Fuel Impact on Flue Gas Fouling in Fired Heaters: Techno-Environmental Analysis.
Saved in:
| Title: | Fuel Impact on Flue Gas Fouling in Fired Heaters: Techno-Environmental Analysis. |
|---|---|
| Authors: | Petropoulou, Eirini1 (AUTHOR), Giamalakis, Dimitris1 (AUTHOR), Aristeidopoulou, Antonia1 (AUTHOR), Plellis-Tsaltakis, Constantinos1 (AUTHOR), Oakley, David2 (AUTHOR), Kennedy, James2 (AUTHOR), Pugh, Simon2 (AUTHOR), Zettler, Hans2 (AUTHOR), Ishiyama, Edward Masato2 (AUTHOR) edward.ishiyama@htri.net |
| Source: | Heat Transfer Engineering. 2026, Vol. 47 Issue 11/12, p963-976. 14p. |
| Subject Terms: | *Gas mixtures, *Hydrogen as fuel, *Slag, *Digital twin, *Flue gases, *Direct-fired heaters |
| Abstract: | Fired heaters are essential in process industries, providing heat for various operations. Their performance is tightly linked to safety, particularly regarding heater tube temperatures and operational limits. Key challenges in efficient heater operation include fouling and slagging—where deposits form on the tubes' surfaces. This study introduces a method to assess fired heater performance using digital twin models and commercial software. The approach estimates fouling in the convection section and slagging on radiant tubes based on monitoring data, while also considering the impact of different fuel mixtures. A case study at Hellenic Petroleum's Aspropyrgos Refinery examines how this method aids in making better technical and economic decisions. It shows how fuel choices, such as a mix of fuel gas, off gas, and fuel oil, influence heater slagging and the need for shutdowns when safety limits are reached. Additionally, "what if" scenarios evaluate the potential of switching to 100% hydrogen fuel, assessing its impact on heater operations and performance. These findings highlight the importance of fuel selection in balancing cost, performance, and maintenance. [ABSTRACT FROM AUTHOR] |
| Database: | Energy & Power Source |
|
Full text is not displayed to guests.
Login for full access.
|
|
| Abstract: | Fired heaters are essential in process industries, providing heat for various operations. Their performance is tightly linked to safety, particularly regarding heater tube temperatures and operational limits. Key challenges in efficient heater operation include fouling and slagging—where deposits form on the tubes' surfaces. This study introduces a method to assess fired heater performance using digital twin models and commercial software. The approach estimates fouling in the convection section and slagging on radiant tubes based on monitoring data, while also considering the impact of different fuel mixtures. A case study at Hellenic Petroleum's Aspropyrgos Refinery examines how this method aids in making better technical and economic decisions. It shows how fuel choices, such as a mix of fuel gas, off gas, and fuel oil, influence heater slagging and the need for shutdowns when safety limits are reached. Additionally, "what if" scenarios evaluate the potential of switching to 100% hydrogen fuel, assessing its impact on heater operations and performance. These findings highlight the importance of fuel selection in balancing cost, performance, and maintenance. [ABSTRACT FROM AUTHOR] |
|---|---|
| ISSN: | 01457632 |
| DOI: | 10.1080/01457632.2025.2502224 |
