Stacked Radiant Fired Heaters for Compact Reactor Layouts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional hydrocarbon conversion processes, such as catalytic reforming, require extensive space and high capital costs due to the traditional arrangement of fired heaters, which increases the footprint and piping length between reaction zones.
Innovation Solution
The use of stacked sets of radiant fired heaters at different heights, with U-shaped or W-shaped process coils and optimized manifold configurations, reduces the overall space required and minimizes the hydrocarbon exclusion zone, thereby decreasing capital costs and piping length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional fired heaters are arranged in rows at the same height, then the heaters can be easily installed and maintained, but the plant footprint and space requirements increase significantly
Solution Approach 1:
The patent applies vertical stacking of fired heaters at different heights to reduce the horizontal footprint. Multiple heaters are arranged in vertical columns rather than horizontal rows, utilizing the third dimension (height) to accommodate the same number of heaters within a smaller ground area. This dimensional transition directly resolves the contradiction by maintaining heater functionality while significantly reducing plant footprint.
2Device complexity
If traditional horizontal arrangements of fired heaters are used, then the system is simple to design, but the piping length and capital costs increase
Solution Approach 1:
The patent combines multiple fired heaters into integrated vertical assemblies where heaters share common support structures, manifolds, and control systems. This merging approach reduces the number of separate piping connections required between individual heaters and the process system, thereby reducing total piping length and associated capital costs while maintaining design simplicity through modular integration.
Solution Approach 2:
By transitioning from horizontal to vertical arrangement, the patent reduces the horizontal distance between heaters and reaction zones, thereby reducing piping length. The vertical stacking allows shorter, more direct piping routes from heaters to reactors, eliminating long horizontal runs and reducing overall piping requirements.
3Ease of repair
If more space is allocated for fired heater arrangements, then adequate maintenance access is ensured, but the plant size and capital costs increase
Solution Approach 1:
The vertical stacking arrangement maintains adequate maintenance access by providing clearances in the vertical direction and around the stacked assemblies, rather than requiring large horizontal clearances. Maintenance personnel can access heaters from multiple levels, and the compact vertical footprint preserves ground space while ensuring operational accessibility.
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 arrangement reduces the space needed for radiant fired heaters, lowers capital costs, and minimizes the hydrocarbon exclusion zone, enhancing the efficiency and cost-effectiveness of hydrocarbon conversion processes.
Implementation Method 1
radiant fired heaters
Implementation Method 2
burners
Data Source
AI summary
Radiant fired heaters used with reactors are described. The apparatus includes at least two sets of radiant fired heaters, the first set being at a second height less than the first height. Each set of radiant fired heaters comprises at least one radiant fired heater. Each radiant fired heater has at least one process coil disposed within the heater, burners, and a flue gas outlet. There is at least one inlet manifold having an inlet and multiple outlets, with each outlet of the inlet manifold in fluid communication with one process coil inlet. There is an outlet manifold having multiple inlets and an outlet, with the multiple inlets in fluid communication with the process coil outlets. A method of selecting a reforming apparatus arrangement is also described.