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SOLVING HEATER PROBLEMS
UOP can help improve refinery profitability by conducting
detailed heater audits and then strategically targeting
heaters for improvement. Fired heaters are one of the
largest utility users in the refinery, and when not operat-
ing efficiently, can significantly increase operating costs.
UOP can also assess remaining heater life and recom-
mend operating conditions to allow safe heater operation
for years to come.
Our focused approach provides quick, implementable
solutions that will achieve:
Reduced operating costs
Increased charge rates
Improved heater safety
Compliance with government emission regulations.
PHASE I TARGETING
In the targeting phase of the audit, heaters are reviewed
and prioritized based on their criticality. UOP develops a
short list of heaters for which detailed work will follow.
Screening of heaters is based on an economic and techni-
cal evaluation of the following heater information:
Reliability
Operating and maintenance costs
Performance criteria (throughput, cycle length and
environmental limitations)
Visual inspection by UOPs heater specialists
PHASE II DETAILED ANALYSIS
The heater specialist performs a detailed audit for the
heaters on the short list.The on-site activities could
include:
Observing flame patterns, heat distribution, and
tube scaling
Interviewing operators and observe unit operation
in depth
Collecting data for heater simulation and
mass/energy balances of associated equipment
Conducting metallurgical evaluation
Off-site, the specialist models the heater to evaluate the
thermal performance of the process and flue gas. Current
heater operation is compared to design.The operating
profits and expenses for each heater are calculated, and
most profitable operating point is recommended.
Detailed heater audits evaluate the major mechanical
and thermal performance of fired heaters both on the
process and flue gas sides of the heater. Current
HEATER AUDIT
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operation is compared to original design parameters and
to state-of-the-art heater technology. For processes such
as UOPs Platforming process, UOP can provide software
for heater optimization while also maintaining the desired
octane and product quality.
Metallurgical evaluations determine the remaining tube
and tube support life. For refiners already operating
heaters at their maximum, UOP can evaluate the remain-ing heater
life at current conditions, estimate replacement
cost for tubes and tube supports, identify revamp possibil-
ities and recommend new operating conditions based on
the time frame for heater tube replacement.
UOPs final recommendations include the following types
of improvements:
Changes that can be made immediately
Changes that can be implemented at the next
turnaround
Long-term revamp opportunities
REFINERY PROJECTS AND SERVICES
UOP has a unique position in the refining industry since it
has extensive heater operation and design expertise, as
well as in-depth process knowledge. UOP can improve
individual heater performance while taking into account
the affect of heater performance on overall unit and the
profitability in your refinery.
UOP Solutions and Services is a dedicated group of highly
skilled and experienced engineers with strong process,
mechanical and metallurgical backgrounds.Additional sup-
port is provided by UOPs Engineering, Cost Estimating,
Research and Development, and Technical Services
groups.
FOR MORE INFORMATION
For more information, contact your local UOP
representative or contact our Des Plaines sales office:
e-mail: [email protected]
fax: +1-847-391-2253
phone: +1-847-391-2000
UOP 4216-4 xxxxxxxxxxx
2004 UOP LLC. All rights reserved.
The information in this document should not be construed as a
representation for
which UOP assumes legal responsibility, or an authorization or
recommendation to
practice a patented invention without a license.
UOP LLC
25 East Algonquin Road
Des Plaines, IL 60017-5017, U.S.A
www.uop.com
