Session: 16-01: Poster Presentations

Paper Number: 141067

141067 - Innovative Method of Optimizing the Fuel Gas Consumption in Fired Heater and Furnaces 

Abstract: 

Objective/Scope: The objective of this paper is to showcase an innovative method and practice of operating the fired heater or furnace in Gas Oil Separation Plants (GOSPs) to improve fuel gas consumption without significant equipment modifications. The aim is to enhance the operational performance of the fired heater in GOSPs and achieve optimum process results with reduced capital expenditure (CAPEX).

Methods, Procedures, Process: Heating wet crude in the upstream process, particularly in GOSPs, is crucial for effective crude treatment, including the separation of produced water and the production of dry crude according to plant specifications. However, the heating process consumes a significant amount of fuel, typically accomplished by burning diesel in a fired heater or furnace, which exchanges heat with the wet crude through dedicated heat exchangers. A new method was developed specifically for GOSPs to optimize fuel consumption and reduce CAPEX. This involved establishing a new procedure and alarm system to monitor the flow rate of recycled diesel through a dedicated recycle line. The system alerts the console operator to reduce the number of burners in operation, allowing for sufficient heat absorption by the diesel flow inside the furnace.

 Results, Observations, Conclusions: Implementation of the method for monitoring the recycled diesel flow rate resulted in effective optimization of fuel gas consumption. Furthermore, it improved furnace performance by reducing the stack temperature by over 36%. These results demonstrate significant energy savings and environmental benefits that can be achieved in the upstream process. By adopting this innovative method, GOSPs can operate their fired heaters or furnaces more efficiently, leading to substantial reductions in fuel gas consumption and improved overall performance. The approach does not require major equipment modifications, making it a cost-effective solution for enhancing operational efficiency. Furthermore, the reduction in stack temperature contributes to a more sustainable and environmentally friendly operation. The findings of this study have broader implications for the oil and gas industry, as optimizing fuel consumption and reducing CAPEX are key goals for many facilities. The method presented in this paper can serve as a valuable reference for other plants and industries seeking to improve the performance and energy efficiency of their fired heaters or furnaces. Additionally, the environmental benefits achieved through reduced fuel consumption align with the industry's increasing focus on sustainability and reducing carbon emissions. In conclusion, this paper presents a novel approach to operating fired heaters or furnaces in GOSPs, highlighting the benefits of monitoring recycled diesel flow rate to optimize fuel consumption. The results demonstrate the effectiveness of the method in achieving substantial energy savings and improving overall furnace performance. By implementing this approach, GOSPs and other facilities can enhance their operational efficiency, reduce fuel gas consumption, and contribute to a more sustainable future.

Presenting Author: Ali Alshehri Aramco

Presenting Author Biography: Ali Alshehri graduated from King Fahad University of Petroleum and Minerals in chemical engineering. He joined Aramco as process engineer and he has been assigned in many projects and plants. He obtained first granted patent from US Patent and Trademark Office (USPTO) with reference No. 11,209,842. Also, he commissioned new giant Reverse Osmosis Plant for Oil Treatment and he was lead engineer for project execution. He did several assessments for furnaces and fired heater to improve the process performance and to be operated in a sustainable method.

Authors:

Ali Alshehri Aramco