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Aspen Fired Heater
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Aspen Fired Heater

      通过更有效率的设计和操作来提高整个流程的生产能力

•  功能

  •  模拟模型:对于给定炉型及结构尺寸、燃料消耗量、过剩空气系数、被加热介质等,软件能进行以下计算:通过燃烧室和对流室的传热计算及多相流流体计算,可得到被加热流体和烟气的温度分布和压力分布。其中烟气的压力分布是沿燃烧室经对流段至烟囱的非常详细的数据
  • 核算模型:对于给定炉型,指定燃烧段热负荷(通过给定被加热流体在燃烧的出口温度),反算出所需的燃料量(输入方式和模拟模式相同,但需指定被加热流体在燃烧段的出口温度)。
  • 处理能力:被加热流体可以是: (1)单相流体(气相或液相)(2)多相流体(气液二相或气液 - 液三相)

      被加热介质可分布在加热炉的不同部分。该加热炉可用于模拟计算:各种炼油厂、化工厂圆筒炉和方箱加热炉及热回收系统。

•  技术特点

  • 功能强大的在线帮助系统及以图形交互的方式输入燃烧室及对流段的结构尺寸。利用这些功能,用户可以非常容易地完成建模工作
  • 被加热介质最多可达 10 股流,它们可以任意分布于炉子的各部位。它们相对于烟气可以采取逆流或并流
  • 被加热介质可以是单相流或多相流。它们可以采用多路及多管程方式
  • 可以采用气体燃料或液体燃
  • 圆筒炉或方箱炉。燃烧段可以是单排或双排炉管。炉管可以是垂直或螺旋布置,可置于炉中央或圆周排列
  • 方箱炉可以是单体或双体
  • 对流段最多可以分为 9 段。管子可以是光管或翅片管。对流管可以考虑来自燃烧室的辐射传热
  • 烟气排放方式有两种方式,即回收烟气能量(用烟气预热燃料),或不回收烟气能量。烟筒可以是同径或变径。烟筒可带档板
  • 燃烧室和对流段可分别单独建模
  • 可用各种单位,如:国际单位、公制单位及英制单位
  • 支持 .PSF 物性文件格式。用户可通过 .PSF 文件和模拟软件进行数据传递

•  物性数据库

      在模拟过程中,对于被加热介质需要用到以下物性:密度、比热、导热系数、液体的表面张力,对于多相流还需热负荷曲线(温度 - 焓 - 汽化率)。为了取得这些物性, HTFS 提供了一下方法:

  • 热力学物性数据包:将 HYSYS 流程模拟软件中的热力学包引入 HTFS 系统。提供 1000 多个纯组分, 6 种状态方程及 2 个活度计算模型
  • NEL40 包含 40 个纯组分的物性计算方法
  • 可以通过标准的 PSF 物性生成文件,由流程模拟系统提供物性数据

•  模型计算方法

      燃烧室可采用两种计算模型:

  • 均匀混合模型(单区域法),将整个燃烧室视为一个完全混合的一个区域
  • 区域法,将燃烧室沿轴向分成若干段,每个段被认为是一个小的区域。对于每个区域都计算辐射传热、 对流传热、及各种热平衡。最后得出每个区域的详细数据:
  • 烟气和炉壁的温度分布
  • 被加热介质及炉管壁的温度分布

      火焰在每个区域的热量分布可由模型自动计算或由用户自己定义

      在对流段,烟气的温度和压力是沿其流动方向逐段炉管计算的。被加热介质的温度、 压力和管壁温度是逐管计算的。对流段也可考虑辐射传热。烟气的压力降计算考虑了由鼓风机进口到烟囱出口的每个部分。

•  模拟结果输出

      从简洁的总结报告到非常复杂的逐管分析报告, FIHR 软件的输出方式能使您从各个方面研究加热炉的性能。一些非常重要参数还可以用图形方式表现出来。如:压力分布图和温度挟点图等。通过各种曲线图您可以更进一步了解炉子的性能。 FIHR 可以输出以下报告:

  • 简洁汇总报告
  • API 数据报告
  • 炉子每部分的热平衡报告
  • 炉管的热强度报告
  • 烟气温度、压力分布报告
  • 被加热介质的温度及炉管表面温度分布报告(逐管分析)
  • 计算炉管的最高温度
  • 被加热介质的逐管压力分布

     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, GainMore 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: FlexibleModeling 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。

Aspen Fired Heater: Key Technical Features

  • Combined modeling of firebox and convection section
  • Up to 10 process streams in a single heater
  • Handles cylindrical and cabin fireboxes
  • Firebox well-stirred and long-furnace radiation models
  • Firebox wall tubes (vertical horizontal and helical coil)
  • Central tubes and cell-type fireboxes
  • Up to 9 process convection section tube banks 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 calculations using Exchanger Design and Rating methods
  • Combustion calculations for up to 4 fuels in the firebox
  • Fuels can be selected from a standard set of 5 common fuels or specified by gaseous composition or for liquid fuels by ultimate analysis
  • Outputs include the heater overall thermal performance in addition to many detailed reports
  • Evaluation of local process conditions, temperatures, and pressures
  • Flagging of conditions that exceed expected limits
  • Flagging of unstable flow regimes
  • Import of process and property data from Aspen HYSYS
  • Aspen HYSYS Thermodynamics COM Interface and Aspen B-JAC property databanks

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 accuratemodel ismost important. Aspen Fired Heater helps operators achievemaximum efficiency while avoiding operating regimes thatmay 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 COMInterface, 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 Heater easier to use.

      Aspen Fired Heater uses the power and flexibility of theMicrosoft 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 minimize the required user input.

 

                        Graphing is available for enhancing your visual interpretation of output information.

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-basedmodeling, 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.


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