Modeling Furnaces in the Chemical Process Industry
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1 Modeling Furnaces in the Chemical Process Industry Committed Individuals Solving Challenging Problems 746 E. Winchester St., Suite 120 Murray, Utah
2 REI Profile Slide 2 Energy And Environmental Consulting Firm Specializing In:» Combustion System Design and Performance Analysis» Complex CFD Simulations Performance Emissions Operational Impacts» Customized Software» Specialized Equipment» Proof-of-Concept Testing Strong Network of Experts Objective: Solve Challenging Combustion Problems Using Specialist Talent & Technology
3 REI Modeling Strengths Slide 3 Modeling and Analysis Expertise» Combustion, Fuel Conversion & Pollutant Emissions» Unique, Proprietary Modeling Capabilities & Tools Ability to develop and apply advanced chemistry to CFD and process modeling tools» Qualified Combustion Modelers Understand physics, chemistry, mathematics, software Industrial perspective» Experience Over 200 Combustion Systems Modeled Network of Consultants Objective Analyses
4 Slide 4 Selected Industrial Applications & Clients Applications Melting Furnaces Reheat Furnaces Blast Furnace Injection Flash Smelters Cement Kilns Phosphate Kilns CO Boilers Sulfur Recovery Units Process Heaters Cracking Furnaces Incinerators Thermal Oxidizers Burners Enclosed Flares Selected Clients Bayer BHP BP Cadence Callidus Chemtrade Chevron China Steel Cominco ConocoPhillips CPC CPChem Dow Hexcel Holnam Huntsman Chemicals INCO Inland Steel John Zink LaFarge Lone Star Monsanto NOVA Chemicals PCA Persee Chemical Philip Morris Praxair Searles Valley Minerals Technip Solena Solutia SunCoke Thai Olefins
5 Chemical Process Applications Slide 5 Systems Process Heaters Cracking Furnaces Thermal Oxidizers Incinerators Burners Flares Applications Pollutant Emissions (NOx, CO) Waste Stream Disposal Tube Overheating Heat Flux & COT Uniformity Process Yield & Conversion Radiant Efficiency
6 Why Use CFD Modeling? Slide 6 Modeling is a cost effective approach for evaluating system performance, pollutant emissions, and operational impacts Improve understanding Estimate performance Provide conceptual designs Identify operational problems Cheaper than testing More information than testing Does NOT make decisions for engineers, but does help them be more informed
7 REI s Proprietary CFD Software Slide 7 BANFF & GLACIER» 20+ years development and application» Targeted to gas, oil and coal-fired utility boilers ADAPT» ~10 years development and application» Improved geometry resolution (adaptive mesh refinement)» Advanced chemistry» Improved turbulencechemistry interaction» Targeted to gas-fired ultra low-nox systems and premixed combustion Combustion Chemistry Pollutant/ Emissions Chemistry Turbulence Combustion Surface Properties Radiation & Convection Heat Transfer Particle Reactions
8 Chemical Furnace Modeling Challenges Slide 8 Scales! millimeter meter tens of meters» Geometric resolution» Jet velocities» Chemistry vs turbulent mixing Input accuracy» Garbage-in garbage out Chemical Time Scale Slow time scale 10 0 s Physical Time Scale Trade-off between accuracy and turn-around time Intermediate time scale 10-2 s 10-4 s Time scales of flow, transport, turbulence» What are most critical factors for problem of interest Fast time scales, equilibrium chemistry 10-6 s 10-8 s
9 Furnace Model Requirements Slide 9 Accurately represent furnace geometry and operation Sub-models for:» Turbulent fluid mechanics» Combustion chemistry» Turbulence-chemistry interactions» Finite-rate kinetics for ppm-level NOx, CO» Surface properties» Gas-wall-tube heat transfer (conduction, convection, radiation)» Process chemistry Computationally efficiency (parallel execution)
10 Modeling Approach Slide 10 REI currently uses advanced ADAPT CFD software for process heaters/cracking furnaces Accurate modeling provides accurate flame shape, flow patterns, temperature profiles, major species profiles, heat transfer/heat flux profiles, tube temperatures, process fluid heat absorption Provides capability to analyze:» New generation ultra-low NOx burners for new furnaces and revamps» Burner spacing, distribution and burner-burner interactions» Lower emissions (CO and NOx)» Impacts of fuel changes» Non-uniform heat flux profiles and surface temperatures» Sources and fixes for process or convective tube overheating» Test furnace to full-scale furnace scale-up
11 Sample Uses of Modeling Slide 11 Improved Performance» Enhance furnace efficiency» Lower emissions» Study particulate behavior during de-coking process Reduce risk of new technology» Evaluate burner designs and spacing for new furnaces» Compare different burner designs for furnace revamps» Assess impacts of fuel changes» Evaluate coating impacts» Scale burner performance from test furnace to full-scale furnaces Troubleshooting» Identify causes and fixes for process or convective tube overheating» Identify source of heat flux non-uniformities
12 Pyrolysis Furnaces Slide 12
13 Example - Retrofit Burner Evaluation Full-Scale Pyrolysis Furnace Slide 13 Objectives» Improve flame quality» Maintain low NO x emissions Compare retrofit burners» Flame quality (no rollover)» Low NO x and CO emissions» Heat flux profile Use ¼-furnace model» Capture burner-burner interaction» Capture tube heat flux profiles» Maximize burner resolution
14 Retrofit Burner Evaluation Isosurfaces of 5000 ppm CO Slide 14 Original burner Option 1 Option 2 Option 3 Excess fuel between burners Propensity for flame rollover Limited heat flux distribution Good combination of flame quality and heat distribution
15 Retrofit Burner Evaluation NO x Profiles Slide 15 Original burner Option 1 Option 2 Option 3 Option 3 improved flame quality and slightly lowered NO x emissions
16 Example New Furnace Slide 16 Identified improved burners for new ethylene cracking furnace, helped adjust heat flux design basis Incident Flux
17 Example New Burner Slide 17 Evaluated new ultra low-nox burner performance, helped guide burner spacing and port placement 2500 F 5 mol% O mol% CO Height From Furnace Floor (ft) Average Coils 1-5 Coils 6-10 Coils Coils Incident Heat Flux (Btu/hr-ft 2 ) 2748 Btu/hr-ft 2
18 Example Burner Retrofit Slide 18 Evaluated different burner designs to determine best flux profile and NO emissions for furnace retrofit Height From Floor (m) Burner Coil Aver 1 4 Burner Coil Aver 2 4 Burner Coil Aver 3 4 Burner Coil Aver Surface Temperature NO Concentration Average Net Heat Flux to All Coils (W/m 2 )
19 Example Fuel Change Slide 19 Evaluated performance of back-up fuel with new burners Fuel Fraction CO Concentration Back-up Fuel Baseline Fuel Back-up Fuel Baseline Fuel
20 Industrial Furnaces Slide 20
21 CO Boiler Slide 21 Simulation of a CO boiler with process tubes for heating crude oil. CO plenum was simulated to predict the mixing of injection air into the CO plenum to account for impacts of non-uniform air and CO mixing
22 CO Boiler Slide 22 Simulation of CO oxidation and NOx formation in a CO boiler to assess flue gas properties in the boiler that would impact SNCR design.
23 CO Boiler Slide 23 Simulation of flue gas flow, gas temperature, CO, and NOx distributions in approximately 10 different waste-heat recovery CO boilers augmented by natural gas combustion for assessment of SNCR for NOx control.
24 Refinery Process Heater Slide 24 Simulation of a refinery process furnace for evaluation of impacts of modifications of process tube arrangement to mitigate tube overheating.
25 Spent Acid Furnace Slide 25 Simulation of a spent acid furnace fired by fuel oil. Modeling used to verify adequate fuel burnout and aqueous spent acid vaporization achieved with limited droplet impaction on walls
26 Thermal Oxidizer Slide 26 Simulation of an absorber off-gas oxidizer. Simulations were conducted in order to optimize burnout of the waste gas while minimizing NOx formation.
27 Detailed Example Xylene Reboiler Slide 27 Xylene Splitter Reboiler (XSR) 52.5 MMBtu/hr Firing Rate Xylene (l) Bridgewall Convective Section Circumferential Tubes 95/5% Oil/Gas 20% Excess Air 4 Process Tubes Radiant Section Xylene (l,v) Six Natural Draft Oil/Gas Burners Radiant Tubes Hottest At 1/3 Height (why?) Bridgewall Temperatures Too Hot (measurement system reliable?) Convective Tube Localized Overheating (how to fix?)
28 Flow and Temperature Patterns Slide 28 Recirculating Flow Field Long Flames Mix Slowly CO & O 2 Have Similar Profiles Flames Highly Emissive Flow Velocity Temperature Temperature
29 Temperature Profiles Slide 29 Gas Temperature (F) Radial Gas Temperature Profiles ft ft ft Convection Inlet Profile Impacts: Flame Emission Tube Heat Flux & Temperatures Bridgewall Temperatures Convective Tube Temperatures Radial Distance (ft)
30 Flame Emission Slide 30 Process Tube Emission Dependent on Temperature & Emissivity Peak Flame Emission ~1/3 Up Furnace Flame Peak Incident & Net Flux at Same Height (~1/3 up) Peak Temp at Same Height; Location Agrees With Hot Tube Observation
31 Slide 31 Radiant Section Tube Heat Flux Profiles Flux peak 2/3 down tube Incident Flux (BTU/hr/ft 2 ) Flux peak 1/3 up tube Distance Along Tube (ft) Top crossover 6000 Bottom crossover 4000 Qinc D Qnet D 2000 Net Flux (BTU/hr/ft 2 ) High Flux Locations Correlate with Hot Tube Temperatures
32 Bridgewall Temperatures Slide 32 Temperature Contours Probe Measures Max Temperature Entering Convective Section 1400 F 1420 F Hot Gas Hot Tubes 1400 F 1480 F 1460 F 1440 F 1420 F 1400 F Probe Location Gradient Impacts Measurement & Control of Temperature
33 Convective Section Slide 33 Gas Flow Finned Tubes Bare Tubes Tube D Tube Has 2 Passes in Each of 9 Rows Upper 6 Rows Have Fins, Lowest 3 Rows Are Bare Radiant Load Highest at Lowest Tubes Tube 12 Overheating hotter high velocity flue gas due to more open flow area
34 Convective Section Tube Heat Flux Profiles Slide Qinc D Qnet D Incident Flux (BTU/hr/ft 2 ) Net Flux (BTU/hr/ft 2 ) Distance Along Tube (ft) Observation - Net Flux Changes w/ Finned Tubes
35 Slide 35 Convective Section Tube Temperature Profile 800 Tube Section Tube Skin Temperature (F) Temp D Qnet D Distance Along Tube (ft) High Tube Temperatures Correlate w/ High Net Fluxes Net Flux (BTU/hr/ft 2 )
36 Recommended Modification Slide Reduce Row 4 Fins Tube Skin Temperature (F) Row 9 Row 8 Row 7 Row 6 Row 5 Row 4 Row 3 Row 2 Row 1 Add Row 3 Fins Evens Out Net Flux & Tube Skin Temperatures 450 Baseline 400 Rows 3,4 mod Distance Along Tube (ft)
37 XSR Modeling Conclusions Slide 37 Modeling Useful For Furnace Evaluation» Recirculating Flow with Long, Highly Emissive Flames» Radiant Furnace Tube Temperatures Reflect Flame Emission & Match Observation» Long Flames Create Gradients at Bridgewall Modeling Useful For Furnace Troubleshooting» Temperature Gradient at Bridgewall Impacts Measurements & Control» Convective Tube Temperatures Reflect Net Flux Change with Finned Tubes» Design Modification Identified to Minimize Convective Tube Hot Spots
38 For More Information Slide 38
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