Design and supply of a process furnace for a chemical plant

By AITESA

Introduction

In 2021 AITESA provided support to a leading chemical company for an energy improvement project of the 600 mt/day ammonia production plant.

Specifically, AITESA was in charge of the energy improvement of the desulfurization furnaces through the engineering and supply of a new air preheater, as well as the new radiation and convection coils of the process furnace.

Solution

Thermal, mechanical and hydraulic design of the furnace with the new radiation and convection coil.
Validation of the heat recovery system for the new operating conditions.
Design, manufacture and transport to the plant of the new convection sections.
Design of the necessary modifications to the radiant zone for the installation of the new convection sections.
Development of assembly and disassembly procedures
Assembly supervision

Results

Reduction of furnace pressure drop, allowing 100% of the plant to operate with only one furnace (previously two furnaces in parallel).
Drastic reduction of parasitic air and excess air in combustion
Decrease in flue gas emission temperature by 15%.
Decrease in fuel consumption
Improved draft and pressure control of the furnace thanks to variable speed drives on the combustion air and flue gas fan motors.

In this project, which had an existing air preheating system, savings of up to 2.5% are produced. Due to these savings, the payback period for the investment is 3 to 4 years.