FIRED HEATERS

Chemical reactions and processes take place at high

temperatures and hence heat sources are required.
Various sources of heat
Direct fired heaters
Steam heaters
Thermal fluid heaters, e.g., Dowtherm
Electrical heaters
Fluid In
Fluid Out
DIRECT FIRED HEATER
Steam to various users
including turbines,
charge heaters,
Reboilers etc.
Condensate return
to boilers
Fluid In
Fluid Out
to
heat
exchangers
THERMAL FLUID HEATER
Fluid In
Fluid Out
Electrical Power IN
RADIATION
ZONE
FUEL OIL
FUEL GAS
STEAM
CONVECTION
ZONE
STACK
DAMPER
NATURAL DRAFT FIRED HEATER
AIR
RADIATION
ZONE
FUEL OIL
FUEL GAS
STEAM
PLENUM
CHAMBER
CONVECTION
ZONE
STACK
FD FAN
DAMPER
FORCED DRAFT FIRED HEATER
AIR FROM ATMOS.
RADIATION
ZONE
FUEL OIL
FUEL GAS
STEAM
PLENUM
CHAMBER
CONVECTION
ZONE
STACK
ID FAN
FD FAN
DAMPER
BALANCED
DRAFT FIRED
HEATER
RADIATION
ZONE
FUEL OIL
FUEL GAS
STEAM
PLENUM
CHAMBER
CONVECTION
ZONE
STACK
AIR PREHEATER
ID FAN
FD FAN
DAMPER
STEAM
APH
BOTTOM OR UPFIRED
SIDE OR END FIRED
TOP OR DOWNFIRED
CYLINDRICAL HEATER WITH VERTICAL COIL
SECTION
Arbor type
Inlet header
Outlet header
U tube
FINNED TUBES - CONVECTION
STUDDED TUBES - CONVECTION
Bare
tubes
150mm TO
200mm thick
castable
refractory
Bottom
floor
200mm
thick
castable
refractory
with one
layer of
brick
lining
1300 - 1600 C
800 - 900 C
350 - 450 C
CERAWOOL
LINING CAN
BE APPLIED
INSTEAD OF
REFRACTORY
DETAIL OF CERAWOOL LINING
Heater steel
external
shell
Bitumastic
paint coating
SS304 foil 0.2mm thick for
corrosion resistance
25mm thick cerawool
pads laid one after another.
Cerawool blankets hold
down bolts
Cerawool is not used in
furnaces with oil fired burners.

Cost is high
Burner floor
refractory
Air
register
Fuel gas
Fuel oil
Pilot
burner
Burner
tile
BURNER ASSEMBLY
METALLURGY OF TUBES
Depends on the fluid inside and the temperature to which the
fluid is to be heated
Tube metallurgy Max. temp (C)
Carbon steel 540
1.25% Cr - 0.5%Mo 595
2.25% Cr - 1%Mo 650
5%Cr-1%Mo 650
9%Cr-0.5%Mo 705
SS304,SS316,SS321,SS347815
HK40(25Cr-20Ni) 1010
For any selected metallurgy of tubes the design life shall be
minimum 100 000 hours
Metallurgy of tube supports
Tube metallurgy Max. temp (C)
Carbon steel 427 C
2.25%Cr-1%Mo 649
19%Cr-9%Ni 816
25%Cr-12%Ni (Plate) 871
25%Cr-12%Ni (cast) 982
25%Cr-20%Ni(Plate) 871
25%Cr-20%Ni(Cast) 1093
50%Cr-50%Ni 982
If the fuel oil has more than 100ppm vanadium then the
supports shall be 50%Cr-50%Ni or refractory lined for
corrosion resistance purposes.
IMPORTANT DOCUMENTS TO BE REFERRED
Process licensor datasheet
Vendor datasheet
API 560 - Fired heaters for general refinery services
API 530 - Calculation of heater tube thickness
Equipment drawings for individual heater for more details
END
RADIATION
ZONE
FUEL OIL
FUEL GAS
STEAM
PLENUM
CHAMBER
CONVECTION
ZONE
STACK
AIR PREHEATER
ID FAN
FD FAN
DAMPER