Optimizing Burner Combustion with CFD Analysis for Refinery Fired Heaters

At T Solutions India (TSI), we specialize in leveraging computational fluid dynamics (CFD) to optimize burner combustion performance in industrial heating systems. In this case study, we conducted a detailed CFD analysis of a CCR heater featuring four independent radiant cells and a common convection section to analyze combustion characteristics and optimize heat transfer.

CFD Simulation Overview

We performed a comprehensive CFD analysis to understand critical aspects of the burner flame characteristics, flue gas recirculation patterns, radiant tube heat flux, and tube metal temperatures. This analysis provided valuable insights into system performance, highlighting areas for potential improvement and optimization.

The simulation included detailed visualization of the flue gas pathlines, which were colored by temperature to illustrate the flow and temperature distribution throughout the heater. The image below shows the flue gas pathlines, revealing how heat is transferred within the system.

Key Insights

The CFD simulations provided several critical insights into the heater’s performance:

• Combustion Characteristics: Identified the burner and heater configuration’s efficiency, aiding in the optimization of combustion processes.
• Hot Spot Identification: Pinpointed potential hot spots caused by flame impingement or high-temperature flue gas flow over radiant tubes, enabling targeted interventions to prevent equipment damage.
• Velocity and Pressure Profiles: Detailed profiles of flow velocity and pressure within the heater, contributing to a deeper understanding of the system’s dynamics and highlighting areas for process optimization.

TSI Expertise in Burner Combustion Analysis

TSI has extensive experience working with refinery fired heaters across various configurations, including VC, box, and cabin heaters. Our expertise spans a wide range of heater services, such as hot oil, crude, CCR, and process gas heating. We collaborate with leading OEMs to design and optimize burner systems for maximum efficiency and reliability.

The flame profiles shown in the image above, based on the iso-surface of CO 2000 ppmv, further emphasize the importance of CFD in visualizing and optimizing combustion processes for improved performance and safety.

Conclusion

With our in-depth CFD analysis and expertise in burner combustion optimization, TSI continues to provide valuable insights that enhance the efficiency and reliability of industrial heating systems, ensuring better performance and reduced operational costs.