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Fuel Impact on Flue Gas Fouling in Fired Heaters: Techno-Environmental Analysis.

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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
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  Availability: 1
Header DbId: enr
DbLabel: Energy & Power Source
An: 193623333
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
PreciseRelevancyScore: 0
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  Label: Title
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  Data: Fuel Impact on Flue Gas Fouling in Fired Heaters: Techno-Environmental Analysis.
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  Data: <searchLink fieldCode="AR" term="%22Petropoulou%2C+Eirini%22">Petropoulou, Eirini</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Giamalakis%2C+Dimitris%22">Giamalakis, Dimitris</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Aristeidopoulou%2C+Antonia%22">Aristeidopoulou, Antonia</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Plellis-Tsaltakis%2C+Constantinos%22">Plellis-Tsaltakis, Constantinos</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Oakley%2C+David%22">Oakley, David</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kennedy%2C+James%22">Kennedy, James</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Pugh%2C+Simon%22">Pugh, Simon</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zettler%2C+Hans%22">Zettler, Hans</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ishiyama%2C+Edward+Masato%22">Ishiyama, Edward Masato</searchLink><relatesTo>2</relatesTo> (AUTHOR)<i> edward.ishiyama@htri.net</i>
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  Data: <searchLink fieldCode="JN" term="%22Heat+Transfer+Engineering%22">Heat Transfer Engineering</searchLink>. 2026, Vol. 47 Issue 11/12, p963-976. 14p.
– Name: Subject
  Label: Subject Terms
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  Data: *<searchLink fieldCode="DE" term="%22Gas+mixtures%22">Gas mixtures</searchLink><br />*<searchLink fieldCode="DE" term="%22Hydrogen+as+fuel%22">Hydrogen as fuel</searchLink><br />*<searchLink fieldCode="DE" term="%22Slag%22">Slag</searchLink><br />*<searchLink fieldCode="DE" term="%22Digital+twin%22">Digital twin</searchLink><br />*<searchLink fieldCode="DE" term="%22Flue+gases%22">Flue gases</searchLink><br />*<searchLink fieldCode="DE" term="%22Direct-fired+heaters%22">Direct-fired heaters</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: 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]
PLink https://search.ebscohost.com/login.aspx?direct=true&site=eds-live&db=enr&AN=193623333
RecordInfo BibRecord:
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      – Type: doi
        Value: 10.1080/01457632.2025.2502224
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      – Code: eng
        Text: English
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      Pagination:
        PageCount: 14
        StartPage: 963
    Subjects:
      – SubjectFull: Gas mixtures
        Type: general
      – SubjectFull: Hydrogen as fuel
        Type: general
      – SubjectFull: Slag
        Type: general
      – SubjectFull: Digital twin
        Type: general
      – SubjectFull: Flue gases
        Type: general
      – SubjectFull: Direct-fired heaters
        Type: general
    Titles:
      – TitleFull: Fuel Impact on Flue Gas Fouling in Fired Heaters: Techno-Environmental Analysis.
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            NameFull: Petropoulou, Eirini
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            NameFull: Giamalakis, Dimitris
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            NameFull: Aristeidopoulou, Antonia
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            NameFull: Plellis-Tsaltakis, Constantinos
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            NameFull: Oakley, David
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            NameFull: Pugh, Simon
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            NameFull: Zettler, Hans
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          Dates:
            – D: 01
              M: 06
              Text: 2026
              Type: published
              Y: 2026
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              Value: 47
            – Type: issue
              Value: 11/12
          Titles:
            – TitleFull: Heat Transfer Engineering
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