Furnaces
(alsocalledFiredHeaters)
QuickTime and a
TIFF (Uncompressed) decompressor
are needed to see this picture.
JulieKing(2006)
Rev.JohnSandell(2007)
CM4120
FiredHeaters
Whattheylooklike.
FiredHeaters
Ofteninalargechemicalplantorrefinery,
therewillbe50furnaces.
Oftenyouwillpreheatafeedtogetitupto
thetemperatureneededforareactionina
reactor(i.e.,foranendothermicreaction).
Furnacesareoftenusedtopreheatthefeed
beforeitgoesintothereactor.
DirectFiredFurnaces
Wewillfocusondirectfiredfurnaces.
Haveair,fuel(fueloilornaturalgas),and
combustiongasesinthefireboxandthisheats
theprocessstreamsuchasheavyhydrocarbons
(oilsinarefinery)etc.
Processstreambeingheated(likeaprocessgasor
oil)isinsidetubes.
Coolerprocessstreamentersthetopofthefurnace
(convectionsection)andexitsnearthebottom
(radiantsection).
FiredHeaters
BurnerSketch
Burnerslocated
underthe
furnace.
Air/fuelmixes
Getcombustion
Atomizingsteam
usedtogetbetter
air/fuelmixing
Combustion
Rapidchemicalreactionthatoccurswhen
theproperamountsofafuelandoxygenare
combinedwithanignitionsourcetorelease
heatandlight.CO2andH2Oarethe
combustionproductsforacomplete
combustionreaction.
Differentfuelsreleasedifferentamountsof
heat(energy)astheyareburned.
FiredHeater
ComponentsofaFurnace
FuelTrain
Whatisafueltrain?
FireBox
RadiantTubes
ConvectionTubes
DamperandStack
RefractoryLining
BurnersandAirRegisters(letsairinbyburners)
QuickTime and a
TIFF (Uncompressed) decompressor
are needed to see this picture.
FireBoxandRefractoryLayer
Sectioncontainstheburners(underit)
theopenflames,andcombustiongases.
Fireboxislinedwithrefractorybrick
(usuallywhite/tanincolor,lightweight,
chalklike,ceramicmaterial)liningthat
canhandlehightemperaturesand
reflectsheatbackintothefurnace.
FireBoxandRefractoryLayer
Refractorylayerincludesabricklayerand
stainlesssteelrods(sometimesawiremesh)
thatattachtothebrick.
Peepholessotheoperator/engineercan
viewthefireboxflame,getatemperature
reading,etc.
Fireboxtemperaturetypically1,800 oF.
RadiantTubes
Radianttubes(processstreaminsidethem,i.e.oil,
etc)arealongthewallsinthefirebox.They
receivedirectheatfromtheflames(burners).
Sectionoftubesseeshighertemperaturesandhas
afasteraccumulationofcokedepositsoninside
ofthetubes(carbonlikewhenyouBBQon
yourgrill).
Radiantheattransfertypicallyaccountsfor65%
ofthetotalheatabsorbedbytheprocessstream
(oil,etc.).
ConvectionTubes
Convectiontubes(processfluidinsidethem)
areintheroofofthefurnacesoNOTin
contactwiththedirectflamesinthefirebox.
Hotcombustiongasestransferheatthroughthe
metaltubes(oftenfinnedtubestoincrease
efficiency)andintotheprocessfluid.
Convectiveheattransfertypicallyaccountsfor
35%ofthetotalheatabsorbedbytheprocess
stream(oil,etc.).
Whyfinnedtubes?
DamperandStack
Warmairandcombustiongasesleavethe
furnacethoughthestackandenteratmosphere.
Thisnaturaldraft(likeyourchimneyinyour
housethatcarriesthecombustiongasesup)
createsalowerpressureinsidethefurnace.
Draft=atmpressurepressureinsidefired
heater
Typically0.05incheswater(vacuum)bythe
stackdamper
DraftProfile
Damper
Often10ftupinthestackandallows
adjustmentofthestackdraft.
Controlsamountofairintothefurnace.Open
thedamper,andmoreaircomesin.
ControlstheexcessO2intothefurnace.
Typicallywantabout2mol%excessO2or
youwasteenergy(justsendtoomuchhotair
outthestackthatyoudidnotneedtoheat!).
FurnaceControls
TypesofFurnaceDrafts
NaturalDraft:draftisinducedby
buoyancyforcesasthehotairrises
throughthestackandcreatesavacuum
insidefirebox.Pressureinfirebox<
atmpressure
ForcedDraft:fansareusedtoforceair
intotheburners(belowthefirebox)
FurnaceTypesofFurnaceDrafts
InducedDraft:afanisputinthestack
thatenhancesthelowpressureinthe
firebox.
BalancedDraft:uses2fans
1fanpullsairoutthestack
1fanforcesairintotheburners
NaturalandForcedDraft
InducedandBalancedDraft
CommonFurnaceProblems
FlameImpingement:flamesfromthe
burnertouchingatube
Weakensthemetaltubeandcauses
coke(carbon)toforminsidethetube
wheretheprocessfluidflows
Solvebyreducingthefuelsupplyto
theaffectedburner
CommonFurnaceProblems
CokeFormation
Cokingalwaysoccursinsidetheprocess
fluidtubes(typicallytheradianttube
sectionwhereitishottest)inafurnace.
Removecokebyshuttingdownthe
furnace(typicallyonce/3yrs)and
injectingsuperheatedsteamtoremovethe
coke.
CommonFurnaceProblems
ReplaceRefractory
Refractoryinthefireboxbecomesbrittle
andstartstofalloffovertimeathigh
temperatures.
Solvebyshuttingdownthefurnace
(typicallyonce/3yrs)andremovingold
refractoryandinstallingnewrefractory.
CommonFurnaceProblems
FuelCompositionChanges
Fuelcompositionofthefueloilornaturalgas
canchange.
Moreheatafuelproducesduringcombustion,
themoreairisneeded.
Yourprocesscontrolprogramscanhelpyou
here.Controlthe%excessO2(open/close
damper),allowmoreorlessfuelintoburner,
etc.).
CommonFurnaceProblems
ProcessFluidFeedPumpFailure
Furnacewillgettoohot,causingcoking
anddamagingtheequipment(toohotfor
thefurnacematerials).
Trytorestartthefeedpumporstartthe
backupprocessfeedpumpFAST!
Thenisolate(blockoff)theprimaryfeed
pumpandgetitfixedASAP.
CommonFurnaceProblems
Flameout
Occurswhentheburnerflamegoesoutwiththe
fuelstillbeingpumpedintoit.
Nowwehaveunburnedfuelinsidethefurnace.
Oftenhappenswhenthereisnotenoughairinthe
burner.
Solution:Shutdownthefurnace.Stopfuelintothe
burner/furnace.Thisisadangeroussituation!
References
W.L.Luyben,B.D.Tyrus,M.L.Luyben,
PlantwideProcessControl,McGrawHill,
NY,1999.
C.E.Thomas,TheProcessTechnology
Handbook,UhaiPublishing,Berne,NY,
1997.
