Embed Size (px)
DESCRIPTION
Citation preview
Low Cost Value Added Solutions for
Fired Heaters
NOx Reduction
Do it Once, Do it Right
Furnace Improvements Services (FIS) is a full service engineering and consulting company. For
over 14 years, we have been helping end users and owners providing design and engineering services to
reduce their NOx emissions, improve the efficiency and capacity of their fired heaters, boilers and
waste heat recovery units.
FIS have completed over 300 engineering studies and projects. We currently have a team of 45 skilled
engineers on board with offices in Sugar Land, TX and in New Delhi, India. We have experience in de-
sign and revamp all types of refinery fired heaters.
NOx Emissions
Pollutant-emission laws governing combustion equipment are increasing every year. One of the environ-
mental regulations now affecting the Chemical Process Industries (CPI) are the laws covering Nitrogen
Oxides (NOx) emissions.
Finding the means for limiting NOx from fired heaters has become a major thrust of many sectors in the
CPI.
Reducing NOx Emissions in Fired Heaters
The following options are use in the Chemical and Petrochemical companies to reduce NOx emissions.
Flue gas recirculation (FGR). Extracts a portion of the flue gas from the stack and returns it to the fur-
nace along with combustion air. This lowers the peak flame temperature, and cuts thermal-NOx forma-
tion. The addition of flue gas also reduces the Oxygen available to react with the Nitrogen.
Selective Catalytic Reduction (SCR) involves injecting ammonia into the flue gas upstream of a cata-
lyst bed. The chemical reaction involved is:
O2 + 4NO + 4NH3 → 4N2 + 6H2O
NOx and NH3 combine on the catalyst’s surface, forming an
ammonium salt intermediate that subsequently decomposes to
produce elemental Nitrogen and Water. The catalyst lowers
the activation energy of the NOx decomposition reaction,
thereby enabling use of this technology at lower flue gas tem-
peratures. The optimum temp. range for SCR is 600° to 700°F.
Ultra Low NOx Burners, Several designs are available today
that combine two NOx reduction steps into one burner without
any external equipment. These burners typically incorporate
staged air with internal FGR or staged fuel with internal FGR.
Choosing the Best Option for You
FIS has executed several projects regarding low NOx emission. We have the experience and the knowl-
edge to customize the best option for you.
High Quality Technical Work
Case Study
An USA company approach FIS looking for a practical solution
to reduce the NOx in their Crude Heater. This crude heater is the
biggest heater within the clients system, with a heat duty of 750
MMBtu/hr.
The scope was to install a selective catalytic reduction unit, to
reduce NOx emissions to less than 0.01lb/MMBtu. The convec-
tion section was split to get the correct flue gas temperature win-
dow for the SCR. A novel scheme was implemented by FIS that
saved 5 million dollars to the client.
FIS option didn’t require installing new ID fans or duct work.
The ID/FD fans were upgraded. FIS performed the CFD analysis
to ensure there is proper mixing of Ammonia with the flue gases
in the SCR unit and there is uniform distribution of flue gases
over the catalyst bed.
FIS reduced the flue gas temperature leaving stack from 420 deg F to 300 deg F, thus improving the effi-
ciency by 3.5%. The annual fuel savings are approximately 1.5 million dollars.
As you can see, this picture shows the conventional scheme versus FIS scheme. The alternative is to
route the cold and hot flue gas ducting into convection section instead of the stack. The convection sec-
tion is split into two parts by installing a blanking plate. This eliminates the need to install new ID fans
and stack and saves on duct work.
This heater was commissioned in February 2009 and is running successfully ever since.
CONVENTIONAL SCR SCHEME FIS SCR SCHEME
FURNACE IMPROVEMENTS SERVICES
Some of our clients We have an agent near you.
Furnace Improvements Services Inc. 1600 Highway 6 South, Suite 480 Sugar Land, Texas 77478 USA
Tel: (281) 980-0325 Fax: (832) 886-1665
A.G. Furnace Improvements Pvt. Ltd. K-33, Ground Floor
Opp. Balaji Estate, Kalkaji New Delhi, India 110019 Tel: 91-11-405-8-8696 Tel 2: 91-11-262-8-6775
Email: [email protected]
www.heatflux.com
BRAZIL Jose Fleischmann Tel: (+55) 11-5641-4361 Fax: (+55) 11-5641-4361 [email protected]
TAIWAN Douglas Chang Tel: +8862-2706-1544 Mobile: +8869-2106-9827 [email protected]
CANADA Paul Henry Tel: +450-676-3222 Fax: +450-676-5997 [email protected]
U.A.E., OMAN, QATAR Sarwar Ali Tel: +971-6742-5035 Mobile: +9715-0631-7452 [email protected]
INDIA R. Rajamani Tel: + 91 94483 79108 Tel: +91 80 65971113 [email protected]
VENEZUELA, COLUMBIA, ARGENTINA & ARUBA Carlos Alarcon Tel: +58-441-6609-3444 Fax: +58-441-4366-8406 [email protected]
INDIA Ajai Agarwal Tel: +9111-4214-3751 Mobile:+9198-1015-9901 [email protected]
CALIFORNIA, USA David P. Diggins Tel: +94-9497-6551 Mobile:+94-9463-8591 [email protected]
KUWAIT Alex Ambi Tel: +965-2482-9160 ext.126 Mobile: +965-3384-1712 [email protected]
LOUISIANA, USA Charles H. Thatcher Tel: 985-892-4224 Mobile: 985-966-5513 [email protected]
MEXICO Lorena Nieto G. Mobile: (04455)43493284 [email protected]
SOUTHEAST, USA David Gangle Tel: +20-5437-1702 Mobile:+20-5542-7006 [email protected]
SAUDI ARABIA Azfar Mahmood Tel: +966-3899-6333 Mobile: +9665-3451-2635 [email protected]
TEXAS, USA Stan McHugh Tel: +713-839-8788 Mobile:+713-703-8907 [email protected]
Low Cost Value Added Solutions for Fired Heaters
