This project is related to process furnaces feasibility study for efficiency improvement. Totally 18 process furnaces were studied.
The scope of work for iFluids Engineering includes following activities:
- These furnaces have high stack temperatures and scope for efficiency improvement. Following options are evaluated,
- Providing extra rows in convection section of furnaces, wherever space is available.
- Augmentation of existing APH with Plate type or new APH based on revised acid dew point calculation with respect to revised sulphur specification in fuels.
- Calculation of baseline efficiency based on current operating parameters and suggest measures to improve efficiency.
- Conversion of existing natural draft furnaces to balance draft furnaces.
- Performance improvement options.
- Feasibility of pure O2 injection along with combustion air in furnaces.
- Any other option which the vendor finds suitable.
- To provide acid dew point calculation for all process furnaces.
- Review of existing drawings and datasheets of heater, burner, Fuel composition, FD Fan and APH, PFD and P&IDs of relevant section. And to provide analysis of current operating condition.
- To generate a Prioritization matrix for various options based on techno-economic feasibility & recommend for furnace wise implementation.
- To check adequacy of existing equipment such as FD fan, Burners and APH for all studied cases/ options.
- To ensure that the changes made in APH section should not have any adverse effect on radiation section heat distribution, burner flame pattern, flame impingement, draft of heaters etc.
- To check Thermal and hydraulic adequacy of all process furnaces.
- To check draft to determine air side and flue gas side pressure drop in ducts (if applicable).
- To review if suggested modifications are implementable or constructability is feasible based on preliminary assessment of unit layout.
- Simulation results
- Final Study reports
- GHG reduction potential after implementation of suggested modifications
- Cost estimate with an accuracy of +/- 10% for the suggested modifications.