[Fired heater calculations]

[Efficiency]

Mohamed Adel 3/15/25 1

 Fired Heater Efficiency

A fired heater is a critical component in various industrial processes, particularly in the oil and gas,
petrochemical, and power generation sectors. It is used to heat fluids through the combustion of fuel,
typically natural gas or oil, within a furnace. The primary objective of a fired heater is to efficiently
provide the required thermal energy to processes such as distillation, cracking, and other heat-
dependent chemical reactions. By ensuring optimal heat transfer and operational efficiency, fired
heaters play a vital role in enhancing the productivity and safety of industrial systems, while also
minimizing energy consumption and emissions. This article explores the design, operation, and
performance of fired heaters, with a focus on improving their efficiency, sustainability, and safety in
modern industrial applications.

 Efficiency calculation

If you are a DCS operator or process engineer you can calculate the efficiency by three ways two of
them are simple which you need a fast value and the other that is mentioned in API 560.

1. First method

Heater efficiency = (Q absorbed / Q fired) - losses

Q absorbed you can calculate it by finding the heat duty you need to
add to the process feed or gas from Q= MCp∆T [add the heat duty of any stream entering the heater
with the feed if found]

Q fired you can calculate it by Q = M*Calorifc value or M*NHV

2. Second method

Heater efficiency = (H@ / NHV) - losses

H@ you can find it from a chart by using FGT

 3. Third method

As mentioned in API 560, it’s as the previous but it adds the sensible heat of fuel gas used and
combustion air.

 Excess air calculation

Excess air in fired heaters is crucial for ensuring complete combustion of fuel, preventing the
formation of harmful pollutants, and optimizing energy efficiency. The right amount of excess air helps
maintain stable temperatures and minimizes the risk of incomplete combustion, which can lead to soot
formation and higher emissions of carbon monoxide. However, both excessive and insufficient air can
cause problems. Too much excess air can lead to heat loss, reducing the heater's efficiency and
increasing operational costs, as more energy is required to heat the additional air. On the other hand,
too little excess air can result in incomplete combustion, leading to the production of harmful
byproducts like carbon monoxide and unburned hydrocarbons, which can affect safety, environmental
compliance, and equipment longevity. Therefore, maintaining the optimal balance of excess air is
essential for the efficient and safe operation of fired heaters.

To calculate excess air in fired heater follow the next steps:

1. Find the required amount of O2 for complete combustion of the fuel gas by using combustion
equations.
2. Calculate the required amount of air by dividing the result by 0.21 (O2 fraction in air)
3. Use the following equation to calculate the excess air (Air available/Air required) / Air available
Here is an example of it using the spread sheet of Aspen hysys:

 Fired heaters operating problems

1. Tube Overheating & Coking

 Cause: Poor heat distribution, low flow rates, or improper burner operation.
 Effect: Carbon deposition (coking) inside tubes reduces heat transfer efficiency and may
lead to tube failure.
 Solution: Ensure proper fuel-to-air ratio, maintain flow velocity, and periodically de-coke
tubes.

2. Flame Impingement

 Cause: Mis-aligned burners, poor draft control, or excessive firing rates.

 Effect: Localized overheating of tubes, leading to thermal stress and tube rupture.
 Solution: Adjust burner alignment, optimize burner flame patterns, and monitor
temperature profiles.

3. Fuel Gas Mal-distribution & Burner Issues

 Cause: Fuel gas pressure fluctuations, fouled burners, or improper burner adjustment.
 Effect: Incomplete combustion, increased CO emissions, or unstable flames.
  Solution: Regular burner maintenance, check gas distribution, and optimize air-fuel
mixture.

4. Refractory Damage

 Cause: Thermal cycling, improper installation, or fuel gas impingement.

 Effect: Hot spots, heat loss, and potential structural failure of the heater.
 Solution: Inspect refractory regularly and repair cracks or damaged sections.

5. Excessive Stack Emissions (NOx, CO, SOx, Particulates)

 Cause: Poor combustion control, excessive excess air, or low-quality fuel.

 Effect: Environmental non-compliance, efficiency loss, and operational penalties.
 Solution: Use low-NOx burners, optimize combustion parameters, and treat fuel if
necessary.

6. Draft & Airflow Problems

 Cause: Fouled air registers, improper stack height, or forced draft fan malfunction.
 Effect: Poor combustion, flame instability, or low efficiency.
 Solution: Maintain fans and dampers, ensure proper stack height, and monitor oxygen
levels in flue gas.

7. Tube Rupture & Mechanical Failures

 Cause: Excessive thermal cycling, corrosion (sulfur corrosion, oxidation), or high metal
temperatures.
 Effect: Unplanned shutdowns, safety hazards, and costly repairs.
 Solution: Regular thickness monitoring, temperature surveillance, and corrosion
protection measures.

 Cascade versus selective control in fired heater

Both cascade control and feedforward with selective control are advanced control strategies used in
fired heaters to improve performance, efficiency, and stability. However, they differ in their approach
and application.
1. Conventional Cascade Control

Concept:
Cascade control involves two controllers:
Primary (Master) Controller – Controls the main process variable (e.g., outlet temperature of the
fired heater).
Secondary (Slave) Controller – Controls an intermediate variable (e.g., fuel flow or air flow) to
compensate for disturbances faster.

How It Works:
The primary controller measures the process variable (e.g., heater outlet temperature) and generates
a set-point for the secondary controller. The secondary controller adjusts the manipulated variable
(e.g., fuel flow) to achieve the set-point set by the primary controller.

Advantages:
Faster disturbance rejection (since the secondary loop reacts before the primary loop sees the
effect). More precise control over fuel and air ratio, improving combustion efficiency. Reduces lag
and improves stability in heater operation.

Limitations:
It reacts to disturbances but does not anticipate them. Requires proper tuning of both loops to avoid
interaction issues.

2. Feedforward with Selective Control

Concept:
Instead of reacting to process disturbances after they occur, feedforward control anticipates them by
measuring disturbances directly and adjusting the control output accordingly. Selective control is
used when multiple disturbances or constraints must be managed.

How It Works:
Feedforward Control: Disturbance variables (e.g., changes in fuel composition, ambient air
temperature, or feed flow rate) are measured, and corrections are made to the fuel or air flow before
the outlet temperature is affected. Selective Control: The control system selects the most critical
parameter to control based on predefined criteria (e.g., selecting between fuel flow control, air-to-
fuel ratio control, or stack oxygen control depending on operating conditions).

Advantages:
Can respond to process changes faster than cascade control since it acts before the disturbance
affects the process. Improves energy efficiency by dynamically adjusting fuel and air based on
disturbances. Reduces variability in heater outlet temperature, leading to better downstream process
stability.
Limitations:
Requires accurate disturbance measurement and modeling; errors in prediction can lead to incorrect
adjustments. More complex than cascade control, requiring more sensors and advanced control
logic. Comparison & Application in Fired Heaters Which One to Use? If disturbances are minimal and
process dynamics are well understood: Cascade control is a reliable choice. If disturbances (e.g., feed
rate changes, fuel quality variations) are frequent and need proactive correction: Feedforward with
selective control provides better performance.