Analytical solutions

Advanced Combustion Control
of Fired Heaters 

Fired Heater is widely used in oil refining and petrochemical industry providing heat for a main process or cracking reaction by fuel combustion.

 

 

Features

EfficiencyEfficiency 

  • Reduce fuel consumption 
  • Increase throughput 

EmissionsEmissions

  • Reduce SCR load
  • Reduce pollutants 
  • NOx
  • CO
  • CO2

LifecycleLifecycle

  • Tuber hanger life
  • Tube life
  • SCR catalyst 

SafetySafety

  • Compliance with API 556
  • Hazard preventive functions to control situation before trip fuel 
  • New layers of protection
    • Real-time fuel density 
    • Near real-time combustibles 
    • Accurate draft pressure 

TDLS8000 Difference

  • Measurement in radiant section Screen Shot 2018-10-08 at 12.46.01 PM
  • Fast detection of CO breakthrough
    • Single digit low limit of quantification
  • Methane detection
    • LOP for startup safety
  • Averaging oxygen across radiant sections
  • Solid state device
  • Not a potential ignition source 

 

 

Laser Based Analysis 

  • Laser based technology is not an ignition source to flue gas and does not require reference air 
  • Response time is less than 2 seconds 
  • When controlling a fired heater's air/fuel ratio near the CO breakthrough point, an IR or laser based CO specific measurement is recommended 
  • Enables advanced combustion control. Oxygen control at less than 1% may be possible. 

Screen Shot 2018-10-08 at 12.53.22 PM

Stoichiometry 101

Screen Shot 2018-10-08 at 12.55.45 PM


Impact of Air Rich Flue Gas

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Impact of Air on Efficiency 

  • Lowering air equals higher coil outlet temp Screen Shot 2018-10-08 at 1.24.55 PM
    • Reduces firing rate = saves fuel 
    • Less emissions 
    • Increased throughput 
  • High convection temperatures = increased coking 



Asset Sustainability  

  • Tubes and hangers designed with minimal thickness 
    • lower temperatures increase life
    • Operating design temperatures cause failures 

Cross Benefits 

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Conclusion

Higher Air  Lower Air
Higher decoking frequency  Less decoking
Increase fuel Less fuel
Higher NOx Lower NOx
Higher Carbon Emissions Lower Carbon Emissions
Higher NH3 injection rate Lower NH3 injection rate
Shorter SCR catalyst life Longer SCR catalyst life
Shorter tube hanger life Longer tub hanger life
Shorter tube life Longer tube life 

 

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