Case 1: Oxidizer review
Problem: For a chemical industry client, the
operation of their process heater was not acceptable. The heater
was burning heavy residual tars from one process and a fume stream
from another process. The fume stream was uncontrollable. Whatever
came from the process had to be processed. To restrict the fume
stream would upset the process. The tars were controlled in that
they were stored in a tank. Thus the control of the system was
dependent on the fume stream.
The composition of the fume stream would vary over time through
the vent cycle. At times it would contain mainly nitrogen. The
organic component would vary as a function of the operation and
even as to the operators. This was a stream with a widely variable
Solution: A control system was developed that
would safely and efficiently destroy all of the organic materials
in the fume and tar stream. High speed temperature measurement
devices were specified. The system was tested and met the high
destruction requirements of the Boiler and Industrial Furnace
regulations for hazardous waste.
As an additional element, we developed a procedure to utilize
the stored operational data to determine the efficiency of the
unit and to determine when components needed maintenance.
Case 2: Combustion Enhancement
Problem: A chemical plant burning a highly salty
waste was repairing their refractory on a continuous basis. The
refractory repairs in addition to costing money were limiting
the plant production.
Solution: A new nozzle was designed and supplied
to the plant. The new nozzle design significantly improved the
combustion of the unit. Refractory repairs were reduced and operational
time was increased.
Case 3: Fumes in Boiler
Problem: The chemical plant feed fumes from
a process into a boiler. The fume addition was not optimum and
caused the boiler to operate erratically.
Solution: After reviewing the system, a different
boiler was selected to receive the fumes. The method of fume injection
was changed to minimize it impact on the boiler operation. As
a result of the modification, the fumes are now be efficiently
handled by the different boiler. The plant operational costs (natural
gas) have been reduced by the change in operation.
Case 4: Refinery Heater
Problem: A crude oil heater in a refinery was
operating below the desired capacity.
Solution: To obtain the actual operational information
over an extended range of conditions, stack gas composition was
obtained using Therm-A-Cor equipment. The heat transfer and the
firing rate of the burners was reviewed in detail. The plant recorded
operational data, was found to misrepresent the variations in
the chemical composition of the flow streams. The thermal heat
transfer model developed allowed for accurate projections of the
operational conditions. Modifications in the system were proposed
to improve the operational efficiency of the crude oil heater.
Several other fired heaters were reviewed in the plant utilizing
the Therm-A-Cor mobile stack gas analyzer and the recorded operational
data. System efficiency improvements recommendations were made
after the detailed analysis of the operational conditions was