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Fired heaters are used to provide high heat duty, high temperatures, and high heat flux where steam cannot be used. They transfer heat via both convection and radiation. Radiant heat transfer occurs as fuel combusts in the firebox, heating refractory-lined tubes that transfer heat to the fluid being heated. Tubes are mounted around the firebox walls. 50-70% of heat is transferred in the radiant section where flue gas reaches 700-900°C. Further heat is extracted via convection sections before the flue gas exits up the stack. Fired heater design depends on its function, heating duty, fuel type, and air introduction method.

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274 views2 pages

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Fired heaters are used to provide high heat duty, high temperatures, and high heat flux where steam cannot be used. They transfer heat via both convection and radiation. Radiant heat transfer occurs as fuel combusts in the firebox, heating refractory-lined tubes that transfer heat to the fluid being heated. Tubes are mounted around the firebox walls. 50-70% of heat is transferred in the radiant section where flue gas reaches 700-900°C. Further heat is extracted via convection sections before the flue gas exits up the stack. Fired heater design depends on its function, heating duty, fuel type, and air introduction method.

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Fired heaters are used where process heat needs to be supplied

- High heat duty (large reboiler)


- High temperature (where steam can not be used)
- High heat flux
Governing modes of heat transfer in fired heater are convection and radiation. Radiant heat transfer is
used from the combustion of fuel in a fired heater or furnace.

Temperature driving force for radiation heat transfer is far greater than that for convective heat
transfer. Thus for non-fouling surfaces

Fired heater design varies according to

- Function
- Heating duty
- Type of fuel
- Method of introducing air

Combustion takes place in radiant section or firebox which is refractory lined and heat is transferred
to tubes mounted in the chamber through which it passes to the fluid to be heated.

Tubes are mounted around the walls of the radiant section. Temperature of flue gas at end of
radiant section is 700 – 900 deg C. Heat transferred in radiant section is 50-70% of the total heat.

Fuel used for process fired heaters is fuel gas, fuel oil or combination of both.

Heat is further extracted from flue gas in convection section in horizontal bank of tubes.

First few rows of the tubes at the end of radiant section are shock tubes. Able to withstand high
temperatures.

Heat loss from casing is usually 1-3% of the total heat.

Heat loss from the stack is constrained by desire to prevent condensation of water vapor in
convection section. Temperature at which flue gas starts to condense is acid dew point.

Air flow in fired heater:

- Natural draft: Flow of air is created by density difference between hot flue gas and stack.
The stack must be high enough to provide draft.
- Forced draft: Forced draft uses a fan to create the airflow by blowing air into the furnace.
- Induced draft: Induced draft uses a fan between the furnace and the stack, leading to a
pressure in the furnace slightly below atmospheric.
Furnace efficiency:

For a given stack temperature, higher the theoretical flame temperature, the higher the furnace
efficiency.
Lower the stack temperature, higher the furnace efficiency.
Excess air:
Excess air or oxygen is used to ensure complete combustion requirement.
10-15% gaseous fuels
15-20% liquid fuels
Excess oxygen in the flue gas should normally be 3%.
Lesser excess air or air preheating increases theoretical flame temperature and increases furnace
efficiency however is also increases formation of oxides of nitrogen.
Draft:
Draft of the furnace is measured in in. WC or mmWC.

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