Evaluating hydrogen rich fuel gas firing

A sudden shift to hydrogen rich fuel gas firing may not be prudent if a fired heater is
not designed for it

RUPAM MUKHERJEE and SHILPA SINGH

Engineers India Limited (EIL)

F
ired heaters are designed to tions struggling with their carbon specialised item requiring intricate
combust refinery fuel gas which footprints and may become a way of know-how, and should be suited to
may contain a wide array of keeping greenhouse gas emissions a wide range of fuel gases. Dumping
components including hydrogen. at bay. However, there are various hydrogen into the fuel gas header
Generally, hydrogen content in other factors which should be kept may lead to the fuel gas composi-
refinery fuel gas is limited to 10-30 in mind when planning to shift to tion breaching the range for which
vol% depending on the refinery con- hydrogen rich fuel gas firing. the burners were initially designed.
figuration and hydrogen recovery Such excursions, if they persist for
technologies employed. Hydrogen, Why worry about high hydrogen in a long time, will impact the per-
being a fuel with appreciably higher fuel gas? formance and operation of process
heating value and low energy per Petroleum refineries burn a wide fired heaters. Thus it is imperative
unit volume, has to be treated differ- array of fuel gas mixtures depend- that a detailed study of process fur-
ently. In general, maximum recov- ing on the group of units operating naces is undertaken to evaluate the
ery of hydrogen is attempted across or under shutdown. Accordingly, impact of changing fuel gas com-
the refinery complex due to its high the fuel gas composition can vary position. Hydrogen concentration
commercial value. However, there to a large extent. In general, refin- in fuel gas plays a prominent role
can be instances when a gas stream eries have a complex hydrogen bal- as it sharply alters the molecular
rich in hydrogen has to be routed ance across the complex to ensure weight of the fuel gas mix. Methane,
to the fuel gas header. This article that minimal hydrogen is routed to the other main component, should
addresses the impact on thermal flare or for other non-process uses. also be considered in conjunction
design and performance evaluation Hydrogen being a valuable utility, with hydrogen to work out various
of a fired heater for hydrogen rich its recovery and re-use is maximised scenarios.
fuel gas firing (hydrogen content up to the extent that it is economically
to 90 vol%). As a sample case, a nat- feasible. Basis of case study: parameters and
ural draft furnace of moderate heat However, there can be certain considerations
duty in hydrotreating service has instances due to operational upsets In order to evaluate the impact of
been selected for the study. of certain units or failure of critical hydrogen burning in the fired heater,
The study shows that shifting equipment which may end in dump- there are a few aspects to consider,
from conventional refinery fuel ing precious hydrogen into the fuel like the suitability of the fired heater
gas to hydrogen rich fuel gas may gas header. To add to this concern, design for hydrogen rich fuel gas, the
affect the thermal design and per- operational upsets may last for days suitability of the burner design, and
formance parameters of the furnace while the fuel for a fired heater has a the suitability of fuel piping, control
only marginally, unless the furnace rich composition of hydrogen across valves and other equipment. The
is fired near to metallurgical limits the refinery. When designing fired suitability of the fired heater design
or designed with too little margin to heaters, the gamut of fuel composi- for hydrogen rich fuel gas firing
manoeuvre. tions expected to be fired in the fur- demands thorough evaluation; this
There are enough reasons, nace is well defined. Burners are a article focuses on this aspect through
explained in the following sec- a case study.
tions, for the need for a detailed Combustion parameters of hydrogen and methane The generic combustion
study. It is seen that hydrogen parameters of methane and
rich gas firing helps the environ- Parameter Methane Hydrogen hydrogen are shown in Table
mental cause by reducing carbon Molecular weight, kg/kmol 16 2 1. Several of the parameters
dioxide emissions significantly, Lower heating value, kcal/kg 11 972 28 710 shown in Table 1 are critical
thereby helping the refinery with Energy density, kJ/Nm3 35 831 10 801
when applied to fired heaters.
Standard density, kg/Nm 3
0.716 0.09
carbon credits. Thus, hydrogen Flame speed, m/s 0.55 7.7 For example, hydrogen has a
rich fuel gas firing may be an Air to fuel ratio, kg/kg 20.78 41.2 much higher heating value than
alternative to carbon capture methane. Hence, for the same
and sequestration for installa- Table 1 fired duty the mass of hydrogen

www.digitalrefining.com/article/1002591 PTQ Q1 2021 59

 to be fired is far lower. However, the from the respective unit is bypassed
Design parameters of case study furnace
density of hydrogen is appreciably around the ROG PSA and routed
lower than that of methane. Hence, Parameter Values directly to the header, which can
the volumetric flow of hydrogen Absorbed duty, MMkcal/h 17.2 drive the fuel gas mix to the lighter
required to attain the same heat Fluid phase Two phase side. If ROG PSA is not used in a
Type of fired heater Natural draft
input as for methane is much higher. Number of passes 8 refinery, Case 2 effectively becomes
Accordingly, fuel supply piping, Excess air, % 20 the normal fuel gas scenario.
fittings, and valves need to be ade- Case 3 is an extreme case tak-
quately designed to handle this addi- Table 2 ing into account all of the scenarios
tional volume. described for Case 2. Hence, the shut-
Probably the most critical point to • Case 2: 50% Methane + 50 vol% down of any fuel gas contributing
note is the difference in flame speed, hydrogen units bypassing the ROG PSA for
a measure of the rate at which the • Case 3: 10% Methane + 90 vol% maintenance often results in a fuel
fuel burns. Hydrogen has a flame hydrogen gas mix as high as 80 vol% hydrogen.
speed 10 times that of methane, Case 1 represents a common refin- In the current study, Case 3’s hydro-
which means the chances of flash- ery fuel gas composition where gen content was chosen to check
back of hydrogen at lower loads is hydrogen recovery is maximised the extremes of thermal design and
high. This needs to be taken care of through refinery off-gas pressure to test the metallurgical limits. The
during the burner design to avoid swing absorption (ROG PSA). In results of Case 3 can be extended
flashback of burner flame at lower general, refiners maximise extraction to the more practical scenario of 80
loads, leading to extinguishing of the of hydrogen to the extent that this is vol% hydrogen.
flame and release of unburnt hydro- economically beneficial and provides During the course of the study,
carbons into the firebox, a severe enough energy content for the fuel the following common basis was
safety hazard. gas header. followed:
To address such concerns, a Case 2 is a common refinery ratio • The fuel cases were simulated
detailed study was undertaken. For when any or a group of units which keeping the process absorbed duty
the purpose of the study, a natural are heavy contributors to the fuel unchanged
draft gasoil heater with the configu- gas balance are under shutdown for • The fuel cases were simulated pro-
ration shown in Table 2 was selected. maintenance or upset. For example, viding equal percentages of excess air
The study was carried out using units such as the FCC or DCU con- • A well stirred firebox model is
in-house software programs and tribute to the fuel gas mix; if they are assumed
FRNC 5PC software for the fired shut down, this may drive the refin- • Fouling factor, both inside and out-
heater simulation. ery fuel gas composition towards side tubes, remains the same
Three ratios of methane to hydro- the lighter end. Similarly, if the ROG
gen were considered for analysis: PSA is taken off for maintenance, or Performance analysis of the furnace
• Case 1: 90% Methane + 10 vol% in the event of an equipment level For evaluation, the major parameters
hydrogen upset, the hydrogen rich fuel gas that affect fired heater design were
chosen for comparison. These param-
Performance parameters eters are shown in Table 3.

Parameter Case 1 Case 2 Case 3 Analysis of performance parameters

(90% methane (50% methane (10% methane
+ 10 vol% + 50 vol% + 90 vol% The result table throws out certain
hydrogen hydrogen hydrogen critical inferences. As Figure 1 shows,
Fuel LHV, Kcal/ kg 12 210 13 841 20 800 hydrogen rich fuel gas (Case 3 with
Fuel density, KJ/ Nm3 33 328 23 316 13 304 hydrogen volumetrically around
Rate of fuel fired, kg/hr 1839 1606 1046
Vol. fuel firing rate, Nm3/ sec 0.78 1.10 1.9 90%) has a LHV almost 70% higher
Fuel efficiency, % 76.8 77.5 79 than that of ordinary refinery fuel
Air required, kg/h 38 736 37 130 33 170 gas (Case 1 with 10 vol% hydrogen).
Flue gas flow rate, kg/h 40 572 38 690 34 216 Due to this higher heat content per
Radiant duty, % of total 68 68.8 71
Avg. radiant flux, Btu/h.ft2 9323 9436 9660 unit weight, the fuel efficiency of
Peak radiant flux, Btu/h.ft2 17 266 17 483 17 900 the furnace (see Figure 2) is appreci-
Arch temperature, °C 856 855 858 ably higher when Case 3 fuel is fired.
Ex-convection temperature, °C 444 440 433 Purely on a mass basis and consid-
Max. tube metal temperature, °C 568 574 588
Max fin tip temperature, °C 589 577 557 ering 8000 stream hours, Case 3 will
Film temperature, °C 496 503 516 require 8368 t/y of fuel gas whereas
Relative coking rate 0.953 * 102 0.107 * 103 0.139 * 103 Case 1 would require 14 712 t/y,
Carbon dioxide emitted, t/d 120 94 33 which translates to an improvement
Floor flux density, kW/m2 862 854 838
Adiabatic flame temperature, °C 1770 1806 1904 in fuel efficiency of 2.2% and a fuel
NOx emitted (as predicted by FRNC), ppmv 35 41 61 saving of approximately 6300 t/y.
However, on a volumetric basis, an
Table 3 opposing inference is drawn. As

60 PTQ Q1 2021 www.digitalrefining.com/article/1002591

 35 Rate of fuel fired in kg/hr
Heating value * 10 3
30 1839
25
>

1606
20
1046
15
10

0
0 20 40 60 80 100 Case 1 Case 2 Case 3
Hydrogen vol% in fuel gas mix (90% Methane + (50% Methane + (10% Methane +
10% Hydrogen) 50% Hydrogen) 90% Hydrogen)
Fuel LHV in Kcal/kg
Vol. energy density in Kcal/Nm3 Figure 2 Comparison of fuel efficiency translated as fuel firing rate

Figure 1 Heat content analysis ing. In the long run, such fouling high coking service like a delayed
may prove to be a deterrent in the coker.
Table 3 shows, volumetric flow rate smooth operation of the fired heater. Due to higher heat release poten-
for Case 3 is almost 2.5 times that of This fact is also very well captured tial and lower air flow rate in Case 3
Case 1. Hence, the existing piping in the relative coking rate. As can be fuel gas compared to Case 1, the adi-
and valve systems may become lim- seen from Table 3, the relative cok- abatic flame temperature increases
iting for the additional flow require- ing rate for Case 3 is almost 1.4 times by almost 140°C (see Figure 4) for
ment if the same rate of firing is to be higher. A corollary but very impor- which the software reported value
sustained. tant inference is that the run length of the NOx emission rate is almost
The total flue gas generated for could be reduced by almost 1.5 times doubled. This can be a hurdle when-
Case 3 is almost 15% lower com- had the heater been employed in a ever the emission rates of developed
pared to Case 1. This lower flue gas
flow rate results in lower convective
heat pick-up, resulting in a require- 600
ment for higher radiant heat inten- 580
Max film temp in ˚C Max TMT in ˚C
588
sity. Thus, the radiant duty pick-up 574
for Case 3 is increased by 3% to
560 568
compensate for the loss in convec- 540
tive duty. This additional radiant 520
duty is also depicted by the increase 516
500
in radiant flux. However, the arch 503
496
temperature is not affected much by 480
this increase in radiant flux which 460
means that hardware components
440
such as tube supports might not
Case 1 Case 2 Case 3
need to change. However, the maxi- (90% Methane + (50% Methane + (10% Methane +
mum tube metal temperature, which 10% Hydrogen) 50% Hydrogen) 90% Hydrogen)
happens to be experienced in the
shock section tubes, is elevated by Figure 3 Film temperature and TMT comparison
almost 20°C when Case 3 fuel is fired.
Although this may be acceptable for
1920
fired heaters which are designed
1900
with a certain cushion at the design
Adiabatic flame temperature, ˚C

stage, the increase may not be accept- 1880

able for heaters which have been 1860
operated over a long period or have
1840
been designed with little room for
adjustment. 1820
The film temperature (see Figure 1800
3) is found to increase by 20°C for 1780
Case 3 fuel gas firing compared to
1760
Case 1 fuel gas. It is well known that 0 20 40 60 80 100
an increased film temperature may Vol% of hydrogen in fuel gas
cause fluid deterioration or cracking
if the process fluid is prone to foul- Figure 4 Effect of hydrogen vol% on adiabatic flame temperature

www.digitalrefining.com/article/1002591 PTQ Q1 2021 61

 instances are precursors to major
140
accidents. Secondly, the elevated
Carbon dioxide emission, TPD 120 adiabatic flame temperature may
require a metallurgical or refractory
100
upgrade of the burner components.
80 Increased NOx emissions may be a
60
dampener for such an exercise, hence
it is most important to check the
40 suitability of burners from the origi-
20 nal equipment manufacturer for the
revised operating conditions with
0
0 20 40 60 80 100 respect to pore size, metallurgy suit-
Hydrogen vol% in fuel gas mix ability, and NOx emission levels. For
new fired heaters, all such concerns
Figure 5 Analysis of greenhouse gas emissions can be taken care of by properly
defining the fuel gas at the design
economies apply. Having said this, ing. When firing hydrogen rich fuel stage and through extensive site test-
the increase in NOx emissions can be gas for a heavy fouling fluid such as ing of the burners under simulated
weighed against developing burner delayed coker feed, heavy vacuum site conditions.
technologies or through ultra-low residue, asphalt, or heavy vacuum To sum up, it is evident that
NOx burners which employ fuel gasoil, or for a thermic fluid heater hydrogen rich fuel gas firing on a
staging and flue gas recirculation. heating sensitive hot oil, this increase continuous basis in process furnaces
Thus, the increase in adiabatic flame may prove detrimental to unit relia- warrants a detailed study before
temperature may just push the emis- bility as well as product quality. its introduction. The performance
sions out of bounds for an existing Similar studies on heaters with parameters critical to heater oper-
furnace with burners not designed elaborate air preheat systems may ation need to be evaluated for the
to handle 90% hydrogen fuel gas. need to be undertaken to assess the revised fuel as the heat duty split is
However, if this is taken into consid- extent of the impact. However, the driven towards the radiant section.
eration at the design stage, the NOx directional results from the current Burners also need detailed eval-
emissions problem can be overcome study can be extended to heaters uation by the supplier in case the
through proper burner design and with air preheat systems. shift to hydrogen rich fuel gas is
testing. The decrease in convective heat undertaken in an existing furnace.
Last but not least, in fact the most duty pick-up may prove to be a Another important point stems from
promising aspect is the massive deciding factor for platformer or the reduction in carbon footprint
reduction in CO2 emission rate (see CCR unit heaters which typically which augurs well for sustainable
Figure 5). The carbon emission rate house elaborate steam generating development.
is cut by 70%, approximately 90 t/d. and superheating convection sec-
Acknowledgement
This point is critical when applied to tions. In such cases, the reduced con-
The authors would like to extend their thanks to
nationwide furnaces and boilers. vection duty can cause a fall in steam EIL management for permission to publish this
export from the unit which has to article. Special thanks to Dr Shobha Agarwal,
Conclusions be made up by the utility boilers or Mr S C Gupta, and Ms Indrani Krishnan for their
The current study indicates that it cogeneration units. Thus for CCR valuable suggestions and encouragement.
might not be prudent to suddenly unit heaters, this factor needs to be
Rupam Mukherjee is Senior Manager in EIL’s
shift to hydrogen rich fuel gas firing accounted for. Process Thermal department. With over 12
if the fired heater is not designed The high reduction in CO2 emis- years of experience in the design, engineering
for it. A study of the thermal and sions is a very promising aspect of and troubleshooting of fired heater systems, he
mechanical parameters is warranted this technological shift. Future tech- holds a BTech degree in chemical engineering
before such a decision is taken. nical advances may produce lighter from NIT Durgapur and a master’s degree in
For a natural draft furnace with a components and off-gases, hence the energy and environmental management from
proper design and more space for requirement to fire hydrogen rich IIT Delhi. Email: rupam.mukherjee@eil.co.in
adjustment, shifting to hydrogen rich fuel gas might not be restricted to Shilpa Singh is Deputy General Manager in EIL’s
fuel gas firing might not be a major upsets only, rather it may become the Process Thermal department.With over 23 years
of experience, she leads a team of chemical
issue as most of the thermal and primary design case.
engineers involved in grassroot designs, revamp
mechanical parameters may prove Burners play a key role if any shift
studies, capacity, and efficiency improvement
to be well within limit. However, an to high hydrogen fuel gas is under- projects for fired heater systems. She holds a
increase in tube metal temperature taken. The is all the more important BTech degree in chemical engineering from IIT
and film temperature may need to if it is applied to existing fired heat- Delhi. Email: shilpa@eil.co.in.
be reviewed considering fired heater ers. Burners may not be designed to
service. Increased tube metal tem- sustain such high flame velocities, LINKS
perature and film temperature are which may lead to flashback of flame
primary causes for increased cok- and extinguishing of the fire. Such More articles from the following
categories:
Emissions Reduction
Fired Heaters, Furnaces and Boilers
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