Fired Heater Design

2005 Q&A and Technology Forum
Principles & Practices Session Crude/Vacuum Distillation & Coking
FIRED HEATER DESIGN & DECOKING TECHNIQUES

Richard Conticello Patrick Bernhagen
Topics of Discussion:
Overview of Heater Design Factors that Influence Coke Formation Overview & Discussion of Decoking Methods Examples of Rapid Fouling on Coker Heaters Example of Design that Would Promote Coke Formation
Operating & Design Parameters Specified by the Process Engineer

Process Unit & Heater Type Number of Passes (target) Heat Absorbed Fluid Flowrates, Temperatures & Pressures (inlet and outlet) Fluid Properties (API, viscosity, specific heat & thermal conductivity) Pressure Drop Allowable Fouling Factor (or coke laydown thickness) Average Heat Flux % Vaporization Injection Steam/Condensate Requirements Turndown, Alternate Cases and Overdesign Operating Capabilities
Other Special Requirements that Influence the Heater Design

Thermal Efficiency Required (Combustion Air Preheat) Forced Draft Fans & Drivers Induced Draft Fans & Drivers Sootblowers Stack Emissions Burner Type (Low NOx Burners, heat release) Post Combustion (SCR) Fuel Characteristics (burner and pilots) Process Fluid Pass Control Heat Input Control Decoking Requirements
Typical Heater Design Parameters

Crude Heater
Thermal Cracking Tendency: Outlet Temperature,F: Pressure Drop, psi: Target Mass Velocity, lb/(sec-ft2): Radiant Heat Flux, BTU/(hr-ft2): Low 625 to 700 150 to 250 250 to 350 10,000 to 12,000

Vacuum Heater
Low/Slight 715 to 800 50 to 75 250 to 350 (except outlet tube) Radiant Heat Flux, BTU/(hr-ft2): 9,000 to 12,000 Size outlet tubes for less than sonic velocity. Thermal Cracking Tendency: Outlet Temperature,F: Pressure Drop, psi: Target Mass Velocity, lb/(sec-ft2):

Visbreaker Heater
Thermal Cracking Tendency: Outlet Temperature,F: Pressure Drop, psi: Target Mass Velocity, lb/(sec-ft2): Radiant Heat Flux, BTU/(hr-ft2): Medium/High 840 to 890 210 to 350 300 to 400 8,000 to 12,000 (soaking/preheating) 6
Minimum Cold Oil Velocity, ft/sec:

Delayed Coker Heater
Thermal Cracking Tendency: Outlet Temperature,F: Pressure Drop, psi: Target Mass Velocity, lb/(sec-ft2): Radiant Heat Flux, Btu/(hr-ft2): Single Fired Heaters Double Fired Heaters Minimum Cold Oil Velocity, ft/sec: High 920 to 940 350 to 400 350 to 450 8,000 to 10,000 12,000 to 15,000 6
Standard Heater Specifications

Heat Duty Process Flow Rate Temperatures In/Out % Vaporization Pressure Drop Allowable Fuel Composition
Special Design Conditions

Fouling Factor (Coke Thickness) Average Heat Flux Inside Film Temperature Limit Tube Side Velocity Requirements Residence Time Requirements
Heater Designer View

Process Duty- Large or Small Heater Off-Design Cases- Variability Needed Heater Type- OK or Suggest Other Type Heat Flux- Indication of Fluid Sensitivity Fouling/Coking Tendencies- Tube Size
Chemical Fouling (Coking)

This fouling is a function of the fluid composition and the residence time at the temperature range that decomposition, cracking and/or coking can occur. (Source: TEMA) Coking has an impact on Pressure Drop, while fouling factor does not.
Crude Heater Flux Selection

Non-Fouling/Coking Services 12,000 Btu/hr-ft2 Mildly Fouling/Coking Services 10,000 Btu/hr-ft2 Highly Fouling/Coking Services < 9,000 Btu/hr-ft2
Effects of Lower Heat Flux

More Radiant Surface Area Required More Process Fluid Pressure Drop More Passes to fit Pressure Drop More Expensive Heater Lower Inside Film Temperature
Inside Film Temperature

Primary indicator of fouling potential for fouling or coking services. Empirical and not directly determined. Can be translated into something that can be directly measured: Tube Metal Temperature TMT
Effects of Higher Fluid Velocity

Higher Inside Coefficient (Direct Function) Lower TMT (Film Temperature) Higher Pressure Drop (Squared function) Potential Return Bend Erosion
Heater Design is a Compromise of Velocity and Pressure Drop

The number of passes and tube diameter are adjusted to match a Good mass velocity while meeting the allowable pressure drop. Too little pressure drop for a viscous fluid can promote fouling and shorter run lengths.
Residence Time
Time above a specific critical operating temperature can determine tube size, pass arrangement and tube length. It can override previous design considerations.
Heater Types
Vertical Cylindrical Cabin Horizontal Tube Box Double Fired Horizontal Tube
Types of Heavy Oil Fired Heaters

Crude & Vacuum Heaters
Vertical Cylindrical Tube- Low Fouling Fluid Horizontal Tube Cabin/Box- Higher Fouling Fluid
Visbreaker & Coker Heaters

Horizontal Tube Single or Double Fired Design
Vertical Cylindrical Heaters

Lowest Plot Space (Tube Pulling is Upward) Usually Least Cost Highest Radiant Flux Variation- Top to Bottom Typically used for Clean Services Can be Mechanically Pigged
Vertical Cylindrical Heater
Horizontal Tube Heater

Even Heat Flux to Full Tube Length Better Heat Flux Profile- Top to Bottom Large Plot Space (Tube Pulling Outward) Can be Mechanically Pigged Better Design for Severely Fouling Service
Singled Fired Heaters

The most common firing pattern for Heaters Used on Light, Non-asphaltenic VR Peak Flux is 80% above Average Heat Flux
Single Fired Horizontal Tube Heater

(4-pass arrangement)
Double Fired Heaters

Used on Difficult, High Fouling Feedstocks: i.e. High Asphaltenes, Hydrocracked VR High in-tube Velocity, Short Residence Time in Radiant Section More Uniform Heat Flux Around the Tube Higher Average Flux for Same TMT, thus Less Radiant Surface Needed Peak Flux is Only 20% above Average Heat Flux
Double Fired Horizontal Tube Heater

(2-pass arrangement)
CIRCUMFERENTIAL RADIANT HEAT FLUX DISTRIBUTION
SINGLE FIRED TUBES
CIRCUMFERENTIAL RADIANT HEAT FLUX DISTRIBUTION DOUBLE FIRED TUBES
Factors that Influence Coke Formation

Heater Charge Properties Sodium Content causes rapid fouling Asphaltene Content increases fouling Calcium Content Flow Improvers- potential increase in fouling Crude Properties API & viscosity

Operating Parameters
High Heater Outlet Temperatures Process Velocity Low Mass Velocity, Increases Film Temperature Loss of Velocity Steam Low Cold Oil Velocity (target 6 ft/sec minimum) Uneven Heat Distribution - hot spots or cold spots in firebox Residence Time Above Cracking Threshold Low Flow (Turndown) or Poor Flow Distribution Feed Interruptions

Other Issues
Changes Made During Heater Revamp: Change to Low NOx Burners Fuel Heating Value Changes Heavier API Crude Feed Addition of Air Preheat Change Size, Number, and/or Metallurgy Fuel Contaminants- Tip Plugging
Heater Decoking Options

Steam-Air Decoking (Steam & Air Burn)
Performed when heater is off-line Heater box temperature is reduced/cooled
Mechanical (Pigging)
Performed when heater is off-line Heater box temperature is cooled
On-Line Spalling
Performed while heater is in service 1 pass is taken out of service while other passes remain on-line
Heater Decoking Option Summary Table

Type of Heavy Oil Heater Delayed Crude Vacuum Visbreaker Coker Heater Heater Heater Heater Yes Yes Yes Yes Yes Yes Yes Yes N/A N/A Yes Yes
Decoking Option Steam Air Decoking Mechanical On-Line Spalling
Note: Decoking option shown boxed indicates recent client preferences to decoke heater.
Steam-Air Decoking Methodology

Coke is burnt off the heater tubes by firing the furnace in a controlled decoking process by circulating a steam-air mixture at elevated temperatures. Air is used to burn the coke off the tubes. Steam is used to keep the burning temperatures low such that they do not exceed the maximum tolerable temperatures. Typical decoking time 24 to 48 hours per pass depending on amount of coke in tubes.
Mechanical Decoking Methodology (Pigging)

Coke is removed from the heater tube by pumping a metal studded foam or plastic pig with water. The metal studded pig rotates such that it scrapes the coke off the inside of the heater tube. Different size and abrasiveness pigsare used in the decoking process. Pigs are slightly smaller than the inside diameter of the heater tube. Usually pigs are pumped through heater several times forward and backward until overall differential pressure across the tube (inlet to outlet) is restored to its original unfouled condition. Typical decoking time is 18 to 24 hours per heater depending on setup time.
On-line Spalling Methodology

Procedure basis was originally developed by the late Mr. Lloyd Langseth and has been further developed by Foster Wheeler. Coke is removed from the heater tube by varying the steam or condensate flowrate on the fouled tube such that a thermal shock is created that breaks off the coke from the tube. The spalling medium will transfer the coke particles into the heater effluent where it will be collected in the downstream Coke Drum. One pass is spalled while the other coils of the heater remain in normal hydrocarbon service. Typical decoking time is 16 to 24 hours per heater pass.
Steam-Air Decoking
Advantages:
Removes almost all coke from the inside of the tubes Heater firebox does not need to be fully cooled Can be performed by Unit Operators- no outside vendor needed
Disadvantages:
Time & Cost (maintenance & unit loss production) Environmental concerns on venting to atmosphere Disposal of water/coke mixture Potential tube rupture Not found to be effective on crude slates containing inorganic material (i.e. Canadian crudes, some crude flow improvers)
Mechanical Decoking (Pigging)

Advantages:
All coke is removed from the inside of the tubes More environmentally safe than S.A.D. no venting to atm. Pigs do not score inside of tubes Usually performed faster than S.A.D. Clients have reported longer run lengths than S.A.D. Requires outside vendor to perform decoking procedure- unit operators can spend more time on turnaround activities
Disadvantages:
Requires heater to be taken fully out of service Disposition of dirty water required Downtime is 1 to 3 days/heater Cost - specialized decoking vendor needed
On-Line Spalling
Advantages:
Heater remains in service during procedure, one pass at a time Immediate feedback on effectiveness once pass is back in service Allows extended heater run length before pigging is required Coke is collected in downstream coke drum Regular decoking program can be developed by refiner
Disadvantages:
May not get all coke off a particular tube section-still need to eventually fully decoke Potential tube damage due to tube expansion/contraction Potential u-bend corrosion/erosion Potential coke blockage of tube pigging required Can only be performed on 3 or 4 pass heaters with individual pass firing
Rapid Fouling on Coker Heaters

Examples have included:
Spike in Na Content Sludge Deposits/Pipe Scale- after T/A Chemical: Flow Improvers
Added at Well Head Added in Crude Unit
Mechanical: Air Leaks - leads to after burning Operation: Poor Flame Distribution
Example of Design That Would Causes Coke Formation

Horizontal Tube Box Heater in Vacuum Service with multiple passes on each wall.
Mid-Wall Pass Outlet Arrangement Nested Pass on Wall Arrangement
Example of Design Less Susceptible To Coke Formation

Mid-Wall Pass Outlets cause different heat flux and heat input between top pass and the bottom pass on the radiant wall Lower initial cost Sized with similar Radiant Surface Area to the nested design
Example of Design That Would Promote Coke Formation

Nested passes on the radiant wall allow equal heat flux and heat input to each of the two passes More costly due to external jump-overs and the additional coil materials
Summary
As industry moves toward heavier crude slates, attention to fired heater specification and design selection, along with potential fouling tendencies, will become more important in maintaining historical heater run lengths and process unit performance.

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2005 Q&A and Technology Forum

Principles & Practices Session Crude/Vacuum Distillation & Coking