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Aspen FiredHeater™
Maximize process throughput through more efficient design and operationof your fired heaters
Aspen FiredHeater 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 FiredHeater allows designers to explore a wide range of heater configurations. For many
designers, Aspen FiredHeater 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 HTFS models for process heat transfer and pressure
drop along with the well-stirred or long-furnace models of
firebox radiation. Aspen FiredHeater 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 FiredHeater reports range from thermal summaryscreens to comprehensive incremental output.
Aspen FiredHeater™
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 FiredHeater. 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 FiredHeater 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.
Two major physical property databases are included in Aspen
FiredHeater—Aspen COMThermo®, the leading package in oil
& gas processing, and Aspen B-JAC standard properties
package, which handles many common industrial fluids.
These databases provide access to more than 1,100
components and include a range of industry-standard VLE
methods and mixing rules.
Aspen FiredHeater 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 FiredHeatereasier to use.
Aspen FiredHeater: Key Technical Features
• Combined modeling of firebox and convectionsection
• 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 roundfins, serrated fins, circular fins, andrectangular fins
• Flexible, easy-to-use user interface
• Full process thermal and hydrauliccalculations using HTFS methods
• Combustion calculations for up to 4 fuels inthe 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 overall thermalperformance in addition to many detailedreports
• Evaluation of local process conditions,temperatures, and pressures
• Flagging of conditions that exceed expectedlimits
• Flagging of unstable flow regimes
• Import of process and property data fromAspen HYSYS®
• Aspen COMThermo and Aspen B-JACproperty databanks
Aspen FiredHeater™
Thermal Output
Aspen FiredHeater uses the power and flexibility of the Microsoft® Windows environment to allow you to explore unit geometry
and performance detail. In addition, Aspen FiredHeater 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 HTFS+ Product Family
Aspen FiredHeater is a part of the Aspen HTFS+ family of products. Aspen HTFS+ 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 HTFS+ 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, resulting in millions of dollars in cost savings.
For more information, visitwww.aspentech.com.
© 2007 Aspen Technology, Inc. AspenTech®, aspenONE™, and the Aspen leaf logo are trademarks or registeredtrademarks of Aspen Technology, Inc. All rights reserved. 1319-1207
