How to Achieve an Energy-Efficient Fired Heater
New Fired Heaters Should Be Designed for Remote Robotic Cleaning
The design and operation of fired heaters are undergoing significant changes due to the increasing emphasis on energy efficiency and carbon reduction. While these new designs offer numerous benefits, they also present challenges, particularly in the maintenance and cleaning of the convection section.
Elevated Risk of Convection Section Fouling
Modern fired heaters often incorporate enhanced heat recovery systems, such as increased tube surface area and tighter tube spacing in the convection section. While these features improve efficiency, they also create an environment more prone to fouling. i.e. the accumulation of deposits on heat transfer surfaces can negatively affect the heat transfer coefficient of the convection section, leading to higher fuel consumption, increased emissions, and reduced production.
Difficulties of Conventional Cleaning
Conventional cleaning methods, such as traditional hydro-blasting or chemical cleaning, may not effectively remove fouling deep within the coils of modern convection sections.
Robotic Cleaning: An Advanced Fired Heater Cleaning Solution
Robotic cleaning technology offers a proven solution to the challenges of cleaning modern fired heaters. Robots can access tight spaces, navigate complex geometries, and perform cleaning tasks with precision and efficiency. This can lead to reduced downtime, improved safety, more effective fouling removal and ultimately, safety, with no man-entry requirements.
Designing for Robotic Access
To fully realize the benefits of robotic cleaning, new fired heaters should be designed with robotic access in mind. This includes:
- Sufficient space between tube banks: Adequate spacing allows robots to manoeuvre and access all tube surfaces for cleaning.
- Accessibility for robotic deployment and retrieval: Provisions should be made for easy deployment and retrieval of robots, minimizing downtime during cleaning operations.
The Importance of Proactive Planning
Incorporating robotic cleaning readiness into the design of new fired heaters is a proactive approach that can yield significant long-term benefits. By anticipating future maintenance needs and designing for robotic access, refineries can ensure optimal heater performance, reduce downtime, and minimize the environmental impact of their operations.
As the industry continues to evolve towards cleaner and more efficient technologies, embracing innovative solutions like robotic cleaning will be crucial for maintaining the reliability and performance of critical equipment.
IGS Tube Tech provides robotic cleaning technologies and can share the design guidelines as well as past case studies showing 90-95% surface area of the coils directly accessed and cleaned by our service.