Aspen Fired Heater Maximize process throughput through more efficient design and operation of your fired heaters Aspen Fired Heater is the latest generation of thermal design software for the simulation and rating of process fired heaters. Fired heaters are found on almost every process unit in a petroleum refinery and are widely used in petrochemical and bulk chemical production. Correct design and operation of heaters is vital for achieving overall plant operational objectives in terms of efficiency and achievement of desired product slate. The Challenge: Reduce Risk, Gain More Control of Fired Heaters Ninety percent of the energy consumed in a typical refinery is associated with fuel burned in fired heaters. Heaters are vital to the operation of distillation and conversion units. These devices are highly complex heat transfer units involving combustion, radiation, and convective heat transfer, often interacting with several streams in a process. Changes in feedstock or crude composition must be considered carefully in terms of the local process conditions within a heater. Without careful control, heaters can suffer from excessive coking and even tube failure, with serious consequences to safety and plant availability. The AspenTech Solution: Flexible Modeling to Adapt to Changing Conditions The sophisticated modeling of Aspen Fired Heater allows designers to explore a wide range of heater configurations. For many designers, Aspen Fired Heater brings modeling flexibility and ease-of-use with full integration of firebox and convection section processes, combined with draft calculations. It offers the reliability of Aspen Exchanger Design and Rating models for process heat transfer and pressure drop along with the well-stirred or long-furnace models of firebox radiation. Aspen Fired Heater simulations provide heater operators with insight into local process conditions to facilitate optimal operations, maximizing throughput and energy efficiency without impairing safety or reliability. It also allows users to examine local heat flux and tube metal temperatures in the firebox and convection section, thereby avoiding unstable flow regimes in two-phase operations and bringing a better balance of throughput, firing rate, and where applicable, steam injection to the process. Aspen Fired Heater reports range from thermal summary screens to comprehensive incremental output.
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Aspen Fired Heater
Maximize process throughput through more efficient design and operationof your fired heaters
Aspen Fired Heater is the latest generation of thermal design software for the simulation and rating ofprocess fired heaters. Fired heaters are found on almost every process unit in a petroleum refineryand are widely used in petrochemical and bulk chemical production. Correct design and operation ofheaters is vital for achieving overall plant operational objectives in terms of efficiency andachievement of desired product slate.
The Challenge: Reduce Risk, Gain More Control of Fired Heaters
Ninety percent of the energy consumed in a typical refinery is associated with fuel burned in fired heaters. Heaters are vital to
the operation of distillation and conversion units. These devices are highly complex heat transfer units involving combustion,
radiation, and convective heat transfer, often interacting with several streams in a process. Changes in feedstock or crude
composition must be considered carefully in terms of the local process conditions within a heater. Without careful control,
heaters can suffer from excessive coking and even tube failure, with serious consequences to safety and plant availability.
The AspenTech Solution: Flexible Modeling to Adapt to Changing Conditions
The sophisticated modeling of Aspen Fired Heater allows designers to explore a wide range of heater configurations. For many
designers, Aspen Fired Heater brings modeling flexibility and ease-of-use with full integration of firebox and convection section
processes, combined with draft calculations. It offers the reliability of Aspen Exchanger Design and Rating models for process
heat transfer and pressure drop along with the well-stirred or
long-furnace models of firebox radiation. Aspen Fired Heater
simulations provide heater operators with insight into local
process conditions to facilitate optimal operations, maximizing
throughput and energy efficiency without impairing safety or
reliability. It also allows users to examine local heat flux and
tube metal temperatures in the firebox and convection
section, thereby avoiding unstable flow regimes in two-phase
operations and bringing a better balance of throughput, firing
rate, and where applicable, steam injection to the process.
Aspen Fired Heater reports range from thermal summaryscreens to comprehensive incremental output.
Aspen Fired Heater
Wide Range of Applications
Fired heater design involves balancing the thermal and hydraulic
requirements for the main process stream and the subsidiary
streams in the unit, while avoiding excessive capital cost. The
complexity of the interactions and the wide range of possible
configurations necessitate the use of a powerful tool like
Aspen Fired Heater. Its detailed modeling capabilities provide
an accurate assessment of local metal temperatures, allowing
users to select the most appropriate tube materials.
In modern plant operation, profitability is highly dependent on
how well heaters are running. If feedstocks change or pre-heat
trains foul up, the appropriate firing rate is not easy to determine.
Similarly, if fuel changes are required, an accurate model is most
important. Aspen Fired Heater helps operators achieve maximum
efficiency while avoiding operating regimes that may jeopardize
the run-time of the unit (due to excess coking), or that may
even impair the integrity of heater pressure parts. By modeling
a heater in the program, operators gain insight into local
conditions, which goes far beyond that revealed by
instrumentation.
Three major physical property databases are included in Aspen
Fired Heater—Aspen HYSYS® Thermodynamics COM Interface,
the leading package in oil & gas processing, Aspen B-JAC
standard properties package, which handles many common
industrial fluids, and Aspen Properties®. These databases
provide access to more than 1,100 components and include a
range of industry-standard VLE methods and mixing rules.
Aspen Fired Heater has a utility to import process data and
stream properties from Aspen HYSYS®. This allows users to
quickly set up studies of heater performance from the Aspen
HYSYS process flowsheet.
An extensive selection of graphics makes Aspen Fired Heatereasier to use.
Aspen Fired Heater: Key Technical Features
• Combined modeling of firebox andconvection section
• Up to 10 process streams in a single heater
• Handles cylindrical and cabin fireboxes
• Firebox well-stirred and long-furnaceradiation models
• Firebox wall tubes (vertical horizontal andhelical coil)
• Central tubes and cell-type fireboxes
• Up to 9 process convection section tubebanks and processes
• Tubes can be plain or finned
• Convection section tubes with high round fins,serrated fins, circular fins, and rectangular fins
• Flexible, easy-to-use user interface
• Full process thermal and hydraulic calculationsusing Exchanger Design and Rating methods
• Combustion calculations for up to 4 fuelsin the firebox
• Fuels can be selected from a standard set of 5common fuels or specified by gaseouscomposition or for liquid fuels by ultimateanalysis
• Outputs include the heater overallthermal performance in addition to manydetailed reports
• Evaluation of local process conditions,temperatures, and pressures
• Flagging of conditions that exceedexpected limits
• Flagging of unstable flow regimes
• Import of process and property data fromAspen HYSYS®
• Aspen HYSYS Thermodynamics COMInterface and Aspen B-JAC property databanks
Aspen Fired Heater
Thermal Output
Aspen Fired Heater uses the power and flexibility of the Microsoft® Windows environment to allow you to explore unit geometry
and performance detail. In addition, Aspen Fired Heater is designed to support “drag & drop” interfacing with Microsoft Excel, as
well as high-level communication with other software.
Thermal output includes:
• Overall heater thermal performance summary, including details of the heat load and the thermal efficiency of the unit
• Extensive warning and error reporting, alerting you to potential operational problems
• Overviews of thermal performance of each part of the heater, firebox, and tube bank
• Thermal overview of each stream in the heater
• Combustion information and fuel details, including calculated flue gas composition for individual fuels and fuel mixtures
• Comprehensive incremental output, including local temperatures, pressures, and heat flux
• Radiation information including zonal analysis
A number of program defaults helps minimizethe required user input.
Graphing is available for enhancing your visual interpretation ofoutput information.
Worldwide Headquarters
Aspen Technology, Inc.200Wheeler RoadBurlington, MA 01803
phone: +1-781-221-6400fax: [email protected]
EMEA Headquarters
AspenTech Ltd.C1, Reading Int’l Business ParkBasingstoke RoadReading UKRG2 6DT
phone: +44-(0)-1189-226400fax: +44-(0)[email protected]
APAC Headquarters
AspenTech - Shanghai3rd Floor, North WingZhe DaWang Xin Building2966 Jin Ke RoadZhangjiang High-Tech ZonePudong, Shanghai201203, China
phone: +86-21-5137-5000fax: [email protected]
Aspen Exchanger Design and Rating
Aspen Fired Heater is a part of the Aspen Exchanger Design and Rating family of products. Aspen Exchanger
Design and Rating products offer state-of-the-art heat exchanger simulation and design based on over 30
years of industry-leading research. Our aim is to enhance the value of heat transfer solutions by providing
the most integrated product offering across the widest range of technologies. This enables our customers
to use the most advanced physically-based modeling, from unit design and overall process design, through
to optimization and operational monitoring.
aspenONE Process Engineering
Aspen Exchanger Design and Rating family of products is a key component of aspenONE Process Engineering
for chemical, refining, and E&P companies. aspenONE Process Engineering is an integrated lifecycle solution—
from conceptual design through to plant startup and operations support—enabling our customers to build
and operate safer, competitive and more reliable process plants. Companies are able to reduce capital
and operating costs, increase engineering efficiency and quality, and accelerate time-to-market—with
payback in months instead of years.
About AspenTech
AspenTech is a leading provider of award-winning process optimization software and services. AspenTech’s
integrated aspenONE™ solutions enable manufacturers to reduce costs, increase capacity, and optimize
operational performance end-to-end throughout the engineering, plant operations, and supply chain
management processes.
For more information, visitwww.aspentech.com.
© 2008 Aspen Technology, Inc. AspenTech®, aspenONE™, and the Aspen leaf logo are trademarks or registeredtrademarks of Aspen Technology, Inc. All rights reserved. 1319-05-0808
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