1. Fired process heater (FH) – Video introduction

2. Fired process heater

3. API 560 typical heater types

4. API 560 typical burner types

5. Heater components
Recuperating air
preheating
Indirect closed air
preheating
External air
preheating

6. Applications
Process heaters are used in petroleum refineries, power plants and chemical processing industries such as glass industry, cement plants, petrochemicals and synthetics, olefins, ammonia, fertilizer plants, etc.
In a petroleum refinery the unit operations that utilize process heaters include:
► Distillation
► Fluidized Catalytic Cracking (FCC)
► Alkylation
► Catalytic Reforming
► Continuous Catalyst Regeneration (CCR)
► Thermal Cracking
► Coking
► Hydrocracking

7. Process heater design parts

8. Process heater design parts continues ..
Breeching section – transition between convection and stack to recover as much heat before leaving the former
Convection section or preheater - where heat is removed from flue gas to preheat contents of tubes
Shield section – to shield convection pipes from direct radiant heat
Radiant section or a firebox - where radiant heat from the burner is transferred to tubes (85%). The most expensive part in heater.
Draft - negative pressure (vacuum) of the air and/or flue gas measured at any point in the heater measured in in-H2O water column (WC)

11. Fired process heater draft design

12. Problems in convection section
Draft modes
Flue
Problems in convection section
Tramp air
O2 error
Tall flame
Air damper
/ register
Correct draft
positive draft
Negative draft

13. Fired process heater Furnace Improvements Services Inc.
Vertical cylindrical heater
Inclined firing burner

14. Fired process heater - refractory materials
Refractory is used to shield the heater metal casing to 180°F (API 560 specification).
Refractory materials are:
ceramic fiber – fibrous refractory insulation which can be in the form of refractory ceramic fiber (RCF) or man-made vitreous fiber (MMVF) NOTE: Common forms include bulk, blanket, board, and modules.
castable – insulating concrete poured or gunned in place to form a rigid refractory shape or structure
multi-component lining – refractory system consisting of two or more layers of different refractory types
hot-face layer– refractory layer exposed to the highest temperatures in a multilayer or multicomponent lining
The most common types are castable and ceramic fiber.