Processes and apparatuses for heating a process fluid in a heater
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Solution Overview
Problem
Steam cracking furnaces experience a reduction in mass flow rate when operating on high-hydrogen content fuel, leading to decreased conversion of paraffins to olefins and reduced efficiency, potentially making operations unprofitable.
Innovation Solution
The introduction of inert gases, such as nitrogen, into the furnace system to maintain optimal mass flow rates and efficiency, regardless of the fuel composition, by adjusting the flow of inert gases based on the hydrogen content in the fuel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If hydrogen fuel is used to reduce carbon emissions, then carbon emissions are reduced, but mass flow rate through the convection section is reduced
Solution Approach 1:
The patent introduces an inert gas (nitrogen) as an intermediary substance to compensate for the reduced mass flow rate caused by hydrogen fuel usage. The inert gas is injected into the convection section to restore the total mass flow rate to optimal levels, thereby maintaining heat transfer efficiency while allowing continued use of low-carbon hydrogen fuel.
2Object-generated harmful factors
If mass flow rate is reduced due to hydrogen firing, then carbon emissions are reduced, but conversion of paraffins to olefins is reduced
Solution Approach 1:
The inert gas serves as a mediator that restores the mass flow rate necessary for optimal conversion of paraffins to olefins. By adjusting the inert gas injection rate, the system maintains the mass flow conditions required for high conversion efficiency while continuing to use hydrogen fuel for reduced carbon emissions.
Solution Approach 2:
The patent changes the composition parameter of the gas stream by adding inert gas to compensate for the lower mass flow rate of hydrogen combustion. This parameter change restores the optimal conditions for paraffin conversion without requiring a return to hydrocarbon fuels.
3Object-generated harmful factors
If mass flow rate is reduced due to hydrogen firing, then carbon emissions are reduced, but efficiency is reduced
Solution Approach 1:
The inert gas injection acts as a compensatory mechanism that restores the mass flow rate necessary for efficient heat transfer in the convection section. This maintains overall system efficiency while enabling the use of hydrogen fuel for reduced carbon emissions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for efficient operation of steam cracking furnaces on high-hydrogen fuels by maintaining optimal crossover temperatures and mass flow rates, thereby maximizing yield and productivity while reducing carbon emissions.
Implementation Method 1
significantly reduces conductive heat transfer in the convection section of the furnace
Implementation Method 2
significantly reduces conductive heat transfer in the convection section of the furnace
Implementation Method 3
a burner configured to receive a fuel stream and combust the fuel stream in a combustion zone to produce a flame and heat
Implementation Method 4
a radiant section with at least one conduit with a process fluid stream
Implementation Method 5
transferring heat from the heated, mass enriched flue gas to the process fluid stream in the radiant section
Data Source
AI summary
Processes and apparatuses for heating a process fluid with a heater having a burner. Fuel is passed to the burner and combusts to product heat. An inert gas stream is provided to the burner, either upstream or downstream or both, of the burner. The flow of the inert gas stream is controlled based on a composition of the fuel, with more inert gas being passed downstream of the burner to when the amount of hydrogen in the fuel is increased.