PLANT SAFETY AND ENVIRONMENT SPECIALREPORT

Optimized fired heater control

Residual oxygen measurement principle
lowers emissions and improves efficiency
A. J. MOURIS, Hobré Instruments, Purmerend, The Netherlands

T
ighter emission regulations and high heating value of a gas divided by the square taken into account. If large fluctuations in
energy costs pose new challenges to root of its specific gravity) is a measure of the fuel gas composition are expected, the
control systems for fired heaters. the interchangeability of fuel gases when signal from a WI analyzer or calorimeter is
Rapid changes in fuel gas heating value, introduced into a heater via a burner with used for correcting the air/fuel flow ratio.
air demand and composition are typical a fixed differential pressure. Two gases with Typically, the assumption is that there is a
for applications in oil refineries, chemical the same WI will deliver the same amount proportional relationship between heating
plants and many other sites. Traditional of heat into a combustion process per unit value and air demand. Whereas this is cor-
feedback control based on temperature, of time, regardless of the composition. To rect for hydrocarbon-based fuel gases like
stack oxygen and combustibles measure- clarify this concept, consider the following natural gas, for fuel gases containing sig-
ment is not quick enough to handle rapid fuel gas cases: nificant percentages of hydrogen, olefins,
changes effectively. This short coming is • Case 1—40% methane and 60% CO2 and/or oxygen this approach fails.
typically addressed by controlling the excess hydrogen (by volume) The following are fuel gas cases:
air set point with a certain safety margin. • Case 2—58% methane and 42% • Case 1—100% hydrogen
Unfortunately, this approach prevents the nitrogen. • Case 2—88.5% methane and 11.5%
emission of unburned components while The lower heating value by volume nitrogen.
increasing CO2 emission due to poor fuel of these two gases is the same, i.e., 20.82 The WI for both gases is the same,
economy—air is heated unnecessarily and MJ/Nm3. The WI however, is 40.55 MJ/ i.e., 40.9 MJ/Nm3. The Combustion Air
heat transfer efficiency is reduced. NOx Nm3 for Case 1 and 24.39 MJ/Nm3 for Requirement Index (CARI) is defined as
formation is promoted as a result of higher Case 2! This means that the amount of the stoichiometric air demand divided by
oxygen levels in the combustion process. heat delivered per unit of time through the square root of the relative gas density.
For these reasons, feed forward control of the same burner will be 40% lower in the Results: 9.0 for Case 1 and 10.9 for Case
the air/fuel ratio is gaining more attention. second case. 2. This means that if the fuel gas com-
Properly selecting and installing the fuel position changes from hydrogen poor to
gas property analyzer and using the right Air/fuel ratio control. The combus- hydrogen-rich composition the excess air
control parameters are essential to get the tion air flow supplied to an industrial may be controlled 20% too high. Please
best results. furnace is typically linked to the fuel gas note that, instead of WI and CARI, a
flow. In smaller installations, this may be a similar case can be construed for heating
Control parameters. The control mechanical link; in larger installations, air value and air demand; this follows from
system philosophy of fired heaters varies and fuel gas temperature and pressure are the definitions:
depending on the requirements and heater
or boiler design. However, in all cases, the
furnace’s thermal load and the air/fuel ratio Flowmeter
are two critical parameters that must be Sample SG SG Bypass
monitored and controlled. Low
Pressure Bypass
reducer
High Vent
Heat load control. Depending on the
Manifold
control system design, the Wobbe Index
ZRO2 cell
(WI), the heating value and gas density may Restriction
be required as input(s). The heating value is Heat Measuring oven
PI Mixing
the amount of heat produced when a unit exchanger chamber
Drain
volume or fuel mass is burned stoichiomet-
Air station Booster
rically. The higher heating value includes
the heat of water condensation formed in
the combustion process; the lower heat- FIG. 1 Typical residual oxygen content analyzer schematic.
ing value does not. The WI (defined as the
HYDROCARBON PROCESSING NOVEMBER 2010
I 65
 PLANT SAFETY AND ENVIRONMENT SPECIALREPORT

WI = Heating value/√(Specific gravity) • The sample handling system poor indicators for the air demand in fuel
CARI = Air demand/√(Specific gravity) should have minimal internal volume. gas applications. Therefore, it is important
Although a fast-loop theoretically can to select an analyzer based on the residual
Residual oxygen content analy- compensate for any dead volume in the oxygen content principle that stores sepa-
sis. In a typical residual oxygen content system, this will result in excessive vent- rate calibration lines for WI/heating value
analyzer sample, gas is continuously mixed ing and/or flaring of fuel gas. Ideally, the and CARI/air demand.
with combustion air under controlled analyzer has an integrated sample condi- • The analyzer’s rangeability should
conditions followed by catalytic combus- tioning system and requires no additional match all possible cases. Typically, the ana-
tion in an electrically heated furnace. The external sample handling. lyzer should be able to handle large fluctua-
residual oxygen content in the flue gas is • A combustion air requirement tions in the fuel gas composition. Residual
measured with an accurate and reliable zir- signal should be available. As discussed oxygen content analyzers analyze fuel gases
conium oxide sensor. In the control unit, previously, the heating value or WI can be of all possible compositions in the 0–120
the following combustion parameters are
calculated from the oxygen signal and the
(optional) density signal: WI, CARI, calo-
rific value (or BTU) and specific gravity.

OUR MISSION
The concept was first explored in the US,
but the European gas distribution compa-
nies Gaz de France and Dutch Gasunie have

YOUR SAFETY
really optimized the benefits. Their prime
objective was to develop an instrument that
was as fast as possible for optimizing natural
gas blending operations to meet grid entry
specifications. However, in the last decade
the technology has also proven to be very
suitable for fuel gas, vent gas, flare gas, bio-
GET MORE
WITH HART
gas and steel plant offgas applications.

Instrument installation and selec-

tion. When the decision is to install an MSA Ultima® X Series
analyzer for measuring the heating value Gas Monitors
and/or WI for feedforward fuel and air/fuel
ratio control, the following requirements
More efficient asset management
should be fulfilled:
More flexibility with digital
• The analyzer should be as fast as or analog capability
possible. It doesn’t make sense to install a
More compatibility with existing
calorimeter with a 20-sec response time if installed operations
changes occur within seconds. With residual
Ask about our new 10-year warranty
oxygen technology, a response time of less
on DuraSource™ Technology for Ultima
than 5 sec is achievable. XIR and XI Gas Monitors. For your gas
• Signal noise should be as low as detection solutions, contact MSA
possible. High signal noise levels require at 1.800.MSA.INST.
smoothing of the signal, typically by aver-
aging. As a consequence, the response
from the control system to a step-change
will be slower. A residual oxygen content To see videos about the
analyzer offers a repeatability of 0.05% of Ultima X Series of Gas
measured value. Monitors, scan with
• Local installation should be close your Web-enabled
mobile phone.
to the sample tap point. Ideally, the fuel * www.2dscan.com
gas heating value and air demand signal * standard data rates may apply

should be available before the fuel gas leaves

the burner tip. This means that the travel-
ling time of the fuel gas from the sample
tap point to the burner should be longer | G A S M O N I T O R S | S C B A | M U LT I G A S D E T E C T O R S |
than the traveling time from the sample H E A D / E Y E / FAC E P R OT E C T I O N |
tap point to the analyzer plus the analyzer
response time. Outdoor installation in 1.800.MSA.INST | www.MSAnet.com
hazardous areas is not a must, but it often
follows from the requirment of installation
close to the sample tap point.
HYDROCARBON PROCESSING NOVEMBER 2010
I 67
SPECIALREPORT PLANT SAFETY AND ENVIRONMENT

■ In a typical residual MJ/Nm3 (0–3,000 BTU/SCF) range with- º Parameters measured—besides

out the risk for flame-out or overheating. CARI and WI, specific gravity, heating
oxygen content analyzer • Thorough application review. Each value and air demand may be required.
application is different and proper review º Fuel gas hydrocarbon and/or water
sample, gas is continuously is essential. Issues that should be consid- dew point—it is not uncommon that fuel
mixed with combustion ered include: gas is taken from a knock-out vessel. Care
º Calibration gas selection—the “right” must be taken that condensation does not
air under controlled calibrated gases give the best accuracy in take place in sample lines or inside the ana-
conditions followed by most cases, do not contain many compo- lyzer. Ideally, all sample wetted parts should
nents (not more than two preferably) and be heated 10°C–20°C above the maximum
catalytic combustion in an allow sufficient filling pressure even when expected dew point.
electrically heated furnace. ambient temperature may be low. º Sulfur content and presence of other
corrosive components— wrong material
selection can rapidly corrode and clog an
analyzer. Proper component selection and
analyzer design enables continuous opera-
tion even when more than 10% sulfur is
present.
º Overall response time—a lag time
analysis from the sample probe tip to the
analyzer signal output should be provided
to ensure compliance with the require-
ments. This is especially important when
high pressure gas lines must be analyzed.
º Ambient temperature range and haz-
ardous-area certification requirements—these
must be considered.

Conclusion. Feedforward control of

fired heaters utilizing fuel gas with varia-
tions in composition and properties may
result in considerable improved combus-
tion efficiency. Emissions may be reduced
and product quality and equipment life
time can be improved. Online analyz-
ers based on the residual oxygen content
method have the potential to deliver the
parameters to be measured within seconds.

MODERNIZING However, a successful implementation of

the technology requires a clear understand-

Level Measurement ing of what is to be measured and how the

signals are used in the control loop. Also,
the location of installation and a properly
designed sample handling system are key
Sump Level Solution
factors for success. HP
Sump level measurements and pump
LITERATURE CITED
control are often a maintenance 1 API RP 556, First Edition, May 1997.
challenge. The VEGAPULS through-air 2 Driedger, P., “Controlling fired heaters,”
radar and VEGAFLEX guided wave Hydrocarbon Processing, April 1997.
3 Physical Properties of Natural Gases, N.V.
radar provide reliable continuous level Nederlandse Gasunie, 1980. s
measurements. The VEGAMET 391 80-90%

supplies up to six relays, offering 10-20%

lead/lag pump control and giving

power to the measuring instrument. Albert Mouris is technical direc-
tor with Hobré Instruments BV. He
has more than 15 years of experience
in process analysis and sampling sys-
www.ohmartvega.com tems. Previously, Mr. Mouris worked as
info@ohmartvega.com
800.FOR.LEVEL an energy market analyst with the Dutch gas incumbent
Gasunie. He received a chemical engineering degree
from the University of Twente.

Select 168 at www.HydrocarbonProcessing.com/RS

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