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CO Boiler Convection Replacement

Our client Refinery had a CO Boiler in their Catalytic Cracking Unit. The CO Boiler was more than 40 years old. The CO Boiler convection section is used to preheat the FCC charge and also generate superheated steam at 600 psig/710°F.

The Boiler had problems of low economizer tube metal temperature reaching dew point levels and high superheated steam temperature. There were also problems with the tube supports in the hottest zone.

CO Boiler Convection Section Replacement

Item Units Before Revamp After Revamp
Heat Duty Total MM Btu/hr 182.45 220.83
Process Heat Duty MM Btu/hr 81.55 104.91
Process Flow BPD 41,995 48,000
Process ∆T °F 674-459 694-459
Steam Heat Duty MM Btu/hr 100.90 115.92
Steam Flow Lbs/hr 155,170 190,000
Steam Outlet Temp °F 765 714
Economizer TMT °F 301 318
Stack Temp °F 636 577
Efficiency % 68.0 72.6
Fuel Savings $ / annum

0.55 Million*

*Based on $3.0/MM Btu

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