Restoration of Refinery Heaters Using the Technique of Prefabricated Ceramic Fiber Lined Panels

Abstract

Refinery heater fuel requirements often represent 50% of a units operating cost. A one percent change in the efficiency of a heater firing 100 MBtu/hr amounts to more than $25,000 per year. Heater efficiency is influenced by casing hot spots, air leakage, corbel damage, flue gas obstruction and dirty tubes. Efficiency impact is greatest in the convection section since conventional repairs only permit accessing from the outside, thus only hot spots and some air leakage are repaired.

Exxon USA's Baton Rouge refinery has adopted a restoration procedure, using the technique of ceramic fiber lined panels, which corrects all the problem areas and returns the heater to new condition. Restorations have been successfully completed on convection sections as well as total heaters. All restorations have been within a normal turnaround period. Efficiency increases greater than 3% have been realized, as well as improvements in the heater's operation.