FIS-483 Consolidated Engineering Study Report
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
Marathon Petroleum Company, Catlettsburg Refinery, KY<br />
Capacity Improvement <strong>Study</strong> of LPCCR Platformer Heater (1-44-B-1/2/3/4)<br />
1.1 Introduction<br />
Section 1<br />
Executive Summary<br />
<strong>FIS</strong> was employed by Marathon Catlettsburg Refinery, KY to carry out a capacity<br />
improvement study of LPCCR Platformer Heater (1-44-B-1/2/3/4). The existing<br />
Platformer Heater was built in 1992. It is designed for a Naphtha charge rate of 18.2<br />
MBPD and recycle gas rate of 26.4 MMSCFD. It is rated for 106.3 MMBtu/hr<br />
process duty in radiant section. The convection section recovers waste heat of 50.5<br />
MMBtu/hr and generates 55,966 lb/hr of steam.<br />
Marathon is operating the heater at an average of 22.9 MBPD of Naphtha charge<br />
rate. They are fuel gas pressure limited at burners for the Platformer heater.<br />
Marathon is looking to revamp the heater for a Naphtha feed rate 24.5 MBPD which<br />
is maximum operated charge rate as per last one-year operating data and 40<br />
MMSCFD of Recycle Gas flowrate. They want to increase the heat duty to 250<br />
MMBtu/hr utilizing the permitted firing capacity of 280 MMBtu/hr (LHV).<br />
<strong>FIS</strong> performed a Capacity Improvement <strong>Study</strong> to evaluate the complete<br />
performance. <strong>FIS</strong> analyzed the existing design and current operation of the heater.<br />
Based on the above, <strong>FIS</strong> has developed a very economical option for increasing<br />
the capacity of the Platformer Heater using our patented Split Flow Technology.<br />
With the split flow arrangement, the proposed new convection section can provide<br />
44.25 MMBtu/hr of process duty. The scheme also recovers 5.12 MMBtu/hr of<br />
debutanizer reboiler duty and generates 53,061 lb/hr of steam.<br />
1.2 Design Observations<br />
<strong>FIS</strong> reviewed the existing design configuration of the Platformer heater. We ran<br />
the existing heater design simulation and the design is found to be in order. The<br />
simulation results closely match the process conditions, bridge wall temperature<br />
and steam generation in the datasheet.<br />
1.3 Operating Observations<br />
<strong>FIS</strong> analyzed daily operating data of Platformer Heater for one year provided by<br />
Marathon. The following observations were made regarding the current operation<br />
of the heater:<br />
Furnace Improvements<br />
Low Cost Solutions for Fired Heaters 10