Item:

• A crude heater, designed for 30,000 barrels per day, of cabin type with 5Cr radiant and shock-row tubes and a carbon steel convection section

Objective:

• To define upgrade options for the furnace so as to allow the capacity of the crude distillation unit to be increased to around 40,000 bbl/day, as part of a refinery debottlenecking project

Approach:

• Definition of basic heater parameters by performing baseline simulations of design and of current operating conditions
• Identification of likely limitations to operation at a higher process throughput
• Proposition of upgrade options to overcome these limitations, with an analysis of the technical advantages and disadvantages of each
• Level 1 life assessment of existing furnace tubes, under conditions pertinent to the favoured upgrade option

Results:

• Six options were identified:
  - operate the furnace unmodified
  - extend the stack to increase draught
  - install a forced draught system
  - install an air preheat system with coupled I/D-F/D fans
  - install a process preheater furnace
  - install a twin furnace in parallel
• Operation with the furnace unmodified would be the most economic option; installation of a process preheater would be the favoured upgrade
• Life assessment indicated that tube replacement would be needed in around 5 years if the furnace were to be operated unmodified
• Careful control of operating conditions would be required if the furnace were to be operated unmodified

Benefits:

• Most cost-effective option defined, and associated advantages and disadvantages identified
• Optimal balance between improved performance, component life and capital spend attained
• Operational, inspection and maintenance requirements identified for successful achievement of the debottlenecking objective