Furnaces

(alsocalledFiredHeaters)
QuickTime and a
TIFF (Uncompressed) decompressor
are needed to see this picture.

JulieKing(2006)
Rev.JohnSandell(2007)

CM4120

FiredHeaters
Whattheylooklike.

FiredHeaters
Ofteninalargechemicalplantorrefinery,
therewillbe50furnaces.
Oftenyouwillpreheatafeedtogetitupto
thetemperatureneededforareactionina
reactor(i.e.,foranendothermicreaction).
Furnacesareoftenusedtopreheatthefeed
beforeitgoesintothereactor.

DirectFiredFurnaces

Wewillfocusondirectfiredfurnaces.
Haveair,fuel(fueloilornaturalgas),and
combustiongasesinthefireboxandthisheats
theprocessstreamsuchasheavyhydrocarbons
(oilsinarefinery)etc.
Processstreambeingheated(likeaprocessgasor
oil)isinsidetubes.
Coolerprocessstreamentersthetopofthefurnace
(convectionsection)andexitsnearthebottom
(radiantsection).

FiredHeaters

BurnerSketch
Burnerslocated
underthe
furnace.
Air/fuelmixes
Getcombustion
Atomizingsteam
usedtogetbetter
air/fuelmixing

Combustion
Rapidchemicalreactionthatoccurswhen
theproperamountsofafuelandoxygenare
combinedwithanignitionsourcetorelease
heatandlight.CO2andH2Oarethe
combustionproductsforacomplete
combustionreaction.
Differentfuelsreleasedifferentamountsof
heat(energy)astheyareburned.

FiredHeater

ComponentsofaFurnace

FuelTrain
Whatisafueltrain?
FireBox
RadiantTubes
ConvectionTubes
DamperandStack
RefractoryLining
BurnersandAirRegisters(letsairinbyburners)
QuickTime and a
TIFF (Uncompressed) decompressor
are needed to see this picture.

FireBoxandRefractoryLayer
Sectioncontainstheburners(underit)

theopenflames,andcombustiongases.
Fireboxislinedwithrefractorybrick
(usuallywhite/tanincolor,lightweight,
chalklike,ceramicmaterial)liningthat
canhandlehightemperaturesand
reflectsheatbackintothefurnace.

FireBoxandRefractoryLayer
Refractorylayerincludesabricklayerand
stainlesssteelrods(sometimesawiremesh)
thatattachtothebrick.
Peepholessotheoperator/engineercan
viewthefireboxflame,getatemperature
reading,etc.
Fireboxtemperaturetypically1,800 oF.

RadiantTubes

Radianttubes(processstreaminsidethem,i.e.oil,
etc)arealongthewallsinthefirebox.They
receivedirectheatfromtheflames(burners).
Sectionoftubesseeshighertemperaturesandhas
afasteraccumulationofcokedepositsoninside
ofthetubes(carbonlikewhenyouBBQon
yourgrill).
Radiantheattransfertypicallyaccountsfor65%
ofthetotalheatabsorbedbytheprocessstream
(oil,etc.).

ConvectionTubes

Convectiontubes(processfluidinsidethem)
areintheroofofthefurnacesoNOTin
contactwiththedirectflamesinthefirebox.
Hotcombustiongasestransferheatthroughthe
metaltubes(oftenfinnedtubestoincrease
efficiency)andintotheprocessfluid.
Convectiveheattransfertypicallyaccountsfor
35%ofthetotalheatabsorbedbytheprocess
stream(oil,etc.).

Whyfinnedtubes?

DamperandStack

Warmairandcombustiongasesleavethe
furnacethoughthestackandenteratmosphere.
Thisnaturaldraft(likeyourchimneyinyour
housethatcarriesthecombustiongasesup)
createsalowerpressureinsidethefurnace.
Draft=atmpressurepressureinsidefired
heater
Typically0.05incheswater(vacuum)bythe
stackdamper

DraftProfile

Damper

Often10ftupinthestackandallows
adjustmentofthestackdraft.
Controlsamountofairintothefurnace.Open
thedamper,andmoreaircomesin.
ControlstheexcessO2intothefurnace.
Typicallywantabout2mol%excessO2or
youwasteenergy(justsendtoomuchhotair
outthestackthatyoudidnotneedtoheat!).

FurnaceControls

TypesofFurnaceDrafts
NaturalDraft:draftisinducedby

buoyancyforcesasthehotairrises
throughthestackandcreatesavacuum
insidefirebox.Pressureinfirebox<
atmpressure
ForcedDraft:fansareusedtoforceair
intotheburners(belowthefirebox)

FurnaceTypesofFurnaceDrafts
InducedDraft:afanisputinthestack

thatenhancesthelowpressureinthe
firebox.
BalancedDraft:uses2fans
1fanpullsairoutthestack
1fanforcesairintotheburners

NaturalandForcedDraft

InducedandBalancedDraft

CommonFurnaceProblems
FlameImpingement:flamesfromthe

burnertouchingatube
Weakensthemetaltubeandcauses
coke(carbon)toforminsidethetube
wheretheprocessfluidflows
Solvebyreducingthefuelsupplyto
theaffectedburner

CommonFurnaceProblems

CokeFormation
Cokingalwaysoccursinsidetheprocess
fluidtubes(typicallytheradianttube
sectionwhereitishottest)inafurnace.
Removecokebyshuttingdownthe
furnace(typicallyonce/3yrs)and
injectingsuperheatedsteamtoremovethe
coke.

CommonFurnaceProblems

ReplaceRefractory
Refractoryinthefireboxbecomesbrittle
andstartstofalloffovertimeathigh
temperatures.
Solvebyshuttingdownthefurnace
(typicallyonce/3yrs)andremovingold
refractoryandinstallingnewrefractory.

CommonFurnaceProblems

FuelCompositionChanges
Fuelcompositionofthefueloilornaturalgas
canchange.
Moreheatafuelproducesduringcombustion,
themoreairisneeded.
Yourprocesscontrolprogramscanhelpyou
here.Controlthe%excessO2(open/close
damper),allowmoreorlessfuelintoburner,
etc.).

CommonFurnaceProblems

ProcessFluidFeedPumpFailure
Furnacewillgettoohot,causingcoking
anddamagingtheequipment(toohotfor
thefurnacematerials).
Trytorestartthefeedpumporstartthe
backupprocessfeedpumpFAST!
Thenisolate(blockoff)theprimaryfeed
pumpandgetitfixedASAP.

CommonFurnaceProblems

Flameout
Occurswhentheburnerflamegoesoutwiththe
fuelstillbeingpumpedintoit.
Nowwehaveunburnedfuelinsidethefurnace.
Oftenhappenswhenthereisnotenoughairinthe
burner.
Solution:Shutdownthefurnace.Stopfuelintothe
burner/furnace.Thisisadangeroussituation!

References
W.L.Luyben,B.D.Tyrus,M.L.Luyben,
PlantwideProcessControl,McGrawHill,
NY,1999.
C.E.Thomas,TheProcessTechnology
Handbook,UhaiPublishing,Berne,NY,
1997.