Process Heaters

JOHN ZINK COMPANY
PROCESS HEATERS
JOHN ZINK®
KOCH CHEMICAL TECHNOLOGY GROUP LIMITED
PROCESS HEATERS
THE PURPOSE OF THE HEATER IS TO INCREASE

THE TEMPERATURE OF THE PROCESS FLUID
This has to be done under the following constraints:

 Operate smoothly
 Provide the required turndown of the plant
 Minimize fuel consumption
 Provide safe operations
 Minimize emissions
 Limit combustion noise
JOHN ZINK®
A KOCH INDUSTRIES COMPANY
Vertical Cylindrical - All Radiant
Radiant
Coil
Burner
JOHN ZINK®
Vertical Cylindrical
with Convection Section
Convection Coil
Radiant
Coil
Burner
JOHN ZINK®
Vertical Cylindrical with Helical Coil
Radiant
Coil
Burner
JOHN ZINK®
Cabin (End Fired)
Convection Coil
Radiant Coil
Burners
JOHN ZINK®
Cabin (Floor Fired)
Convection Coil
Radiant Coil
Burner
JOHN ZINK®
Twin Cell Cabin
Convection Coil
Radiant Coil
Burners
JOHN ZINK®
JOHN ZINK®
Arbor or Wicket Type
Convection Coil
Radiant Coil
Burner
JOHN ZINK®
UOP Platformer
Single fired U-Tube: Dual fired U-Tube:
Burners
JOHN ZINK®
Twin Cell Radiant Wall
Convection Coil
Radiant Coil
Burner
JOHN ZINK®
Foster Wheeler terrace wall Downfired Reformer
JOHN ZINK®
Heat Transfer in a Furnace
 By radiation
 By convection
 By conduction
JOHN ZINK®
How do we transfer heat to the coils?
 Overall heat exchange is divided between

radiant & convection section as follows:
 60 to 80 % to the Radiant Coil

 40 to 20 % to the Convection Coil
the split depends on the design of the furnace
JOHN ZINK®
Heat Transfer
Temperature Difference !!!
JOHN ZINK®
Heat Transfer - Conduction
Fourier’s law of heat conduction:

T
q   kA
x
JOHN ZINK®
Heat Transfer - Convection
Newton’s law of cooling:
q  hATw  T 
JOHN ZINK®
Heat Transfer - Radiation
q  1 A1 T  T
1
4
2
4

hv
JOHN ZINK®
Heat Transfer
Conduction
JOHN ZINK®
Factors Affecting Conduction
 Temperature difference
 Thermal conductivity
 Wall thickness
JOHN ZINK®
Conduction
Twall, outside
Twall, inside
Wall Thickness
JOHN ZINK®
Other Factors Affecting Conduction
 Thermal conductivity
 Wall thickness
– Fouling
– Coke
JOHN ZINK®
Conduction
Twall, outside
Twall, inside
Wall Thickness
JOHN ZINK®
Heat Transfer
Convection
JOHN ZINK®
Factors Affecting Convection
 Fluid velocity
 Surface area
JOHN ZINK®
Convection
Process Tfluid Twall, inside

Fluid,
Vfluid
JOHN ZINK®
Furnace Gases
Radiant Tubes
JOHN ZINK®
Furnace Gases
Convection Tubes
JOHN ZINK®
Heat Transfer
Radiation
JOHN ZINK®
Radiation
JOHN ZINK®
Factors Affecting Radiation
JOHN ZINK®
 Emissivity
– Gas = Low emissivity
– Oil = High emissivity
JOHN ZINK®
Gas = Low emissivity
JOHN ZINK®
Oil = High emissivity
JOHN ZINK®
Flame Radiation
 Burner to tube distance

is important
x’  Flame radiation is
directly proportional to
the square of the
distance
 Small burner to tube
2x’ clearance results in
flame impingement, hot
spots, and tube failures
JOHN ZINK®
 Emissivity
– Gas = Low emissivity
– Oil = High emissivity
 View Factor
JOHN ZINK®
Heaters & Heat flux
Typical design main parameters in a Process Heater
Service Heat Flux (*) Mass vel.(^^)
Crude 12,000 250 - 350

Vacuum 12,000 125 - 350
Reboilers 12,000 250 - 350
Asphalt 6,000 250 - 350
Cat.Reformer 12,000 35 - 200 vap.
Visbreaker 8-12,000 600 - 900
(*) Btu/h/Sq.Ft
(^^) Lb/s/Sq.In
JOHN ZINK®
HEAT FLUX
43
Heat transfer sprofil „Heat Flux“: 42

41
Flux Profile
40
39
Test Identification: Test Case 38
37
Test Furnace Number: 14 36

Furnace
35
Bridge Wall Temperature 2100 F 34
33
Air Preheat Temperature 77 F 32
31
O 3.1 % 30
2 29
Fuel Pressure 25.0 psig 28
27
H2 50.0 %
Fuels
26
25
TNG 50.0 % 24
Elevation, ft
23
C3H8 0.0 % 22
Inerts 0.0 % 21
20
Ld (See Ld Calculator) 50.0 in2 19
Burner 18
Split (See Ld Calculator) 7.5 % 17

16
15
14
13
12
11
10
The heat transfer is given by the burner 9
8
geometry and the split of the heat liberation 7
6
floor / side wall. It can hardly be influenced 5
during the operation. 4

3
2
1 Flux, % of Max Flux
0
60 70 80 90 100
JOHN ZINK®
Process heaters
Dry Stack Loss Moisture Loss
Heat to Charge
Setting Losses
Heat to charge
Efficiency = Heat Input
Heat Input
JOHN ZINK®
Process heaters
Thermal efficiency:
process heat
Gross : εth, HHV [%] 
heat input [HHV]
process heat
Net : εth, LHV [%] 
heat input [LHV]
Moisture loss:
Heat lost by not recovering latent heat of water vapour from the combustion
products.
Moisture loss [%]  εth, HHV  εth, LHV
Stack loss:
Heat lost by flue gases at high temperature.
Setting loss:
Heat lost by conductivity through heater walls.
JOHN ZINK®
Draft and Stack
 Function of the stack

 Natural draft & Forced draft
 Importance of draft in a process furnace
JOHN ZINK®
Functions of the Stack
 Furnish the required draft to the combustion

equipment.
 Keep the inside of the heater under negative

pressure in all its parts.
 Discharge the products of combustion to the

atmosphere and keep emissions under control
JOHN ZINK®
Natural and Forced Draft
 Most heaters use natural draft for induction of

the combustion air into the burners.
 The stacks, properly sized in height, are

supplying the required draft to the burners.
 In a forced draft heater, the stack is not the main

source of the air to the burners, but still keeps the
floor at negative pressure.
JOHN ZINK®
Furnace Draft
This force is created by the difference in density

(temperature) between the hot furnace gases and
the colder atmospheric external air.
The hot gases are thus capable to expand and

create a buoyant energy inside the heater,
necessary to induce fresh air into the furnace and to
overcome all the pressure drops encountered
before they exit to the atmosphere.
The draft effect is proportional to the height of the

gas column ( stack height ) and the temperature
difference.
JOHN ZINK®
Static draft effect per foot of stack
height (in WC / ft)
300 °F 0.0044
400 °F 0.0056
500 °F 0.0066
600 °F 0.0074
800 °F 0.0086
1000 °F 0.0094
1200 °F 0.0100
1400 °F 0.0105
1600 °F 0.0109
2000 °F 0.0115
(Air at 60°F)
JOHN ZINK®
Process heaters
Draft increase per height of radiation section, Ambient air temperature 15°C :
1
[mmWC per m height of radiation section]
0.9
0.8
Furnace draft
0.7
0.6
0.5
0.4
0.3
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
Temperature at outlet of radiation section [°C]
JOHN ZINK®
Process heaters
Typical draft profile of a natural draft furnace:
Stack
Convection section
Radiation section
Burners
-1.0 -0.8 -0.6 -0.4 -0.2 0

mbar
JOHN ZINK®
Positive and Negative Draft
 Typical draft at the top of radiant section :

- 2 to - 3 mm WC.
 Typical draft at heater floor (depends on Radiant
Section height) :
- 5 to - 25 mm WC
 Typical draft gradient inside the radiant section
of a heater is approx. :
0.9 mm WC / 1 meter of height
 The minimum stack draft occurs:
Summertime with low atm. pressure
 The maximum stack draft occurs :
Wintertime, with high atm. pressure
JOHN ZINK®
Importance of draft
The draft control is very important since :
 TOO LOW DRAFT
– Radiant section may have positive pressure
with unsafe operation (hot flue gases escape
from heater)
 TOO HIGH DRAFT

– Air inleakage become significant
JOHN ZINK®
Function of Furnace Linings
 Retain the heat inside the walls

 Minimize heat losses to the outside
 Protect heater structure from excessive heat
 Keep the heater shell temperature at a safe value
for operators
 Radiate heat back to the process fluid in the
radiant section
JOHN ZINK®
Tubes Coils
The tube coils circulate the process fluid inside the

furnace, to be heated.
 Tubes size is determined by the process flowrate
and by the velocity inside the pipes (pressure drop).
 Tubes length is determined by the geometry of
the furnace.
 Tubes material is determined by the stated max. heat
flux and by the corrosive nature of the process fluid.
All tubes are supported and guided by special supports
(tube hangers), both in Radiant and Convection section.
JOHN ZINK®
Bare and extended surfaces
The Radiant Section tubes are always bare, due to

the high heat flux and combustion gas
temperatures.
The extended surface can be used only in the
Convection Section of the heaters.
It may be of three basic types:
 SOLID FINS
 CUT FINS
 SOLID STUDS
JOHN ZINK®
Finned tubes
Example of fin density on a tube.
Example for 5 fins per inch
1 inch
Fin Height
Tube diameter
Tube
Fin thickness
FIN
Tube wall
JOHN ZINK®
Studded Tubes
STUDS (with staggered arrangement)
TUBE
Studs typical arrangement on a tube
JOHN ZINK®
SOOTBLOWERS
Sootblowers are used to clean the external surfaces

of the convection tubes from ash and other
particulates, that may be produced during
incomplete combustion of heavy and/or dirty fuels,
or carried by the fuel itself.
JOHN ZINK®
Steam Consumption Performance
THANK YOU !
International Headquarters:
11920 East Apache
Tulsa, Oklahoma 74116 USA
European Headquarters:
PO Box 83 - Industrielle Riedgen
L3401 Dudelange, Luxembourg
www.johnzink.com
JOHN ZINK®

Process Heaters

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Process Heaters

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JOHN ZINK COMPANY

THE PURPOSE OF THE HEATER IS TO INCREASE

This has to be done under the following constraints:

Single fired U-Tube: Dual fired U-Tube:

 Overall heat exchange is divided between

 60 to 80 % to the Radiant Coil

the split depends on the design of the furnace

Temperature Difference !!!

Fourier’s law of heat conduction:

Newton’s law of cooling:

Process Tfluid Twall, inside

 Burner to tube distance

Service Heat Flux (*) Mass vel.(^^)

Crude 12,000 250 - 350

Heat transfer sprofil „Heat Flux“: 42

Test Furnace Number: 14 36

Ld (See Ld Calculator) 50.0 in2 19

Split (See Ld Calculator) 7.5 % 17

during the operation. 4

Dry Stack Loss Moisture Loss

 Function of the stack

 Furnish the required draft to the combustion

 Keep the inside of the heater under negative

 Discharge the products of combustion to the

 Most heaters use natural draft for induction of

 The stacks, properly sized in height, are

 In a forced draft heater, the stack is not the main

This force is created by the difference in density

The hot gases are thus capable to expand and

The draft effect is proportional to the height of the

Typical draft profile of a natural draft furnace:

-1.0 -0.8 -0.6 -0.4 -0.2 0

 Typical draft at the top of radiant section :

 TOO HIGH DRAFT

 Retain the heat inside the walls

The tube coils circulate the process fluid inside the

The Radiant Section tubes are always bare, due to

STUDS (with staggered arrangement)

Studs typical arrangement on a tube

Sootblowers are used to clean the external surfaces

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