Abstract
In this paper results of analysis of process steam boiler operation with maximum continuous steam production of 75 t/h, steam pressure and temperature of 45,5 bar and 412 oC are presented. Steam boiler is predicted to operate within steam production facility of oil and gas refinery in Pančevo, Serbia. On the demand of purchaser steam boiler is enabled to operate with various fuels as well as with two or three fuels simultaneously. By fuels intake facilities it is enabled to introduce refinery gas, fuel oil and high-temperature waste gas to the boilers furnace. Waste gas is guided from FCC (Fuel catalyst cracking) facility and presents two-component fluid with polydisperse solid phase composed of particles of diameter smaller than 40 µm. Recent changes in steam consumption in refinery resulted in modifications in boiler`s operating regime and, further on, in significant changes in its operational parameters. At present, in new conditions, boiler operates with frequent pipe bursts on pipe bundles of boiler economizer which requires forced interruption in steam production as well as time and cost consuming operations for resuming boiler work. In this paper results of thermal calculations for design and new operational conditions are presented for the purpose of identification of cause of frequent unscheduled steam production interruptions. After analysis of presented results, recommendations on how to modify certain boiler operational parameters in order to eliminate or reduce possibility of such unfavourable occurance has been provided.
Highlights
Process steam boiler located in oil and gas refinery in Pančevo, Serbia, produces overheated steam utilized for domestic electricity production as well as for the needs of technological processes within refinery
For the purpose of assessing influence of particular parameters on overall heat exchange in steam boiler control calculations has been conducted for maximum continual fresh steam massflow rate (75 t/h) and designed parameters of feedwater and fresh steam in case when boiler works in REFINERY GAS (RG) and RG+WASTE GAS (WG) regimes
By comparing of flue gas outlet temperatures it can be stated that temperature is higher for approximately 50 oC when boiler operates in RG+WG regimes which contributes to the higher values of heat loss in outlet flue gas and lower values of boiler efficiency rate
Summary
Process steam boiler located in oil and gas refinery in Pančevo, Serbia, produces overheated steam utilized for domestic electricity production as well as for the needs of technological processes within refinery. Recent changes in steam consumption in entire facility occurred which led to significant reduction of fresh steam flow rate in process steam boiler, even below minimum level. In such operational conditions pipe burst on economizer pipe bundles are frequent which requires immediate. Shutdown of steam boiler and unscheduled interruption in steam production. Such occurrence led to the reduction in boiler operational effectiveness, reliability and cost-effectiveness which requires conduction of analysis of boiler operational parameters in new working conditions in order to detect cause of such time and cost-consuming outages. In order to verify fouling factors of all heat exchangers visual inspection of interior of flue gas tract has been conducted
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