Furnace

The furnace known either as a boiler or a heater, and it uses in oil

refineries. Fuel gas is burned with air by a combustion device to
generate the heat. The furnace is of cabin type with horizontal
tubes designed for a heat duty of 215 GJ/H. After combustion, the
resultant hot flue gas flows up through the stack and discharges
into the atmosphere. Recoverable heat from the flue gas is further
removed in the super heater section before the flue gas leaves
the furnace through the stack. Furnaces can be classified into
four general categories, based on efficiency and design.
Natural draft: The first category would be natural draft,
atmospheric burner furnaces. These furnaces consisted of castiron or riveted-steel heat exchangers built within an outer shell of
brick, masonry, or steel. The system was simple, had few controls,
a single automatic gas valve, and no blower. They have been
operated with wood, coke, coal, trash, paper, natural gas, and fuel
oil.
Forced-air: The second category of residential furnace is the
forced-air, atmospheric burner style with a cast-iron or sectional
steel heat exchanger. This style furnace was used to replace the
big, natural draft systems, and was sometimes installed on the
existing gravity duct work. The heated air was moved by blowers
which were belt driven and designed for a wide range of speeds.
Forced draft: The third category of furnace is the forced draft,
mid-efficiency furnace with a steel heat exchanger and multispeed blower. These furnaces were physically much more
compact than the previous styles. These furnaces have multispeed blowers and were designed to work with central airconditioning systems.
Condensing: The fourth category of furnace is the high-efficiency,
or condensing furnace. High-efficiency furnaces can achieve from
89% to 98% fuel efficiency. This style of furnace includes a sealed
combustion area, combustion draft inducer and a secondary heat
exchanger. Because the heat exchanger removes most of the

heat from the exhaust gas, it actually condenses water vapor and
other chemicals.
Burners: The combustion device consists of four floor mounted
burners. Each burner has fuel gas and pilot gas lines, with a block
valve on the pilot gas line and an adjustable valve on the fuel gas
line. Each burner also has an igniter and a secondary air register.
Draft System: The air intake into the furnace box is by natural
draft mechanism. The tall structure provides the necessary draft
at the base of the furnace for air to flow through the burner
assembly. A damper is provided at the furnace stack for
controlling the pressure in the furnace box.
The process feed is heated through 2 passes in the furnace. It is
important to maintain a uniform flow over the two passes. The
fluid flow rate at each pass is controlled two override controllers,
Fuel Gas Low Pressure Controller (PC315L) and Fuel Gas High
Pressure Controller (PC316H), are provided to protect the furnace
from low and high fuel gas pressures respectively. The purpose of
these overrides is to ensure that the fuel gas pressure always
stays in the stable operating region of the burner flame. by its
individual Flow Controller (FC110 & FC120).
Furnace Arch Pressure Control (PC405): It is important to maintain
the furnace pressure to ensure that adequate amount of air
(excess air) is provided for a given fuel flow rate. Normally, the
opening of the air registers is fixed and the air flow rate is
determined by the furnace pressure. As the furnace pressure
increases, the air flow rate decreases. Similarly, as the furnace
pressure decreases, the air flow rate increases.
Initial Conditions: Two initial conditions are provided. Each of them
when loaded starts the simulation at a particular operating
condition of the furnace unit. The initial conditions are:
a. Cold Start-Up Condition: In this initial condition the furnace unit
is in a complete shutdown state. The unit is at ambient conditions
with no inventory in any vessels. The startup exercise of the
furnace unit can be performed with this initial condition.

b. Design Operating Condition: This is the normal initial condition.

In this initial condition, the furnace unit is at a steady state with
all burners in service. The operating conditions are the same as
the design operating conditions. This initial condition can be used
to study the effect of changes in operating conditions on the
performance of the unit. Also this initial condition can be used for
studying the effect of malfunctions and for performing the
shutdown exercise of the unit.