Debottlenecking

options for a CDU

furnace
Item:

A crude heater, designed for 30,000 barrels per day, of cabin type with 5Cr radiant and
shock-row tubes and a carbon steel convection section

Objective:

To define upgrade options for the furnace so as to allow the capacity of the crude
distillation unit to be increased to around 40,000 bbl/day, as part of a refinery
debottlenecking project

Approach:

 Definition of basic heater parameters by performing baseline simulations of design and

of current operating conditions
 Identification of likely limitations to operation at a higher process throughput
 Proposition of upgrade options to overcome these limitations, with an analysis of the
technical advantages and disadvantages of each
 Level 1 life assessment, using SES TubeLife®, of existing furnace tubes under
conditions pertinent to the favoured upgrade option
Results:

Six options were identified:

 operate the furnace unmodified

 extend the stack to increase draught
 install a forced draught system
 install an air preheat system with coupled I/D-F/D fans
 install a process preheater furnace
 install a twin furnace in parallel
Operation with the furnace unmodified would be the most economic option; installation of a
process preheater would be the favoured upgrade
Life assessment indicated that tube replacement would be needed in around 5 years if the
furnace were to be operated unmodified

Careful control of operating conditions would be required if the furnace were to be operated
unmodified

Benefits:

 Most cost-effective option defined, and associated advantages and disadvantages

identified
 Optimal balance between improved performance, component life and capital spend
attained
 Operational, inspection and maintenance requirements identified for successful
achievement of the debottlenecking objective
http://www.stress-engineering.uk/debottlenecking-options-for-a-cdu-furnace/