FIS was contacted by the refinery and requested we develop an economical scheme for improving efficiency. FIS redesigned the convection sections with a “Split Flow Technology” scheme. In this scheme the feed was heated pressure drop across the heater remained the same even at higher capacity, due to this parallel processing. The additional piping used was only half the size of manifolds, and the existing stacks were reused. This scheme was nearly half the cost of conventional revamp. For NOx emissions reduction, FIS evaluated different schemes and arrived at replacing the existing burners with Ultra Low NOx burners with internal flue gas recirculation.
FIS carried out the entire scope of activities from conceptualization to commissioning of this heater revamp. The heater was successfully commissioned in October 2002. After revamp, the thermal efficiency of this heater was increased from 66% to 87% and the NOx emissions were reduced to less than 0.035 lbs Btu. The client is very pleased with the heater performance and has decided to go ahead with a similar revamp of their second reforming furnace.