On the Possibility of Applying Dynamic Mode Maps for Furnaces in Oil Refining Industries

Tubular furnaces play a critical role in primary crude oil processing, providing the necessary heat for feedstock to reach temperatures required for subsequent fractionation. Their operational efficiency is directly linked to heating uniformity, minimal fuel consumption, and safe operation. Traditional furnace control relies on static operating maps, which, despite their simplicity, fail to account for dynamic process variations, including fluctuations in feedstock quality, load changes, equipment status, as well as variations in draft parameters in both the convection and radiant sections, and burner gas pressure. Suboptimal draft and gas pressure management can lead to uneven heating, localized overheating, increased fuel consumption, and the risk of emergency shutdowns. This paper investigates the potential for applying dynamic process regime mapping to optimize draft control in tubular furnaces within primary oil refining units. The focus is placed on draft control in both the convection and radiant sections of the furnace, as these areas are critical for uniform heat distribution. Dynamic regime maps, unlike static ones, enable real-time adjustments to draft and gas pressure parameters, accounting for current operating conditions, including changes in fuel flow, air flow, flue gas temperature, furnace pressure drop, and burner gas pressure. The objective of this study is to develop a dynamic regime map concept that will ensure optimized draft and gas pressure management, reduce heating non-uniformity, decrease fuel consumption, and minimize the risk of tube overheating. The research includes an analysis of existing furnace control methods, with particular emphasis on draft and burner gas pressure control. Factors affecting draft in the convection and radiant sections, and burner gas pressure, were investigated, and the need for dynamic correction of these parameters was substantiated. A dynamic regime map concept, based on the use of key parameters characterizing furnace condition and performance, was developed. An algorithm for the dynamic adjustment of draft and gas pressure parameters was proposed, which adapts furnace operation to changing external conditions and ensures optimal combustion conditions. An assessment of the potential effectiveness of the proposed approach was conducted, demonstrating that the implementation of dynamic regime maps can significantly improve draft and gas pressure management, reduce fuel consumption, and enhance the operational safety of furnaces. The findings of this study demonstrate the significant potential for using dynamic regime maps to optimize draft and gas pressure control in oil refinery fired heaters. The proposed approach can deliver more uniform heating, lower fuel consumption, minimize the risk of coil overheating, and improve the overall furnace efficiency. Future research directions include further development of dynamic draft and gas pressure control models, considering the characteristics of different furnace types and their operating conditions, as well as experimental validation of the developed solutions in real industrial settings.