f urnace impr ovement s services - eplptx.comeplptx.com/brochures/furnace improvements -...

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FIS’ PATENTED TECHNOLOGIESFurnace Improvements patented four technologies for improving the performance of fired heaters. These patented technologies are aimed at overcoming existing limitations in the capacity and efficiency of heaters as well as resolving operational problems.

Technology Application

Split Flow Technology Increases capacity with limited process side pressure drop

Flue Gas Injection Reduces coking & tube metal temperatures

Inclined Firing System Reduces flame impingement and high tube metal temperatures

Spider Gas Tip Shorter flame gas burners

Two of these technologies are highlighted below.

Inclined Firing System Most tube failures in fired heaters occur due to high tube metal temperatures (TMTs). Flame impingement due to long burner flames results in higher TMTs and coking that affect the performance of the heater. Furnace Improvements developed the patented Inclined Firing System (IFS) to reduce flame impingement on heater tubes. With this burner arrangement, a heater will have the following advantages:

Elimination of hot spots

Longer tube life

Increased heater run lengths

More uniform heat transfer along the tubes’ lengths

Lower coking rates of internal tube surfaces

Base Case Inclined Firing System Base Case Inclined Firing System

Clients report 200‐250 °F lower TMTs with the Inclined Firing System.

Above: CFD Modeling illustrates how IFS reduces flame impingement by angling the flame away from the heater tubes.

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FIS’ PATENTED TECHNOLOGIES

Split Flow Technology When refiners wish to increase the capacity of their fired heaters, “Split Flow” aims to improve the utilization of thermal energy for process heating. This objective is achieved by splitting the process fluid into two parallel streams: Main Stream: The fluid in the first stream

is heated predominantly by the convective and radiant heat transfer mechanism.

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stream is heated predominantly by the convective heat transfer mechanism.

The streams are then combined at the heater outlet. This technology has been used very successfully for capacity increase revamps of fired heaters particularly in Platformer heaters. It is suitable for increasing the capacity of a heater by 15‐30%. Other advantages of the Split Flow Technology include:

Higher heater efficiency

Lower process pressure drop

Lower firing rate

Lower firebox temperatures

Lower radiant heat fluxes

Lower TMTs

Lower installation costs

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Furnace Improvements Services

REFERENCE LIST

Email: [email protected] Web: www.heatflux.com

Furnace Improvements Building Green Fired Heaters- Highest Efficiency- Lowest Emissions- Longest Run Length

Revamping – Training – Troubleshooting

www.heatflux.com

Client Air Products Location La Porte, TX Scope of Work Review and Inspection of Feed Preheaters Field Survey/Recommendation for Oxygen Analyzers in Feed Preheaters Location Pasadena, TX Scope of Work Development of Steam Reformer Plant Handbook Client Alon USA Location Big Spring, TX Scope of Work Hydrogen Heater Efficiency and Capacity Increase (77H-001) Project

Capacity and Efficiency increase project for Naphtha Stabilizer Reboiler Heater (77-H002)

Increasing Capacity project for Reactor Charge Heater (080-H-001) NOx Reduction and Mechanical Rerating of a Crude Heater NOx Reduction in FCC Unit Charge Heater

Capacity and Efficiency increment for HDS and Reformer Depentanizer Reboiler Heaters

Client Belgian Refining Corp. Location Belgium Scope of Work Engineering Study for tube vibration in Vacuum Feed Heater (B-0702)

Client Bechtel Location Houston, TX

Scope of Work Fired Heaters Design and Documentation Review for Reliance Jamnagar Refinery

Client Burns & McDonnell Location Philadelphia, PA Scope of Work Engineering Services for Specifications and Supply of Process Furnaces Location Philadelphia, PA Scope of Work Simulation for Vacuum Heater with new tube MOC Location Ponca City, OK Scope of Work Design Evaluation of Fired Heater Location Ponca City, OK Scope of Work Evaluation of two existing Heaters for new Operating Conditions

Client Chevron Location Kapolei, HI Scope of Work Simulation Runs of Vacuum Heater Supply of Knock out Drum and Filtering System for Fuel Gas Burner Testing of Crude Heater Supply of New Oil Tips for Crude Heater Burners



www.heatflux.com

Client Chevron Location Pascagoula, MS Scope of Work Review of Vacuum Heater Coking Problem

Client Citgo Location Corpus Christi, TX Scope of Work Engineering Study for Improving Efficiency of Crude and Vacuum Heaters Turnkey supply of GHT Charge Heater Field Survey and Study of Excess Air Reduction in (2) Unibon Heaters Performance Improvement Study for CO Boiler

Efficiency Improvement and Cost Estimate Study for No. 4 Platformer Heater along with Stripper Reboiler and Stabilizer Reboiler Heaters

Design, Engineering and Project Management for Efficiency Improvement for No. 4 Platformer Heater

Engineering Study to Improve Performance of Stabilizer Reboiler

Efficiency Improvement , NOx reduction, and Study of Isostripper Reboiler Heater

Project Design Basis for Capacity Improvement and NOx Reduction for No.5 Platformer Charge Furnace

Modeling and NOx Estimation for No. 5 Platformer Heater Engineering Study for Platformer Heater

Engineering Study for Improving Performance and Capacity of Crude and Vacuum Heaters

Engineering Services for Installing New Burners for Platformer Heater CO Boiler Rerating Report as Flue Gas Cooler Engineering Study of Crude heater (11-F-1)

Client Citgo Location Lake Charles, LA Scope of Work Engineering Study of Vacuum Heater for Naphtha Service CFD Modeling of Air Ducting of Platform Heater

Inspection and Recommendations for Performance Improvements of B-6 Heater

Mechanical Inspection of New Crude and Vacuum Heaters

Basic Design and Specifications of Crude and Vacuum Heaters Including Transfer Lines

Performance Improvement study of (5) Unicracker Heaters with Air Preheating System

Client Citgo Location Lemont, IL Scope of Work Engineering study on CO Boiler



www.heatflux.com

Client

Phillips 66

Location Belle Chasse, LA Scope of Work Crude Heater SCR NOx Reduction Project

NOx Reduction in Heaters 1391-H-4, 1791-H-1 and 291-H-2 Engineering Study

NOx Reduction & Efficiency Improvement for Reboiler Heaters (491-H-1/2)

Client Phillips 66 Location Borger, TX Scope of Work Conversion of Unit No. 40 CO Boiler to Fuel Gas Fired Boiler

Feasibility Study for SCR Installation Downstream Steam Methane Reformer

Engineering Study for Reducing Coking in a Crude Heater Client Phillips 66 Location Ferndale, WA Scope of Work Efficiency Improvement Study for Depropanizer Reboiler Heater

Client Phillips 66 Location Humber, UK Scope of Work Fired Heater Training School

Client Phillips 66 Location Linden, NJ Scope of Work CFD Modeling of Feed Water Distribution in CO Boiler Economizer Coils

Client Phillips 66 Location Los Angeles, CA Scope of Work Performance Improvement Study for Vacuum Heaters H-33/34

Client Phillips 66 Location Mont Belvieu, Texas Scope of Work Engineering Study of Boilers (B0-202)

Client ConocoPhillips Location Ponca City, OK Scope of Work Performance Analysis, Engineering and Project Services for NOx Reduction Client ConocoPhillips Location Rodeo, CA Scope of Work Capacity Improvement Study of Crude and Vacuum Heaters



www.heatflux.com

(B-601 & B-602)

Client Phillips 66 Location Roxana, IL Scope of Work Design, Fabricate and Deliver a New Natural Draft Box Vacuum Heater Engineering Study of Boiler Design and Engineering Services for new 165 MMBtu/hr Hot Oil Heater CCU1 & CCU2 Steam Drums Re-Rate Study CO Boiler Tuning Engineering Study for Vacuum Heater and Transfer Line Rerating Engineering Drawings for Steam Methane Reformer Heater Rerating to Hydrotreating service using S-Zorb Process CR-3 Heaters (H4 &H5) –NOx Reduction and Capacity Increase Project Engineering Study for Rerating Reformer Heaters with Low NOx Burners Burner Rerating and Analysis for Hydrocracker Charge Heater

Design of new Convection Section and Recommendations for Improved Performance of CFHT Heater

Engineering Study for CCU1 CO Heater (H-1) Convection Section

Detailed Engineering & Project Services for Burner Replacement in CFHT Heater

Energy Audit of (4) Fired Heaters Engineering Study to Increase the Capacity of CO Heater Engineering, Procurement & Supply of HCU/CR1 Ducts Supply of Peep Doors for Heaters Training for Operators on H-4 and H-5 Heaters Process design package for a waste heat boiler for an SCR installation Engineering Study of Coker Preheater (H-36) Modeling Study on H1 and H2 Heater

Client ConocoPhillips Location Santa Maria, CA Scope of Work Field Survey of Crude Heaters

Client ConocoPhillips Location Trainer, PA Scope of Work Engineering Study to Increase Capacity of Isocracker Charge Heater Engineering Study of Fractionator heater Engineering Study – Burner Replacement

Client ConocoPhillips Location Wilhelmshaven, Germany Scope of Work Field Optimization of Three Fired Heaters (B1402, B1901 and B1201)



www.heatflux.com

Engineering Study on Crude Heater B-1101 and B-1102 Client

CountryMark CO-OP

Location Mt. Vernon, IN Scope of Work Vacuum Heater Capacity Increase Revamp Project Capacity Increase project for Naphtha Splitter Reboiler Capacity Increase Revamp for Reactor Charge Heater (210-H-100) Engineering Study of Unifiner Heater (400-H5) Engineering Study of Crude & Vacuum Heater (200-H2)

Client Devon Energy Location Riverton, WY Scope of Work Turnkey Supply of New Hot Oil Heater

Client Exxon Mobil Location Chalmette, LA Scope of Work Field Survey of Atmospheric Heater F-5

Client Foster Wheeler Location Port Arthur, TX

Scope of Work Engineering Study for Identifying Shortfall in Performance of First Stage Charge Heater

Client Frontier Oil Location El Dorado, KS Scope of Work Engineering Study for Performance Improvement of (2) Fired Heaters Engineering Study for Performance Improvement of Crude Furnace

Engineering and Specifications for New Air Preheater and Burner Replacement

Engineering Study of Kerosene Hydrotreater (HTU1) Change Heater ( B-2031)

Client Frontier Oil Location Cheyenne, WY Scope of Work Engineering Study of Charge Heater

Client Georgia Gulf Location Pasadena, TX Scope of Work Engineering Study for Hot Oil Heater

Client Hovensa LLC Location St. Croix, USVI Scope of Work Engineering Study and Evaluation of Air Preheater Systems



www.heatflux.com

Cost Estimation and Specifications for Stack Damper Actuators Efficiency Improvement Study of No.2 Platformer Heater Best Practices Manual for Air Preheaters

Client HPCL Location Visakhapatnam, India

Scope of Work Capacity Increase Project for CDU2 Crude (11-F-01) and Vacuum (12-F-01) Heaters

Client HPCL Location Mumbai, India Scope of Work Capacity Increase project for FRE APS (31-F-01) and VPS (32-F-01) Capacity Improvement Study for P.D.A. Heater Engineers and operators Training Program, August 2010 Client IOCL Location Bongaigaon, India Scope of Work CDU Heater Study Client IOCL Location Vadodara, India Scope of Work Fired Heater Training School, April 2010

Client IOCL Location Gujarat, India Scope of Work Fired Heater Training School, November 2009 Performance Improvement study of Visbreaker Furnace Client IOCL Location Panipat, India Scope of Work Fired Heater Training School, August 2010 Client Jacobs Engineering Location Baton Rouge, LA

Scope of Work Design and Engineering of CCU-2 CO Heater (H-2) Stem Coils and Header Box Modification

Structural Analysis and Design for CCU-1 Heater

Client KNPC Location Ahmadi, Kuwait Scope of Work Engineering Study for Eocene Crude Heater (39-H-001)



www.heatflux.com

Client Koch Industries Location Rotterdam, Netherlands Scope of Work Increase Run Length Engineering Study for Crude Heater

Client Koch Refining Location Corpus Christi, TX Scope of Work Engineering Study of Fractionator Reboiler Heater and Reactor Engineering Study of Atmospheric Heater Engineering Study of First Stage Hydro Cracker Heater Client KTI BV Location Erdol Chemie, Köln, Germany Scope of Work Burner Test for Ethylene Furnaces

Client Lion Oil Location El Dorado, AR Scope of Work NOx Reduction Revamp Project for six Heaters

Client Lyondell/Citgo Refining Location Pasadena, TX Scope of Work Tuning of (8) Fired Heaters for NOx Emissions

Fired Heaters Training of More Than 300 Operators for Safe Engineering Services for Improving the Performance of Fired Heaters

Rerating of Convection Section and Performance Improvement Study Client Mitchell Gas Location Anderson, TX Scope of Work Review of Instrumentation and Control Scheme for Thermal Oxidizer Engineering Assistance for Installation of a Thermal Oxidizer Efficiency Improvement of Hot Oil Heater Supply of New Gas Tips

Client Mitchell Gas Location Tricounty, TX Scope of Work Servicing of Hot Oil Heater

Client Mitchell Gas Location Seven Oaks, TX Scope of Work Review of Inquiry and Bids for Regeneration Gas Heater

Client Mobil Oil Location Beaumont, TX Scope of Work Engineering Study of B-2 and B-3 Vacuum Heaters and APH



www.heatflux.com

Client Motiva Enterprise Location Convent, LA Scope of Work Participation in a RCA Study to Improve the Performance of H-Oil Heater

Client Murphy Oil Location Meraux, LA Scope of Work Field Survey of Crude Heater

Client Orion Refining Location Norco, LA Scope of Work Performance Improvement Study for Coker Heaters Client Paramount Petroleum Refining Location Paramount, CA Scope of Work Heater Simulation for Re-run Tower Heater H-301

Client Pasadena Refining Location Pasadena, TX Scope of Work Engineering Study for Naphtha Hydrotreater Reactor Charge Heater

Client Petrozuata Location Puerto La Cruz, Venezuela Scope of Work Field survey and analysis of (6) Crude Heaters Client

Reliance Industries Limited

Location Mumbai, India Scope of Work Fired Heater Training School, February 2010 Fired Heater Training School, April 2010 Client Raytheon Engineers & Contractors Location Equatorial Guinea Scope of Work Review of Reformer Inquiry Specifications

Client Samsung Engineering America Inc. Location Houston, Texas Scope of Work Consulting and Design Services for fired Heaters

Client Shell Location Deer Park, TX Scope of Work Engineering Study to Restore and Improve the Capacity of Hot Oil Heater

with APH



www.heatflux.com

Client Specified Fuels and Chemicals Location Channelview, TX Scope of Work Tuning of (2) Hot Oil Heaters for Efficiency Improvement

Client Star Enterprise Location Port Arthur, TX

Scope of Work Design, Engineering and Supply of Intermediate Tube sheets, Tube sheet Sleeves and Header Boxes

Field Survey and Modeling of (4) Heaters, Infrared Thermograph of (9) Fireboxes

Client Sunoco Inc. Location Philadelphia, PA Scope of Work Engineering Study of Crude and Vacuum Heater –Tube Replacement Engineering Study of Air Supply duct for Air Flow Distribution

Client Targa Resources Location Mont Belvieu, TX Scope of Work Engineering Study of HRSG Boiler

Client Thermax Ltd., India Location India Scope of Work Thermal Design

Client Texaco Location Port Arthur, TX Scope of Work Modeling of Crude, Vacuum, and Naphtha Reboiler

Client Total Location Antwerpen, Germany Scope of Work Efficiency Improvement Study for Crude Oil Furnace B-5301 Engineering Study for tube vibration in Fractionator feed heater Client Total Location Normandy, France Scope of Work Performance Improvement Study for Hydrocraker Furnaces

(90-F-101, 90-F-102) Client Valero Location Ardmore, OK Scope of Work Feasibility Study of (10) Fired Heaters for Increasing Capacity of the Units Engineering Study for Efficiency Improvement of (3) Crude Heaters



www.heatflux.com

Client Valero Location Houston, TX Scope of Work Survey of Burners during Shutdown Client

Valero

Location Lima, OH Scope of Work Engineering and Project Services for Capacity Increase and NOx Reduction Engineering Study of Crude Furnace

Client Valero Location Norco, LA

Scope of Work CCR Platformer Heater Capacity Increase with Proprietary Split Flow Technology

Client Valero Location Port Arthur, TX Scope of Work Reactor Charge Heater Capacity Increase Project NOx Reduction Study for Boilers 34 & 35 Capacity, Efficiency & Reliability Improvement of (3) Platformer Heaters

Engineering Study for Determining the Cause of Back Firing in Fractionators Feed Heater

Client Valero Location Texas City, TX

Scope of Work Engineering Study of Crude and Vacuum Heaters (H-16 & H-17) Capacity Increase

Engineering and Project Services for Capacity Improvement of Platformer and NHT Heaters

Topper Heater Air Preheating System Engineering Study CDHDS Reboiler Efficiency Improvement Project Engineering Study of Alky Heater Performance Improvements

Client Valero Location Three Rivers, TX Scope of Work Engineering Study for Efficiency Improvement of Crude Heater Client Western Refining Location El Paso, TX Scope of Work Fired Heater Training School

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