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DYNSIM Best Practices 3 - Furnace
DYNSIM Best Practices 3 - Furnace
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Publication date: Monday, March 28, 2022
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Contents
Introduction.......................................................................................................... 5
Example 1 ........................................................................................................... 25
Feeds and Products Tab ...................................................................................................................... 26
Basic Tab ............................................................................................................................................ 28
Tuning ................................................................................................................................................ 29
Radiation Heat Transfer ...................................................................................................................... 30
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Convective Heat Transfer Tab .............................................................................................................. 32
Thermo Tab ........................................................................................................................................ 33
Fuel Gas and Air Network .................................................................................................................... 34
Example 2 ........................................................................................................... 37
Convection Section F101 ..................................................................................................................... 38
Feeds and Products Tab ............................................................................................................................. 38
Basic Tab ..................................................................................................................................................... 40
Radiant Heat Transfer ................................................................................................................................ 41
Convective Heat Transfer Tab .................................................................................................................... 43
Radiation Section F101A ..................................................................................................................... 45
Radiation Section F101B...................................................................................................................... 49
Troubleshooting Issues while Modeling a Furnace ............................................................................... 52
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Introduction
Fired Heater models a direct-fired process heater and the process heater is a direct-fired exchanger, which uses
the hot gases of combustion to elevate the temperature of feed flowing through the coils of tubes, aligns
through the heater. This Fired Heater model design allows flexibility for diverse applications in the chemical
process industry such as refineries, gas plants, petrochemicals and synthetics, olefins, ammonia and fertilizer
plants. Based on the nature of application, it may be termed as a fired heater or a furnace.
Fired Heater simulates both radiant and convective heat transfer to one or more tube passes. The flue gas side
(firebox) is a pressure node with a Compressible holdup and the tube passes (process) are flow device(s) with
Incompressible holdup. Also, the firebox can include multiple tube passes as well as multiple gas nodes. Each
tube pass resides in a single gas node. Although the pressure is the same for each gas node, a separate energy
balance is maintained for each gas node to calculate heat transfer from the gas to the tubes.
Fired Heater excludes the combustion calculations. A separate Combustor model can be used to produce hot
combustion gas to feed the Fired Heater, or heat can be added directly to the appropriate gas node.
The firebox includes the thermal capacitance of the refractory walls, which can radiate heat to the tubes and
transfer heat to the surroundings. Also, the thermal capacitance of the tube walls is modeled.
A convective section can be modeled with an additional gas node where radiant heat transfer coefficients are
set to zero.
Fired Heater includes a capability to calculate its internal heat transfer coefficient from reference conditions.
These reference conditions can either be supplied from plant data or from a furnace design program.
Fired Heater also supports reactions for individual tube passes.
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Fundamental Calculations of a Fired Heater
The firebox has a Compressible model to calculate pressure dynamics. Since the firebox is assumed to operate at
a single pressure for all gas nodes, the overall pressure calculation must be decoupled from the energy balance
for each gas node. Consequently, the following equation is used to compute the firebox pressure:
where:
Ff - Forward flow (kg-mol/sec)
Fr - Reverse flow (kg-mol/sec)
P - Firebox pressure (kPa)
Vol - Firebox volume (m3)
Kdps - Pressure derivative scale factor
R - Average fluid density in the gas nodes (kg-mol/m3)
where:
Atr - Projected cold plane area (m2)
Nt - Number of tubes passes
Len - Length of tube (m)
Spacing - Center to center spacing between the tubes (m)
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Fundamental Calculations of a Fired Heater
where:
Atr - Projected cold plane area (m2)
Kgts - Overall gas to tube radiant scale factor (dimensionless)
Kgt - Overall gas to tube radiant coefficient (dimensionless)
Qgtr - Radiant transfer from gas to a tube pass (kJ/sec)
σ- Stefan-Boltzmann constant (kJ/m/sec/K4)
Tg - Gas node (bridge wall) temperature (K)
Tt - Tube skin temperature (K)
The gas node has forced and natural convective heat transfer coefficient accounting for heat transfer from fluid
to the tube. At high inlet fluid flow rate, the heat transfer is by forced convection and at low fluid flow rates, the
heat transfer is by natural convection.
where:
Atr - Tube area projected or cold plane area for radiant heat transfer (m2)
Krts - Overall refractory to tube radiant scale factor (dimensionless)
Krt - Overall refractory to tube radiant coefficient (dimensionless)
Qrt - Radiant transfer from refractory to tubes (kJ/sec)
σ- Stefan- Boltzmann constant (kJ/ m2/sec/K4)
Tt - Tube skin temperature (K)
Tr - Refractory temperature (K)
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Fundamental Calculations of a Fired Heater
where:
Ar - Total area of refractory surface for the gas node (m2)
Tamb - Ambient temperature (K)
Tr - Refractory temperature (K)
Ql - Heat loss from refractory to surroundings (kJ/sec)
Ul - Loss heat transfer coefficient (kW/m2-K)
A negative value of Ql indicates that the refractory is at a higher temperature than ambient.
where:
Khc - Lumped radiant coefficient, which can be Kgr, Kgt, or Krt (dimensionless)
a - Direct effectiveness or "view" factor
εh - Hot body emissivity, which can be either gas or refractory (dimensionless)
εc - Cold body emissivity, which can be either refractory or tube (dimensionless)
Convection Section
A convection section can be modeled by creating a second gas node. The tubes in this gas node can be modeled
with no radiant heat transfer by setting the overall radiant to zero.
Heat Streams
Heat transfer from an external source to the flue gas can be configured through heat streams. These heat
streams should originate from any source that performs heat transfer calculations and sets Q in the heat stream,
such as Utility Exchanger. Any number of heat streams can be connected.
Fired Heater supports external heat input directly to the fluid through the parameters Qimp.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Fundamental Calculations of a Fired Heater
Flash Calculations
AVEVA™ Dynamic Simulation application uses a vapor only flash for the flue gas section. The Internal Phases is
set to Vapor, while External Phases is set to Mixed.
Reactions
Fired Heater also supports reactions in the tube pass. A RXN sub-model can be included in the tube passes, if the
reactions are enabled.
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Configuration of Gas Nodes in AVEVA
Dynamic Simulation
Typical configurations of Gas nodes – Radiation, Convection, and Economizer (BFW to steam) with three tube
passes
Typical configurations of Gas nodes – Radiation and Convection with eight tube passes
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Configuration of Gas Nodes in AVEVA Dynamic Simulation
Typical configurations of Gas nodes – Radiation and Convection as two different model objects with eight
tube passes
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Furnace Modeling
General Description
Furnace designs vary as to their function, heating duty, type of fuel, and method of introducing Air. However
most process furnaces have some common features and these features are discussed in the same order as they
appear in AVEVA Dynamic Simulation Fired Heater Data Entry. Starting with the P&ID and the Furnace data
sheet.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
Furnace P&ID
From the screen shot of the data sheet and the P&ID, it is clear that there are three sections -- Radiation,
Convection, and Superheat. Process fluid flows through Radiation and Convection sections and steam through
Superheat section. These three sections are of different heat flux Zones, so they need to be represented by a
different gas node -- namely Radiation, Convection, and Superheat for steam. Use one gas node to represent
each section (this is a simple case and other complicated cases will be discussed at a later stage in this document
with examples).
The process fluid is also divided into two passes, where the two passes are going through Radiation section (two
passes) and Convection section (two passes), and this gives 2+2=4 tube passes for process and one tube pass for
the steam, which finally gives three gas nodes and five tube passes for Furnace configuration.
Select the Fired Heater from process equipment icon pallet, place it on the flow sheet, and enter the number of
gas nodes and number of tube passes in the configuration window of the furnace as shown below.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
Convective area = [Number of tubes] (in each pass)*3.14(Pi)*[Diameter of tube] (outer diameter)*[Length of
tube]
Volume of the tube = [Number of tubes] (in each pass)*3.14(Pi)*[square of Diameter of tube] (inside
diameter)*[Length of tube]/ [4]
Metal mass = ([volume of the tube based on outer diameter] – [volume of the tube based on inner
diameter])*[density of the material]
Note: If density of the material is not available, use density of Carbon steel (generally heat exchanger tubes
contain Molybdenum as the major constituent usually nine Cr or five Cr with carbon steel)
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
Radiant Heat Transfer tab with check box to use reference conditions
If the check box in Radiant Heat Transfer tab is checked then all coefficients in this tab are calculated by AVEVA
Dynamic Simulation application. Specify the Gas reference temperature, reference refractory temperature,
reference tube temperature, and reference Tube heat duty. Values obtained here can be used as starting tuning
parameters.
Gas node Refractory Area: This is the surface area of the refractory material in respective gas nodes. (This is the
surface area of the walls along which the tubes are arranged in the furnace. For a box type furnace, it will be a
rectangle and for a cylindrical type it will be a cylinder). Even for this, the data sheet with dimensions is
compulsory.
Overall, coefficient gas to refractory determines the amount of heat transferred from gas to refractory material.
This coefficient is tuned to attain the required refractory temperature and if correct design values are used, this
coefficient remains less then one. Higher values can make the model unstable.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
Radiant Area (cold plane): This is the surface area of tubes exposed to the refractory material. (As circular tubes
are exposed to refractory, only projected area is taken into account.) Cold area = [number of tubes]*[length of
tube]*[diameter of tube].
Note: In most of the cases, where the design data is available, a good starting point for tuning is default
coefficients. For further tuning of the coefficients, heat absorbed in the Radiation section should be 75-80% of
the total heat absorbed by process fluid. Also, to have a good dynamics during startup and shutdown, heat to be
absorbed through radiation from gas to process fluid and the refractory to process fluid should be 40-60%,
In Normal design convention, the total heat absorbed by the process fluid is 65-70% through radiation and the
rest 30-35% is through convection (both in radiation section and convection section).
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
Reactions Tab
Reactions can be enabled on the process side, and for this select the tube pass in which reactions are to be
enabled and check the Enable reactions tab. This is, however, not required as the SRU (Sulfur Recovery Unit),
where the reactive furnace is used in the process is modeled differently.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
Thermo Tab
Choose appropriate Thermo for the process. On completion of the data entry, the completed AVEVA Dynamic
Simulation flow sheet looks like Combustor and Furnace flow sheet figure.
Combustor
Combustor/Burner is an essential part of a furnace and, depending on the firing methods, burners in vertical
cylindrical furnaces are mostly located at the bottom and fire upward. Other furnaces may have side/opposed
fired burners to combust the fuel and air to produce heat. If a furnace has to be lit, it is done using a pilot flame
which works using an ignition transformer and mostly remains lit. The pilot lights, which generally uses natural
gas, is used to light the main flame.
Fired Heater in AVEVA Dynamic Simulation application does not include the combustion calculations and as feed
to the Fired Heater, a separate Combustor model is used to produce hot flue gases. Combustor is a flow device
in AVEVA Dynamic Simulation application and has different fuels types options to compute the outlet conditions
of the gas:
1. Feed components
2. Natural gas
3. Fuel oil
4. Ultimate analysis
There is a provision in the Combustor model to start the combustion through a pilot command. As combustion
can only take place if a pilot is lit, the pilot command has to be linked such that if any of the pilot burners in a
furnace is ON, pilot command should be made 1 (where 1 is ON and 0 is OFF).
Typically, a number of pilot and main burners are available in a furnace depending on the heat requirement on
the process side. Also, the number of ON burners depend on the heat requirement. Pilot command should
remain ON when the main burner or any one single burner is ON.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
Both, the number of pilot and main burners, is usually represented in AVEVA Dynamic Simulation application
using a slider or a button for each pilot and main burner. The gas flow to the burners is also dependent on the
number of burners in use which is represented as an equation written in the conductance calculation of a pipe.
This has to be done for both the pilot and main burners.
Figure shows the three states of the Combustor model. In the first case, the pilot command is in OFF mode. In
the second figure, the pilot command is ON, but no main burner is ON (flow through combustor is very small)
and finally in the last case, main fuel gas flow is ON.
Combustor states
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
Note: A Combustor model with zero flow through it whilst the AVEVA Dynamic Simulation model is running can
crash the model, therefore a minimum flow of air (1 kg/hr) is recommended even in shutdown conditions. Set a
small value for KJLEAK on all the valves in the air line.
Another important aspect of Furnace modeling which is different from other flow sheet modeling is the DPLIN
parameter. DPLIN is a parameter below the threshold defined value of 10KPa that would make pressure drop
and flow relationship linear. Default value of DPLIN is 0.1bar=10kpa. As the pressure drop in the flue gas side, in
the order of just tens of pascals, DPLIN has to be less than the smallest pressure drop possible on the flue gas
side to retain the pressure nonlienear drop/flow relationship. The value can be as low as 1Pa (one pascal).
To change the DPLIN parameter, right-click on the stream and go to edit and on the row layout change edit to
AdvEdit and change the DPLIN value, see
This DPLIN parameter is only available on the stream next to a pressure node,that is, on the flue gas line, and it
has to be changed after every pressure node.
Another important aspect is that the flue gas side flows are large along with the sizes of the flow devices,
therefore the value of conductance of a pipe is large, say 150. The conductance of flow devices are tuned based
on the box pressure drop required.
See the screen shot from a flow sheet containing a combustor and the flow devices on the flue gas line. The
conductance and pressure drop are displayed at steady state to have a feel for the numbers.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Furnace Modeling
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Example 1
In this example, three nodes are defined, namely, Radiation, Convection, and Superheat sections for steam
generation. Except for steam process fluid, the other main process fluid enters the convection section, and flows
to the radiation section, and comes out through the radiation section. There are four passes in convection
section and all these four passes enter the radiation section. In AVEVA Dynamic Simulation model, each gas
node is represented by a number. Usually, number ‘1’ is assigned to the gas node nearest to the burners, but in
this example, it is the radiation zone.
The numbering is illustrated in AVEVA Dynamic Simulation model (Table:Conventions for the gas nodes/zones).
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
Radiation 1
Convection ( process fluid) 2
Convection (steam) 3
FEEDTUBELOC 9 size
FEEDTUBELOC[CC_03S07] 7
FEEDTUBELOC[CC_03S08] 6
FEEDTUBELOC[CC_03S09] 5
FEEDTUBELOC[CC_03S10] 4
FEEDTUBELOC[CC_03S11] 8
FEEDTUBELOC[CC_03S12] 3
FEEDTUBELOC[CC_03S13] 2
FEEDTUBELOC[CC_03S14] 1
FEEDTUBELOC[CC_03S15] 0
MAPOFEEDSTREAM 1 size
MAPOFEEDSTREAM[CC_03S29] 0
MAPOPRODSTREAM 1 size
MAPOPRODSTREAM[CC_03S37] 0
OFEEDSTREAM 1 size
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
OFEEDSTREAM[0] CC_03S29
OGASHEATSTREAM 0 size
OPRODSTREAM 1 size
OPRODSTREAM[0] CC_03S37
OTUBEFEEDSTREAM 9 size
OTUBEFEEDSTREAM[0] CC_03S07
OTUBEFEEDSTREAM[1] CC_03S08
OTUBEFEEDSTREAM[2] CC_03S09
OTUBEFEEDSTREAM[3] CC_03S10
OTUBEFEEDSTREAM[4] CC_03S11
OTUBEFEEDSTREAM[5] CC_03S12
OTUBEFEEDSTREAM[6] CC_03S13
OTUBEFEEDSTREAM[7] CC_03S14
OTUBEFEEDSTREAM[8] CC_03S15
OTUBEPRODSTREAM 9 size
OTUBEPRODSTREAM[0] CC_03S12
OTUBEPRODSTREAM[1] CC_03S13
OTUBEPRODSTREAM[2] CC_03S14
OTUBEPRODSTREAM[3] CC_03S15
OTUBEPRODSTREAM[4] CC_03S16
OTUBEPRODSTREAM[5] CC_03S17
OTUBEPRODSTREAM[6] CC_03S18
OTUBEPRODSTREAM[7] CC_03S19
OTUBEPRODSTREAM[8] CC_03S02
PRODTUBELOC[CC_03S12] 7
PRODTUBELOC[CC_03S13] 6
PRODTUBELOC[CC_03S14] 5
PRODTUBELOC[CC_03S15] 4
PRODTUBELOC[CC_03S16] 3
PRODTUBELOC[CC_03S17] 2
PRODTUBELOC[CC_03S18] 1
PRODTUBELOC[CC_03S19] 0
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
PRODTUBELOC[CC_03S02] 8
PRODTUBELOC[CC_03S02] 8
Note: Mapping the tube passes entering and leaving the furnace.
The numbers indicate the tube pass number and array of feed and product streams (as assigned by a stream
name). All these are in the Feeds and Products tab of the DEW.
Basic Tab
The refractory volume is calculated from the dimensions available in the datasheet and mass has been assumed
and tuned corresponding to heat transfer from refractory to the surroundings and during start up and shut
down.
Convective area, tube volume and tube metal mass are calculated from the data available in the datasheet.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
The flow conductance is tuned based on the pressure drop required across the furnace tubes and for optimum
flow controller openings during steady state.
Basic Tab
Tuning
Generally, for tuning the furnace, the outlet temperature across each Gas node must be known i.e., outlet of
Radiation section and outlet of Convection section after the Process fluid tubes and ultimately outlet of the
furnace after the steam tubes.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
To obtain the gas node temperatures for each section follow these steps:
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
Thermo Tab
A Component slate FUELGAS and Thermo method of SRK01 is used here. The main components required in the
FULEGAS slate will be discussed later.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
Similarly, on the tube pass side, a slate with name Reactor has been configured with a thermo method SRK01.
Thermo tab
The rest of the tabs in this model are of minor importance and defaults are used.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 1
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Example 2
This is an example of a furnace with two radiation sections and a common convection section. The modeling and
tuning philosophy is the same as explained in example 1. This is a balanced draft model with a Forced and
Induced draft fan with an air pre-heater. This is a crude pre-heat furnace with feed entering the convection
section and getting distributed in both the radiation sections. The convection section is named in AVEVA
Dynamic Simulation as F101 and both the radiation sections are named as F101A & F101B. The process fluid
enters the furnace (8 passes) convection section and Boiler Feed Water (BFW) enters the convection section and
gets converted to steam and leaves the section. All the eight passes leave the convection and distribute into four
passes each to each radiation section. There are 68 burners i.e. 34 main burners and 34 pilot burners to each
radiation zone. In AVEVA Dynamic Simulation application, you have to model three furnaces representing each
section of a furnace namely radiation zone 1 and 2 and the convection section. So each furnace will have one gas
node and each section of the radiation zone will have four passes and convection has nine passes (8+1 passes).
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
Basic Tab
Fire box volume and refractory mass are assumed for both the nodes in the convective section. Here node 1 is
for the process fluid and node 2 is for the BFW. Tube volume and area and metal mass are calculated from the
data sheet. The flow conductance across is tuned for the required flow and pressure drop across the furnace on
the tube pass side.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
Following are the values needed after tuning. To get these values, tune all the heat transfer coefficients to get
the highlighted values. All the duties are for reference. For radiant heat transfer, the convection duties are
tuned for nearly 3-4% of the total duty required.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
F101B Configuration
Check the mapping of the streams from the convective section entering the radiation section F101B.
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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AVEVA™ Dynamic Simulation Furnace Modeling Guidelines
Example 2
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