1 Reformer Boilers Of CPP Crude, HCU, CCR2, VBU
Gas Fired
Oil Fired
Combination
BURNER ORIENTATION
SIDE FIRED
BURNERS IN THE SIDE CCR1 REFORMER Shorter Heaters Different Arrangements (RW)
BURNER ORIENTATION
TOP FIRED
BURNERS ON THE TOP FIRING DOWN H2 REFORMER Better Heat Flux Control Heater Size Smaller Material Near Cracking
BURNER ORIENTATION
BOTTOM FIRED
BURNERS ARRANGED AT THE BOTTOM ALL HEATERS Oil can be used High Heat Duty
BURNER ORIENTATION
RADIANT WALL
Burner fires to Wall Heat Radiates from Wall Tubes see heat not fire Even Distribution of Heat
BURNER ORIENTATION
INDIRECT FIRED
ORIENTATION OF TUBES
- HELICAL COIL
- VERTICAL COIL
- HORIZONTAL COILS
SHAPE OF HEATER
CYLINDRICAL
CABIN
BOX
NOMENCLATURE
Shock Tubes
Nomenclature
Stack Damper Arch Convection Tubes Shock Bank Radiant Tubes Refractory Lining
Firebox
HEAT TRANSFER
By radiation By convection
HEAT TRANSFER
Convection Section Heat transfer from hot gases to tubes
BURNERS
Functions of a burner
Carries fuel into the heater Mixes fuel with air Provides area for safe burning
TYPES OF BURNERS
Gas
Oil
TYPES
Combination
Pilot
PILOT BURNERS
Provide flame inside heater at all times Low heat duty burners Normally gas fired Air and gas is pre-mixed in a mixer Mixture is burned in the pilot
PILOTS
MIXER ASSEMBLY
GAS BURNERS
Fuel used is Fuel Gas/ LPG/ Methane Low heat duty burners No need for special atomization Clean burning- no deposition on tubes Can be round flames or flat flames
GAS BURNERS
ROUND FLAME
FLAT FLAME
OIL BURNERS
Fuel used is fuel oil LSHS/ VR Atomizes the fuel into easily burnable particles Atomization by means of
OIL BURNERS
ATOMIZATION
Atomized Mixture OilEnters Oil & Steam Spud Mixes Velocity is Sprayed Increased
COMBINATION BURNERS
COMBINATION BURNERS
AIR
Provides air for combustion to oil gun Provides air for combustion for gas burners
Secondary air
AIRS
Tertiary Air
Found in low NOX burners At high temperature Nitrogen in air and Oxygen tend to form NO or NO2 To prevent this tertiary air or cooling air is provided around the burner
AIRS
TERTIARY AIR
SEC AIR
PRIMARY AIR
TROUBLESHOOTING
Problems
Flame Impingement Tall Flame Bushy Flame Oil Seepage Clinker Formation Meltdown
FLAME IMPINGEMENT
Probable Cause
Misalignment
Correction
Correct Alignment
Tall flame
Excess fuel pressure/ atomizing media pressure Burner too high in the block Lower pressure of fuel/ atomizer Burner too low in block
Bushy flame
OIL SEEPAGE
Cause
CLINKER FORMATION
MELTDOWN
Any Above left Unattended High Heat of Tip Melting Spillage Fire Meltdown
REFRACTORY
Types
Castables
Applied after forming a mortar Ready use, applied with mortar Std dimensions, locked with ceramic cup locks Preformed sections, locked to holders
Ceramic blankets
Ceramic modules
REFRACTORY - APPLICATION
Castable Fire Brick / Insulating Brick Fire brick, Insulating brick, Ceramic blankets
Radiant wall
REFRACTORY-APPLICATION
Corbel
Castable
Castable with potassium silicate coating
Ducts
REFRACTORY - DRYOUT
Slow Increase in Heat Hold at different steps (60, 80, 100, >100)
THANK YOU