ScheduleRevamp and Innovative Design of Fired Equipment
Monday, October 16
Session 1A / 8:30 AM / WelcomeR. S. Kistler, HTRI
D. Waibel, AFRC/John Zink Company
9:00 AM / Keynote address
Recent developments in respect to the Hottel-Sarofim Zone Method
J. J. Noble, Department of Chemical Engineering, Massachusetts Institute of Technology
10:00 – 10:30 AM / Break
Session 1B / 10:30 AM / Combined fireside and process modeling of delayed coking
M. Henneke, CD-adapco, Tulsa, OK, USA
11:00 AM / Simulation study of an industrial-scale petrochemical furnace
S. X. Chen, M. Lorra, D. Yeates, and C. Jian, Simulation Technology Solutions, John Zink Company, Tulsa, OK, USA
11:30 AM / Particle concentration, flue gas composition and temperature measurements at the furnace exit of a 350 MWe oil fired boiler
A. Diego-Marin and C. Melendez-Cervantes, Instituto de Investigaciones Electricas
12:00 – 1:30 PM / Lunch
Session 1C / 1:30 PM / IFRF Update
L. Tognotti, University of Pisa
2:00 PM / A pilot-scale furnace to simulate full-scale industrial technologies
P. Hughes, P. Gogolek, and P. Lappas, CANMET Energy Technology Centre, Ottawa
(CETC-O), ON, Canada
2:30 PM / Direct fired heater revamps: Multiple goals and expedited solutions
D. Schmitt, Increase Performance, Inc.
3:00 - 3:30 PM / Break
Session 1D / 3:30 PM / Naphtha reforming heater case study
D. Mickity, ConocoPhillips
4:00 PM / Application of flame spectroscopy for alkali metal monitoring in a glass melting furnace
T. Parameswaran and P. M. J. Hughes, CanmetEnergyTechnologyCenter, Nepean
Ontario, Canada
4:30 PM / AFRC Business Meeting
D. Waibel, AFRC/John Zink Company
5:00 - 6:00 PM / Reception
Tuesday, October 17
Session 2A / 8:30 AM / Gas turbine NOx reduction retrofitJ. G. Seebold, Chevron (retired)
9:00 AM / Aspects of energy efficiency upgrades for heating and heat treating furnaces
J. G. Wuenning, WS Inc., Elyria, OH
9:30 AM / OXY-combustion - a viable solution for reduced emissions and minimized
energy consumption
M. Mortberg, R. Tsiava, and P. Recourt, AIR LIQUIDE R&D, Jouy-en-Josas, France;
A. Rensgard and J. Niska, MEFOS, Lulea, Sweden
10:00 - 10:30 AM / Break
Session 2B / 10:30 AM / Towards best practices for flares—International Flare Consortium update
P. Gogolek, CETC-Ottawa, NRCan, Ottawa, Ontario, Canada; J. Pohl, Oryxe Energy International, Irvine, CA, USA; R. Schwartz, John Zink, Tulsa, OK; J. Seebold, Chevron (retired), Atherton, CA
11:00 AM / Innovative steam-assisted flare design
J. Hong, S. Fox, A. Patel, C. Baukal, and K. Leary, John Zink Company, LLC
11:30 AM / Comparing CFD predicted air egression rates into flare stacks to estimates by Husa methodology
J. D. Smith and L. D. Berg, Alion Science & Technology, Tulsa, OK; S. K. Smith, Zeeco, Inc., Tulsa, OK
12:00 - 1:30 PM / Lunch
Session 2C / 1:30 PM / A 3D computer code for simulating gas flares under a variety of wind conditions
A. Suo-Antilla and J. D. Smith, Alion Science & Technology
2:00 PM / Flameless combustion: The next generation of direct fired heaters
W. C. Gibson, Great Southern Flameless, LLC
2:30 PM / Experimental study of flameless combustion in a strong-jet/weak-jet furnace
Y. He, Y. J. Lee, M. D. Matovic, and E. W. Grandmaison, Queen's University, Kingston,
ON, Canada
3:00 - 3:30 PM / Break
Session 2D / 3:30 PM / Effect of coal properties on radiant boiler heat transfer
J. H. Pohl, Oryxe Energy International, Irvine, CA
4:00 PM / Monitoring of pilot scale pulverized coal flames with uv-vis spectroscopic sensor
S. A. Zelepouga, D. Rue, and V. Soupos, Gas Technology Institute, Des Plaines, IL;
A. V. Saveliev, University of Illinois at Chicago
4:30 PM / To be announced
HTRI
Wednesday, October 18
8:30 AM - 12:00 PM / Xfh Workshop - free to all symposium registrantsNotes
Notes
2006 AFRC International Symposiumpage 1
Session 1AMonday, October 16, 20068:30 – 10:00 AM
Session 1A
8:30 AM / WelcomeR. S. Kistler, HTRI
D. Waibel, AFRC/John Zink Company
9:00 AM / Keynote address
Recent developments in respect to the Hottel-Sarofim Zone Method
J. J. Noble, Department of Chemical Engineering, Massachusetts Institute of Technology
Notes
Recent developments in respect to the Hottel-Sarofim
Zone Method
James J. Noble, Department of Chemical Engineering, Massachusetts Institute of Technology
The Zone Method for practical furnace simulation and design had its origins in the 1920’s and 1930’s at a time when digital computers did not exist. This presentation begins with a postscript to a lecture delivered to the AFRC by Professor Hottel circa 35 years ago when the “Long-Furnace” and one zone “Well-Stirred Combustor Chamber” were state of the art furnace design models. Some classic Zoning results will re-visited in the light of modern computational resources. Recently the “Heat Transfer by Radiation” section of Perry’s Chemical Engineers’ Handbook [Section 5, Edition 8] has been completely re-written to include both the classic zoning models as well as the incorporation of Matrix Methods which permit extensive exploitation of modern digital computation techniques to large multizone furnace systems. Subsequently a research program has been initiated at MIT with the goal of development of a multi-dimensional SUPERZONE code which routinely incorporates thousands of zones and will interface with turbulence CFM models such as FLUENT so as to permit resolution of fine-scale furnace behavior. The relation of Zoning to the contemporary Discrete Ordinate Method [DO] and the Finite-Volume Approach [FV] will be discussed. Both of these methodologies are structured [directional discretization] so as to permit allowance for directionally non-isotropic effects such as anisotropic scatter and directionally-dependent surface emission and reflectivity. It is argued that the requisite non-isotropic data are generally not readily available for industrial furnaces nor are directional effects necessarily the dominant phenomenology. Apparently the directional generality which characterizes the DO and FV methods has come at the cost of excessive computation times and loss of accuracy in optically thin or transparent systems.
It is proposed that the Zoning Matrix Approach may well lead to a new benchmark for Engineering Furnace Design with the following characteristics:
1Conceptually simple with a short learning curve for design engineers.
2Computationally robust and fast because it is strictly conservative of radiant energy and is not iterative in nature.
3Allowance for the dependence of gas emissivities on both composition and temperature.
4Ready incorporation of isotropic scatter and perfectly specular surfaces.
The actual detailed mathematics of the Matrix Method will be kept to a minimum. Rather, radiation phenomenology and comparison of methodologies will be discussed in the context of numerous 2D computational examples.
James J. Noble, Research Affiliate, Department of Chemical Engineering, MIT, obtained a B.Ch.E. from RPI and a Ph.D. in Chemical Engineering from the Fuels Research Laboratory at MIT under the supervision of H.C. Hottel and A.F. Sarofim. His is a former Research Professor in the Departments of Civil & Environmental Engineering and Chemical Engineering at TuftsUniversity and was a principal at the TuftsCenter for Environmental Management. His research focused on Computer Modeling of Environmental Systems and Pollution Prevention. He has also taught at ImperialCollege (London) and MIT and held industrial positions at Union Carbide and Cabot Corporations. He is a Registered Professional Engineer in Massachusetts and the UK, is former Editor-in-Chief of Hazardous Waste & Hazardous Materials and is a Fellow of AIChE.
Department of Chemical Engineering 66-460, Massachusetts Institute of Technology
77 Massachusetts Avenue, Cambridge, MA02139-4307
Transfer Technology Associates, 55 Horace Road, Belmont, MA02478-2313
Phone 617-489-0335, mobile 617-827-3910, fax 617-258-5042,
Notes
2006 AFRC International Symposiumpage 1
Session 1BMonday, October 16, 200610:30 AM – 12:00 PM
Session 1B
10:30 AM / Combined fireside and process modeling of delayed cokingM. Henneke, CD-adapco, Tulsa, OK, USA
11:00 AM / Simulation study of an industrial-scale petrochemical furnace
S. Chen, M. Lorra, D. Yeates, and C. Jian, Simulation Technology Solutions, John Zink Company, Tulsa, OK, USA
11:30 AM / Particle concentration, flue gas composition and temperature measurements at the furnace exit of a 350 MWe oil fired boiler
A. Diego-Marin and C. Melendez-Cervantes, Instituto de Investigaciones Electricas
Notes
Combined fireside and process modeling of delayed coking
Mike Henneke, CD-adapco
CFD has been used extensively for fireside modeling of process heaters in petrochemical applications. In a number of cases, process-side modeling has been implemented as well but these models are much less frequent.
This paper discusses work in progress to develop the necessary simulation capability to analyze the multi-phase heat transfer processes including coking within the radiant coil. The purpose of this effort is to extend the runtime of a particular delayed coker but the capability will be generally applicable. Challenges include coupling the necessary physical properties into the CFD analysis and analyzing the multi-phase flow with precipitation of coke particles.
Author
CD-adapco, 3202 S. Memorial, Suite 1, Tulsa, OK 74145
(918) 280-0200 x100,
Simulation study of an industrial-scale petrochemical furnace
S. X. Chen, M. Lorra, D. Yeates, C. Jian
Simulation Technology Solutions, John Zink Company LLC, Tulsa, Oklahoma, U.S.A.
A simulation study of an industrial-scale petrochemical furnace, using Computational Fluid Dynamics (CFD), is presented. This work is part of John Zink Company’s effort to continuously improve its methodology for simulating large refinery process heaters. The wide range of length scales in CFD models of large process heaters with intricate burner configurations leads to large computer memory requirements and demands extended computing resources. Different meshing strategies aimed at reducing the size and complexity of CFD models are studied. Heater performance and burner flame behavior are sensitive to the process side boundary conditions. The effects of different methods for process side boundary treatment are also studied. In order to compare the various modeling methodologies, a data acquisition campaign is carried out on an industrial-scale petrochemical furnace located at John Zink Company’s Test Facility in Tulsa, Oklahoma. The test furnace is equipped with two full-scale process burners. Pertinent process data such as temperature, species, and heat flux are obtained at various location of the furnace.
The presentation with include visual illustrations of the test furnace and the various sections inside the furnace. Burner geometry and arrangement will also be presented. Details of the data acquisition campaign are discussed along with the operating conditions.
Simulation results are discussed in the context of the two main focus areas, i.e., meshing strategy and process side boundary treatment. Comparisons of simulation predictions against measurements are discussed throughout the presentation. More specifically, discussions on comparison of temperature distributions, oxygen and carbon monoxide distributions, and heat flux distribution along the furnace height are presented. Computation efficiency and turn around time are the main focus of the present work. Discussion along these lines is also presented.
Shirley X. Chen is an advanced CFD engineer at John Zink Company’s Simulation Technology Solutions Group. She has over 15 years of experience in the power generation and petrochemical industries. Her areas of expertise include radiative heat transfer, fossil fuel combustion, and computer simulations. She has over 15 papers published in peer reviewed journals and conference proceedings. Shirley obtained her Ph.D. from the University of Oklahoma. She is a current member of ASME and The Combustion Institute.
contact
Particle concentration, flue gas composition and temperature measurements at the furnace exit of a
350 MWe oil fired boiler
A. Diego-Marin and C. Melendez-Cervantes, Instituto de Investigaciones Electricas
Solid particle concentration has beenmeasured simultaneously at the furnace exit and at the stack of a 350 MWe heavy fuel oil fired boiler. In the furnace, water cooled probes of 6 meter in length were introduced on both left and right side walls. Also, flue gas temperature and composition were conducted. The readings were taken from 0.5 m away from the wall, with increments of 0.5 m, until reach almost the center of the furnace cross section.
The particle concentration at the stack was 60% with respect to that obtained at the flue gas furnace exit. Also, asymmetric flue gas temperature profiles (1200 to 1320 °C), and gas composition (200 to 2400 ppm of CO) were found at the inlet of the first superheter tubes. In the walls furnace, large variation of incident heat flux was also found.
Flue gas analyses at the air preheters inlet did not show anomalous conditions on this oil fired boiler. However, it was found a deficient mixing of air and heavy fuel oil in some burners, which produced premature plugging of superheters and air preheaters baskets.
The analyses at the furnace exit can be useful to identify early anomalous conditions that will affect the operation of an utility or industrial boiler.
Author
Instituto de Investigaciones Electricas, Reforma 113, Col. Palmira, 62490,
Cuernavaca, Morelos, México
2006 AFRC International Symposiumpage 1
Session 1BMonday, October 16, 200610:30 AM – 12:00 PM
Session 1C
1:30 PM / IFRF UpdateL. Tognotti, University of Pisa
2:00 PM / A pilot-scale furnace to simulate full-scale industrial technologies
P. Hughes, P. Gogolek, and P. Lappas, CANMET Energy Technology Centre, Ottawa (CETC-O), ON, Canada
2:30 PM / Direct fired heater revamps: Multiple goals and expedited solutions
D. Schmitt, Increase Performance, Inc.
Notes
IFRF update
L. Tognotti, University of Pisa
L. Tognotti
contact information
A pilot-scale furnace to simulate full-scale industrial technologies
P. Hughes, P. Gogolek, and P. Lappas, CANMET Energy Technology Centre, Ottawa, (CETC-O), ON, Canada
The CANMET Energy Technology Centre, Ottawa (CETC-O) has installed a large furnace to compliment their research facility. Previously located at Queen’s University, the Pilot-Scale Industrial Furnace (PSIF) has been moved to CETC-O and will be used to study burner and combustion technologies for application in a variety of industrial processes. The furnace has the inside dimensions, 4.5 m long by 3.0 m wide by 1.0 m high and a maximum firing rate of 1.2 Mw. Originally fitted with 3 wall and 9 roof burners and a recuperator, the PSIF will be configured to study burner technologies such as high temperature air combustion (HTAC), and oxygen firing, and opportunity fuels such as coke oven gas, blast furnace gas, refinery fuel gas and petroleum coke. As well it will handle furnace configurations simulating refinery heaters, kilns and reheat furnaces. The PSIF facility will be flexible enough to simulate full-scale industrial furnace geometries and because of the availability of the advanced probing technologies at CETC-O, unprecedented data will be available for the modelling and understanding of the full-scale burner and furnace technologies. The presentation will focus on the furnace capabilities and the configurations planned for testing.
P. Hughes
contact information
Direct fired heater revamps: multiple goals and expedited solutions
D. Schmitt, Increase Performance, Inc.
This paper will explore two recent projects to demonstrate how a fully integrated engineering, design, and manufacturing firm can make a difference in project execution and completion.
The first project explored is the revamp and modification of an existing crude furnace to eliminate poor burner combustion, draft limitations, tube overheating, and allow increased product throughput, while increasing overall system efficiency. The data requirements and collection methods will be discussed in detail. Following data collection, the thermal rating for the direct fired heater including air preheat is evaluated to determine current operating conditions and then to determine target future operating conditions. A gas side analysis of the fired heater and air preheat system reveals that the existing air heater must be replaced and the burners modified to eliminate existing difficulties and meet future requirements. Initially, burner modifications helped, but later replacement of air heater, elimination of air leakage, and improvements to the ID and FD fan allowed heater to meet and exceed requirements.
The second project explored is the modification and restoration of a furnace built in 1974, but never installed, to make it usable in a new Diesel Hydrotreater Unit being constructed at a refinery in Tyler Texas. This project offered some exciting challenges, such as, modifying a heater originally designed for 24.5 MM Btu/hr absorbed duty at 73% efficiency to a service of 33.0 MM Btu/hr at 89.8% efficiency, and totally structurally re-engineering the unit for a location hundreds of miles from original intended site, and designing and manufacturing missing pieces including the stack support structure, lower plenums, upper breeching duct, ladders and platforms, crossovers, and burners. The thermal design required addition of convection process tube rows as well as a new boiler evaporator section to be added. The added requirement that the burners be a Low NOx design, but utilizing the original burner tiles, along with quick delivery required special design and testing techniques. The restoration problems and solutions are discussed in detail, as well as erection difficulties.
Included are examples and results of methods for radiant and convection section thermal rating, as well as, gas side pressure and temperature loss analysis. The methods/software utilized in these analyses is discussed in the paper. Detailed methods, formulas, and procedures based on Lobo & Evans methods for radiant heat transfer and Escoa method for convection heat transfer in finned tubes are provided as a supplement to the paper to attendees.Attendees will also receive a mini CD loaded with these procedures and many, many useful JavaScript calculators.
David Schmitt is President of Increase Performance, Inc.
Increase Performance, Inc., 11333 E. Pine St.-Ste. 28, Tulsa, OK
2006 AFRC International Symposiumpage 1
Session 1BMonday, October 16, 200610:30 AM – 12:00 PM
Session 1D
3:30 PM / Naphtha reforming heater case studyD. Mickity, ConocoPhillips
4:00 PM / Application of flame spectroscopy for alkali metal monitoring in a glass melting furnace
T. Parameswaran and P. M. J. Hughes, CanmetEnergyTechnologyCenter, NepeanOntario, Canada
4:30 PM / AFRC Business Meeting
D. Waibel, AFRC/John Zink Company
Notes
Naphtha reforming heater case study
Douglas Mickity, ConocoPhillips
ConocoPhillips’ (“COP”) Bayway Refinery owns and operates a 32 kB/D naphtha reforming unit that was commissioned in 1971. The main heater on this unit, F102/3/4/5, is a combined reactor feed preheater / interheater, with five firing cells providing heat to four process coils. A common convection section provides convective pre-heat to the reactor preheat coil and the first interheat coil.
Historically, maintaining design throughput of the naphtha reforming unit has been difficult due to operating limits in F102-5, particularly tube metal temperature and draft limitations. Operation with positive firebox pressure was not uncommon. Conversion to ULNOx burner technology in 1998 exacerbated these problems. Furthermore, at roughly 76% efficiency (LHV basis), and about 350 MMBtu/h firing rate (HHV basis), F102-5 has been cited as one of the “Top Opportunities” in the COP circuit for potential energy savings.