FIS-483 Consolidated Engineering Study Report

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Marathon Petroleum Company, Catlettsburg Refinery, KY Capacity Improvement Study of LPCCR Platformer Heater (1-44-B-1/2/3/4) 1.1 Introduction Section 1 Executive Summary FIS was employed by Marathon Catlettsburg Refinery, KY to carry out a capacity improvement study of LPCCR Platformer Heater (1-44-B-1/2/3/4). The existing Platformer Heater was built in 1992. It is designed for a Naphtha charge rate of 18.2 MBPD and recycle gas rate of 26.4 MMSCFD. It is rated for 106.3 MMBtu/hr process duty in radiant section. The convection section recovers waste heat of 50.5 MMBtu/hr and generates 55,966 lb/hr of steam. Marathon is operating the heater at an average of 22.9 MBPD of Naphtha charge rate. They are fuel gas pressure limited at burners for the Platformer heater. Marathon is looking to revamp the heater for a Naphtha feed rate 24.5 MBPD which is maximum operated charge rate as per last one-year operating data and 40 MMSCFD of Recycle Gas flowrate. They want to increase the heat duty to 250 MMBtu/hr utilizing the permitted firing capacity of 280 MMBtu/hr (LHV). FIS performed a Capacity Improvement Study to evaluate the complete performance. FIS analyzed the existing design and current operation of the heater. Based on the above, FIS has developed a very economical option for increasing the capacity of the Platformer Heater using our patented Split Flow Technology. With the split flow arrangement, the proposed new convection section can provide 44.25 MMBtu/hr of process duty. The scheme also recovers 5.12 MMBtu/hr of debutanizer reboiler duty and generates 53,061 lb/hr of steam. 1.2 Design Observations FIS reviewed the existing design configuration of the Platformer heater. We ran the existing heater design simulation and the design is found to be in order. The simulation results closely match the process conditions, bridge wall temperature and steam generation in the datasheet. 1.3 Operating Observations FIS analyzed daily operating data of Platformer Heater for one year provided by Marathon. The following observations were made regarding the current operation of the heater: Furnace Improvements Low Cost Solutions for Fired Heaters 10
Marathon Petroleum Company, Catlettsburg Refinery, KY Capacity Improvement Study of LPCCR Platformer Heater (1-44-B-1/2/3/4) Average feed flow rate to each cell is 263,190 lb/hr. Average firing rate is 235.22 MMBtu/hr. Feed inlet and outlet temperature in each cell are lower than the original design temperatures. Feed temperature rise in Charge Heater, inter heater 1 and Inter Heater 2 is higher than the design by 20°F. Flue gas temperature leaving the convection section is around 571°F. The excess O2 is in the range of 4.4%. The burners are operated at higher fuel gas pressure in all the radiant cells than the original design. The average fuel gas pressure for No.1 Interheater, Charge heater, No.2 Interheater and No.3 Interheater are 22.2 psig, 25.1 psig, 22.4 psig and 28.5 psig respectively. Firing rate (LHV) calculated from fuel pressure almost matches the firing rate provided by client The calculated bridgewall temperature is higher than the actual. It could be that the radiant duty is higher than the calculated. Operating data simulation is indicating that the firing rates should be lower than the actual. It is also indicating that actual steam production is lower than calculated. We are not able to close the heat balance. 1.4 Recommendation FIS recommends recovering process heat duty in convection section based on FIS Split Flow Technology. We have optimized the required process duty as well as the design steam generation. In the proposed split flow arrangement, the process flow to the heater is split between radiant and convection sections. About 22.4-26.5% of the charge rate goes to the convection section split flow coil and the balance to the radiant coils. FIS proposes to run split flow piping from the inlet manifolds to the new convection coils and then return the convection section outlet split flow piping back to the outlet manifold from the radiant. We recommend installing a butterfly control valve to control the flow to the split flow convection coils so that the outlet temperature is maintained the same as the radiant section. The new convection section will be completely prefabricated in the shop. It consists 15 rows of tubes arranged in two modules. The bottom module consists of 7 rows of tubes and the top module consist of the rest 8 rows of tubes. The proposed convection houses process split flow coils for all four cells in the bottom module. The process coils consist of bare and finned tube rows. The steam generation coils are arranged above the process coils. The debutanizer reboiler coils are sandwiched between the steam generation coils. Furnace Improvements Low Cost Solutions for Fired Heaters 11
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FURNACE IMPROVEMENTS PROPOSED CONVE
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FIS-483 Consolidated Engineering Study Report

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