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FIRED HEATERS

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Chemical reactions and processes take place at high

temperatures and hence heat sources are required.

Various sources of heat

Direct fired heaters

Steam heaters

Thermal fluid heaters, e.g., Dowtherm

Electrical heaters

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Fluid In Fluid Out

DIRECT FIRED HEATER

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Steam to various users

including turbines,

charge heaters,Reboilers etc.

Condensate returnto boilers

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Fluid In Fluid Out

to

heatexchangers

THERMAL FLUID HEATER

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Fluid In

Fluid Out

Electrical Power IN

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RADIATIONZONE

FUEL OIL

FUEL GASSTEAM

CONVECTIONZONE

STACK

DAMPER

NATURAL DRAFT FIRED HEATER

AIR

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RADIATIONZONE

FUEL OIL

FUEL GASSTEAM

PLENUM

CHAMBER

CONVECTIONZONE

STACK

FD FAN

DAMPER

FORCED DRAFT FIRED HEATER

AIR FROM ATMOS.

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RADIATIONZONE

FUEL OIL

FUEL GASSTEAM

PLENUM

CHAMBER

CONVECTIONZONE

STACK

ID FAN

FD FAN

DAMPER

BALANCED

DRAFT FIRED

HEATER

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RADIATIONZONE

FUEL OILFUEL GAS

STEAM

PLENUM

CHAMBER

CONVECTIONZONE

STACK

AIR PREHEATER

ID FAN

FD FAN

DAMPER

STEAM

APH

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BOTTOM OR UPFIRED

SIDE OR END FIRED

TOP OR DOWNFIRED

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CYLINDRICAL HEATER WITH VERTICAL COIL

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SECTION

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Arbor type

Inlet header Outlet header

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Utube

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FINNED TUBES - CONVECTION

STUDDED TUBES - CONVECTION

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Bare

tubes

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150mm TO

200mm thick

castablerefractory

Bottomfloor

200mm

thick

castable

refractory

with one

layer of

brick

lining

1300 - 1600 C

800 - 900 C

350 - 450 C

CERAWOOL

LINING CANBE APPLIED

INSTEAD OF

REFRACTORY

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DETAIL OF CERAWOOL LINING

Heater steelexternal

shell

Bitumasticpaint coating

SS304 foil 0.2mm thick for

corrosion resistance

25mm thick cerawool

pads laid one after another.

Cerawool blankets hold

down bolts

Cerawool is not used in

furnaces with oil fired burners.

Cost is high

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Burner floor

refractory

Air

register

Fuel gas

Fuel oilPilot

burner

Burner

tile

BURNER ASSEMBLY

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METALLURGY OF TUBES

Depends on the fluid inside and the temperature to which the

fluid is to be heated

Tube metallurgy Max. temp (C)

Carbon steel 540

1.25% Cr - 0.5%Mo 5952.25% Cr - 1%Mo 650

5%Cr-1%Mo 650

9%Cr-0.5%Mo 705

SS304,SS316,SS321 815

HK40(25Cr-20Ni) 1010

For any selected metallurgy of tubes the design life shall be

minimum 100 000 hours

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Metallurgy of tube supports

Tube metallurgy Max. temp (C)

Carbon steel 427 C

2.25%Cr-1%Mo 649

19%Cr-9%Ni 816

25%Cr-12%Ni (Plate) 87125%Cr-12%Ni (cast) 982

25%Cr-20%Ni(Plate) 871

25%Cr-20%Ni(Cast) 1093

50%Cr-50%Ni 982

If the fuel oil has more than 100ppm vanadium then the

supports shall be 50%Cr-50%Ni or refractory lined for

corrosion resistance purposes.

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IMPORTANT DOCUMENTS TO BE REFERRED

Process licensor datasheet

Vendor datasheet

API 560 - Fired heaters for general refinery services

API 530 - Calculation of heater tube thickness

Equipment drawings for individual heater for more details

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END

STACK

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RADIATIONZONE

FUEL OILFUEL GAS

STEAM

PLENUM

CHAMBER

CONVECTION

ZONE

STACK

AIR PREHEATER

ID FAN

FD FAN

DAMPER