Furnace Improvements (FIS) was employed to develop the best capacity improvement scheme for a #2 Platformer Heater and NHT Heaters.

The Platformer Heater (H-20/21/22) was originally designed for 12,000 BPD operation and rated for 119.6 MMBtu/hr process heat duty. The design thermal efficiency of the heater is ~ 88% and was operating at 80 – 81%.

Three all radiant heaters (H-18/19/23) along with a  3-cell Platformer Heater, share a common convection section and a stack.

The heaters were running at 13,000 to 15,000 BPD charge rate. The client wished to revamp the heaters to 18,000 BPD capacity.

The conventional revamp option was to extend the existing radiant cells. The other option was to install a new heater for the extra duty required. Extending radiant cells has the following disadvantages:

FIS’ recommendation was to increase the capacity of the heater with our patented “Split Flow Technology”.  Based on this, the convection section was replaced with a new one. The existing convection section was used for steam generation. The new convection section is being used for heating split flow streams for all NHT heaters (H-18/19/23) and Platformer Heaters (H-20/21), in addition to steam generation.

The heaters were revamped for 18,000 BPD capacity and a design heat duty of 150.4 MMBtu/hr. The revamp cost was one fourth of the alternate design. The heater firing was limited to the design firing rate. The thermal efficiency of the heaters was increased from 80% to 89%. The heater was successfully revamped in January 2006, not only for increased capacity but also for improved thermal efficiency and improved reliability. In addition, the Platformer Heater burners were replaced with new Ultra Low NOx flat flame burners.