FIS Company Brochure

Furnace Improvements Services

Low Cost Value Added Solutions for Fired Heaters

Increased Capacity

Longer Run Lengths

Higher Efficiency

Lower NOx Emissions

Furnace Improvements Services Inc.

1600 Highway 6, Suite 480 Sugar Land, TX 77478

Tel: (281)980-0325 Fax: 1-877-395-0760

A.G. Furnace Improvements Pvt. Ltd. K-33, Kalkaji

New Delhi – 110019 Tel 1: 91-11-405 8 8696 Tel 2: 91-11-262-8 6775

Email: [email protected] Web: www.heatflux.com

mailto:[email protected]

Revamping – Training – Troubleshooting www.heatflux.com

Furnace Improvements Global

AUSTRALIA, SINGAPORE, NEWZEALAND, INDONESIA &

MALASYA Kate Gimblett

Tel: +61 (0) 7 5435 2205 Mobile: +61 (0) 417 087 129 [email protected]

TAIWAN Douglas Chang

Tel: 886-2-2706-1544 Mobile:886-921-069-827 [email protected]

BAHRAIN George Mathew

Tel: 00 973 17 785757 (M): 00973 36683942

[email protected]

UNITED ARAB EMIRATES Sarwar Ali

Tel: ++971 6 742 50 35 Mobile:++971 50 6317452

[email protected]

BRAZIL Jose Fleischmann

Tel: (+55) 11-5641-4361 Fax: (+55) 11-5641-4361

[email protected]

VENEZUELA, ARUBA, ARGENTINA, COLOMBIA,

Carlos Alarcon Tel: 58-4416-6093444 Fax: 58-414-3668406

[email protected]

CANADA Paul Henry

Tel: 450-676-3222 Fax: 450-676-5997 [email protected]

CALIFORNIA, USA David P. Diggins Tel: (949)497-6551

Mobile: (949) 463-8591 [email protected]

INDIA

R. Rajamani Tel: + 91 94483 79108 Tel2: +91 80 65971113 [email protected]

Ajai Agarwal Tel: (+9111) 421-43751 Mobile:(+91) 981-01-59901 [email protected]

LOUISIANA, USA Charles H. Thatcher

Tel: 985-892-4224 Mobile: 985-966-5513

[email protected]

KUWAIT Alex Ambi

Tel: (965) 248-29160 ext.126 Mobile: (965) 338-41712 [email protected]

SOUTHEAST, USA David Gangle

Tel: 205 437-1702 Mobile: 205 542-7006

[email protected]

MEXICO Jorge Ruiz Silva

Cel: 1+52 55 54 62 04 0 [email protected]

TEXAS, USA Stan McHugh

Tel: (713)839-8788 Mobile: (713) 703-8907 [email protected]

SAUDI ARABIA Azfar Mahmood

Tel: +966-3-899-6333

[email protected] Mobile: +966-5-3451-2635

UTAH, MONTANA, NEVADA, IDAHO, WYOMING

Allan Woodbury Tel: + 801 274-3333

Mobile: + 801 918-4826 [email protected]



Furnace Improvements Low Cost Solutions for Fired Heaters

Furnace Improvements Services (FIS) was started in March 1996 in Sugar Land, TX. Our mission is to provide services for improving the performance of existing fired heaters in refineries and petrochemical plants. FIS started with conducting engineering studies for fired heaters and provided solutions to customers to overcome operational problems. FIS also saw a need for training young engineers and operators on how to operate fired heaters and started offering heater training courses. For over 15 years, FIS has been helping end users and owners with design and engineering services to improve the performance and efficiency of their fired heaters, boilers and reduce refinery NOx emissions. After handling more than 300 studies and projects for CITGO, Valero, ConocoPhillips, Alon, Frontier and other refineries, FIS has developed into a full service engineering and consulting company. FIS started supplying new heaters on a turnkey basis in 2002. FIS currently has a team of forty-five people employed, with offices in Sugar Land, TX and in New Delhi, India. We have been growing at the rate of 35% per year with a vision to be the ultimate technology provider for fired heaters and boilers. Our Expertise FIS can design and revamp all refinery fired heaters including Crude, Vacuum, Catalytic Reformer, Hot Oil, Coker Heater and CO Boilers. Our skilled group of engineers has a combined experience of over 300 years. FIS also provides design of new fired heaters to end users. Our designs are the most economical, efficient, and reliable. We ensure that key design parameters are not compromised and heaters perform to their full capacity from day one. We are the only heater company that has developed expertise in rating of industrial boilers and CO boilers. FIS has rated boilers for: • Exxon Beaumont (TX) – CO Boiler • Citgo Corpus Christi (TX) – CO Boiler • Valero Port Arthur (TX) – Boiler NOx Reduction • ConocoPhillips Borger (TX) – Boiler NOx Reduction • ConocoPhillips Wood River (IL) - Boiler NOx Reduction • Targa HRSG Boiler (TX) – Performance Improvement • ConocoPhillips Bayway (TX) – Performance Improvement of Economaizer



New Heaters FIS provides these services for design, engineering and supply of fired heaters:

1. Engineering

• Thermal Design and Modeling of New Fired Heaters • Development of API Data Sheets • Mechanical Design • CFD Modeling • Pressure Parts Design • Intermediate Tube Sheets, Hangers Design • Structural Analysis and Design (STAAD) • GA, Fabrication and Erection Drawings

2. Procurement • Material Requisitions and Engineering

Specifications. • Vendor Bid Evaluation • Purchase Requisitions

3. Project Management • Planning and Scheduling • Project Monitoring • Project Progress Report • Vendor Coordination/Follow Up with Client

4. Fabrication • Fabrication Sub-contracted to Renowned

Shops • Shop Inspection and Quality Control

5. Site Services • Job Walk with Erection Contractors • Erection Supervision • Heater Start-Up/Commissioning

New Heater Supply Furnace Improvements has supplied the following heaters: • Citgo Corpus Christi - GHT Heater • Devon Energy - Hot Oil Heater • ConocoPhillips - Hot Oil Heater • ConocoPhillips - Vacuum Heater



Revamping Services Revamping fired heaters is a practical and effective way to improve heater performance. This focuses on working with existing components and as a result, investment and downtime is minimized. FIS projects are accessed in the following areas:

• Capacity Increase • Efficiency Improvement • NOx Reduction

A fired heater revamping project typically has the following phases: Phase I → Engineering Study +/- 30% Cost Estimates. Phase II → Project Design Basis Report with +/- 10% Cost Estimates. Phase III → Detailed Engineering, Project Services, Execution Furnace Improvements’ scope of services includes but is not limited to:

• Design • Engineering • Project Management • Procurement • Fabrication • Site Services

Here are some revamp projects FIS has carried out: • Valero, Wilmington Refinery - Platformer Heater, Capacity Improvement • Citgo, Corpus Christi, TX - Platformer Heater, Efficiency Improvement and NOx

Reduction • ConocoPhillips, Borger, TX - U40 Boiler NOx Reduction FIS office in Delhi carries out Mechanical Design and Detailed Engineering. Due to the time difference, work is performed on a 24 hour basis and at much lower cost kept schedules.



Computational Fluid Dynamics (CFD) Modeling Computational Fluid Dynamics (CFD) involves the solution of mass, momentum and heat transfer equations in a particular domain, which is comprised of the geometry of interest. CFD was developed during the past two decades. Its accuracy in predicting real world problems has improved with the present age computers and better models. At Furnace Improvements we utilize CFD to study the design and operating conditions of heaters, analyze problems and provide solutions. The following are a few areas of concern where FIS has applied this tool:

1. Flow Maldistribution 2. Mixing (Ammonia Injection Grid & Flue Gas Recirculation Mix Box Design) 3. Combustion (Burner & Heater Design) 4. Tube Failures 5. Heat Transfer

Note: The CFD applications are not limited to the listed items. Furnace Improvements is making every effort to explore its varied applications and use this powerful tool if and when it is required. CFD gives a competitive edge over other analysis due to its visual presentation of the observations. FIS has applied the CFD studies in the following cases:

• ConocoPhillips, Roxana, IL - CO Emission Reduction • ConocoPhillips, Alliance Refinery - NOx Reduction of Crude Heater • ConocoPhillips, Borger, TX - U40 Boiler NOx Reduction • ConocoPhillips – Economizer Flow Modeling • Citgo Lake Charles – Modeling of Combustion Air Ducts



FIS Technologies FIS has realized that many heaters present common problems such as:

• Low Capacity • High Tube Skin Temperature • Coking Issues • Bad Burner Flame

FIS developed and patented three different technologies to eliminate these issues Flue Gas Injection, Split Flow and the Inclined Firing System. Flue Gas Injection * Furnace Improvements has developed Flue Gas Injection (FGI) as a remedy to:

• High tube skin temperatures • Coking issues • Increasing capacity but not increasing

radiant flux. This new technology reduces the firebox temperature by taking a part of the flue gas from the stack and injecting it near the radiant tubes through specially designed nozzles in the heater floor. This technology requires the following additional hardware:

• FGI Fan (Induced Draft Fan) • Cold Flue Gas Ducting to Heater Floor

Flue Gas Injection Scheme

*Patent # US 7,484,478 B2



Split Flow Technology* Furnace Improvements has developed a new approach to increase the capacity of fired heaters without increasing the process side pressure drop. “Split Flow” aims at improved utilization of thermal energy for process heating. This is achieved by splitting the process fluid into two parallel streams: Main Stream – The fluid in the first stream is heated predominantly by the convection and

radiant heat transfer mechanism. Split Stream – The fluid in the second stream is heated predominantly by the

convective heat transfer mechanism. The streams are combined at the heater outlet. This technology has been very successful for capacity increase revamps in Platformer Heaters. It is extremely efficient and a low cost process. It is very suitable for an increasing capacity by 15-30%. We have implemented this technology at: • Alon - H2 Heater • Alon - DHT Heater • Citgo Corpus Christi Refinery

• ConocoPhillips - ReformerCatalytic Heater • Valero Texas City Refinery • Valero Wilmington Refinery

Typical Reformer Heater Split Flow Reformer Heater

Revamping – Training – Troubleshooting

*Patent # US 7,204,966 B2

www.heatflux.com


Inclined Firing System * Most tube failures in fired heaters occur due to high tube skin temperatures. Bad burner flames could lead to high tube skin temperatures through flame impingement in the tubes. Furnace Improvements developed the Inclined Firing System technology in order to avoid flame impingement on tubes. The burners are installed at 5-10° angles. With this arrangement the heater will have the following advantages:

• Elimination of flame impingement • Increase of tube life • Increase run length

4'BCD

12'-9"TCD

4'4 ½"

4'4 ½"

Original Firing Scheme

Inclined Firing System

*Patent # US 7,484,478 B2


New Heater Case Studies



Combined Feed Heater The first new heater job by Furnace Improvements (FIS) was for a Corpus Christi refinery. This heater job was executed through Jacobs Engineering Group.


The new vertical cylindrical heater was a combined feed heater with a natural draft. It is used to heat a mixture of hydrocarbon and hydrogen. The heater was designed for a heat duty of 49MMBtu/hr and an efficiency of 82%. FIS’ scope of services included:

• Design

• Engineering

• Fabrication

• Supply

The heater was successfully commissioned in August 2005.

…


Hot Oil Heater Furnace Improvements (FIS) was employed to supply a new Hot Oil Heater (HT-501) for a gas plant in Wyoming.

FIS executed the following activities:

• Process Design

• Mechanical Design

• Structural Analysis

• Material Procurement and Supply

• Field Installation of the Hot Oil

Heater

• Piping

• Instrumentation

• Foundation

FIS supplied the burner management system and procured all the instrumentation controls of the heater. This hot oil heater is designed for a heat duty of 25.0 MMBtu/hr. The heater has an efficiency of 85.3%.

The total duration of this project from start to end was 12 months. This heater was successfully commissioned in August 2007.

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Hot Oil Heater Furnace Improvements (FIS) was employed to supply a new hot oil heater (H-3) in Illinois.

The heater was designed for a total heat duty of 165 MMBtu/hr. The design efficiency of this heater is 88%. This heater is fitted with 18 Ultra Low NOx Burners. FIS executed the heater process, mechanical design, structural analysis, material procurement and fabrication. This heater was supplied in 12 months from the date of award of the contract. The heater was designed in parts and modules to minimize work at the site. All the connections were designed to be bolted connections. This is a 6 pass heater and radiant panels were designed for each pass to fit in each radiant panel. The stack outside diameter is 11’ 3 5/8” and the height is 97’ 2”. This stack was shipped in two pieces which would be bolted at the site. The installation of the hot oil heater has been completed in 2009.

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Vacuum Heater A refinery was facing coking problems in their Vacuum Heater. In addition, they also wanted to revamp the heater to handle Canadian Crude and reduce NOx emissions. FIS did the process study and as a result of the study, the client decided to build a new Vacuum heater with an existing heater foundation. The new heater is 4 ft wider.

This vacuum heater is a horizontal tube box with a convection section. It is designed for a heat duty of 43MMBtu/hr. FIS’ scope involves design, engineering, structural analysis and supply of this heater to the site. The heater has an efficiency of 90%. It was successfully commissioned in March 2009. The heater was delivered within 7 months of starting the job. A few months after the start up, FIS received the following feedback from the client.

“.. we talked about the performance of the VF4 H28 heater since startup. It has been fantastic! The stack temperature is 370-380°F and the fuel gas usage has dropped about 40% from the old heater. This is one of the most efficient heaters in the refinery. The NOx stack testing came back 0.026 lb NOx/MMBtu, which is also outstanding. They are even trying to reduce the O2 even lower, from 4% to 3%. It's a lot different when you have a tight firebox. Great job!!!”

-Client

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Revamping Case Studies



NHT and Platformer Heater Capacity Increase Project

Furnace Improvements (FIS) was employed to develop the best capacity improvement scheme for a #2 Platformer Heater and NHT Heaters. The Platformer Heater (H-20/21/22) was originally designed for 12,000 BPD operation and rated for 119.6 MMBtu/hr process heat duty. The design thermal efficiency of the heater is ~ 88% and was operating at 80 – 81%. Three all radiant heaters (H-18/19/23) along with a 3-cell Platformer Heater, share a common convection section and a stack. The heaters were running at 13,000 to 15,000 BPD charge rate. The client wished to revamp the heaters to 18,000 BPD capacity. The conventional revamp option was to extend the existing radiant cells. The other option was to install a new heater for the extra duty required. Extending radiant cells has the following disadvantages:

• Space limitation • Higher firing rates • Very high cost

FIS’ recommendation was to increase the capacity of the heater with our patented “Split Flow Technology”. Based on this, the convection section was replaced with a new one. The existing convection section was used for steam generation. The new convection section is being used for heating split flow streams for all NHT heaters (H-18/19/23) and Platformer Heaters (H-20/21), in addition to steam generation. The heaters were revamped for 18,000 BPD capacity and a design heat duty of 150.4 MMBtu/hr. The revamp cost was one fourth of the alternate design. The heater firing was limited to the design firing rate. The thermal efficiency of the heaters was increased from 80% to 89%. The heater was successfully revamped in January 2006, not only for increased capacity but also for improved thermal efficiency and improved reliability. In addition, the Platformer Heater burners were replaced with new Ultra Low NOx flat flame burners.

… Revamping – Training – Troubleshooting

www.heatflux.com


Alky Heater (H-2) NOx Reduction and Efficiency Improvement Project

Furnace Improvements (FIS) was hired to perform a turnkey NOx Reduction revamp on an Alky Unit Heater (H-2). The target NOx emission rate was 0.035 lb/MMBtu (HHV). The Alky Heater is a vertical cylindrical heater with a design heat duty of 55 MMBtu/hr. The heater efficiency was very low at 66%. Excess oxygen in the firebox was very high at 8.5%. The heater floor was in bad shape. The heater did not have any stack damper for draft control. FIS’ scope included finalization of thermal design and engineering, procurement of material, fabrication, supply and field installation of the heater. FIS’ scope of services included: • Modification of Existing Floor • Install Eight New Ultra Low NOx Burners (ULNB) • Install New Convection Module • Installation of New Stack and Damper After the revamp, the efficiency increased by 20%. The total cost of the project for the design services, engineering services, fabrication and installation was $1,560,000. The project payout was estimated to be less than 2 years. This heater was successfully commissioned in March 2008.

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Convection Section Modifications in CO Heater for SCR Installation

Furnace Improvements (FIS) was contacted to help with a carbon monoxide (CO) heater (CCU-1) in a fluid catalytic cracking (FCC) unit. It is used to combust the FCC off gas (mainly CO gas) from the spent catalyst regenerator unit. The hot flue gases generated from combustion of FCC off gas are used to preheat the oil and generate super heated steam @ 600 psig / 700 °F. The client was installing a new SCR unit downstream of the CO Heater as a part of their consent decree agreement to reduce the NOX emissions. The new SCR requires a flue gas inlet temperature in the range of 680-700 °F, which required reconfiguring the heat transfer surface in the convection section. Furnace Improvements modeled the convection section for five proposed cases and provided a revised design. The client approved FIS design and we have completed the detail engineering of the revamp convection section. They also had CO slippage problems and post combustion in the convection sections. FIS analyzed this issue as well and came up with a practical solution. FIS developed a computational fluid dynamic (CFD) model of the existing combustion chamber and found out that mixing of FCC off gas and air was very poor in the combustion chamber leading to incomplete combustion in the firebox and post combustion in the convection section.

All modifications to CO Heater (CCU-1) were successfully executed during the February 2008 turnaround.

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Revamping – Training – Troubleshooting www.heatflu

x.com


CDHDS Reboiler Heater (H-60) Efficiency Improvement Project

Furnace Improvements (FIS) was employed by a Texas refinery to develop an efficiency improvement scheme for CDHDS reboiler heater (H-60). The CDHDS reboiler heater is a vertical cylindrical natural draft heater built in 2002. The CDHDS reboiler heater (H-60) was designed for a process duty of 72 MMBtu/hr. With the help of Furnace Improvements it now has a design efficiency of 81%. The heater was operating at an efficiency of 79%, with the flue gas stack temperature of 780°F. FIS reviewed the design and proposed the following changes to improve the efficiency:

• Adding six rows of steam generation coil in convection section

• New stack transition cone • 25 ft of stack extension

In this scheme, 71,000 lb/hr of 450 # steam condensate is flashed to 150 # 2 phase, vapor-liquid stream. Flashing is completed before it enters the convection section. The total heat duty of the heater was increased to 82 MMBtu/hr. The extra 10 MMBtu/hr is absorbed in steam generation coil. Flue gas temperature leaving the stack was reduced at 400°F. The efficiency of the heater was increased to 90%, which brought energy savings of approximately USD $ 590,550 per year. The payback period is 1 year 3 months. This project has been successfully commissioned in October 2007.

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Technical Articles


FIS Company Brochure

Technology

Transcript of FIS Company Brochure