Heater with combined heating PNK-0.73 (Zh), PNK-1.9 (Zh), PNK-3.5 (Zh)

PNK oil  heater with combined heating is designed for heating oil of different viscosity and oil emulsion during processing as well as during transportation. The possibility  of heating the product in the heater to 110 ° C will ensure the use of PNK in the heavy oil processing as well as during stabilization oil and gas condensate. The heater is designed for operation in moderate climate regions ("U" - moderate), category 1 according to GOST 15150. On request, the oil heater can be made for cold climate region (for example, PNA-1.9 HL).

The heater consists of the following main parts:

·         Heating block with a burner;

·         Fuel treatment block;

·         Ventilation block;

·         Control systems.

Oil from the field network enters the product coil consisting of two parts locating in the intermediate heating agent and in the convective (cold) section of the combustion device. Oil is first heated from the heating agent and then from the combustion products and flows out from the heater. Feeding gas for the burners after cleaning and pressure reducing in the fuel preparation  unit is fed to the ignition and main burners, burned in the heater furnace giving heat to the intermediate heat agent and product coils. Cooled combustion products through the chimney are removed from the heater furnace into the atmosphere.

The heating unit is designed to transfer fuel combustion heat to the heated product. The heating block is a tank installed on the base frame and filled with an intermediate heating agent. Furnace and two stream coil are located inside the tank. The main and pilot burners are attached to the flange of the furnace.

The furnace is a U-shaped welded structure from a pipe D = 620 mm. To intensify the convective heat transfer rings-turbulators are installed in the "hot" branch, coil is located in the "cold" branch. The furnace is fixed to the tank with a flange connection.

The coil is a six-section bundle of pipes located in the intermediate heating agent. Each section is made in the form of a two-way flat spiral. The coil located in the "cold" branch of the furnace is a six-row bundle of pipes with a diameter of 89x5 mm. Finned tubes are used to intensify convective heat transfer from combustion products to oil.

The heating block is designed to transfer heat from combustion products to the heated product. The heating unit  is a tank installed on the base frame and filled with an intermediate heating agent (fresh water) with a furnace and coils installed inside. The heating unit is a monoblock that can be transported by any type of transport.

Fuel treatment block is designed to handle the purification, pressure reduction and control devices for supplying fuel to burners.

The devices are mounted in the insulated cabinet.

The ventilation unit is an insulated shelter where radial fan BP1226N315 is installed with 4A100S2 electric motor with power of 4 kW.

The control system is designed for remote ignition of burner devices, control of the oil heating process, operation and emergency alarms, automatic protection of the heater in the emergency event.

The heater uses the principles of "soft" oil heating by the intermediate heat agent (fresh water, water-glycol liquids) and by combustion products of the fuel with moderate temperatures eliminating coke deposits on the inner walls of the coil and disturbances in its operation. The decision to burn fuel gas in the furnace space of the flame tube under a small  excess pressure makes possible to apply the methods of heat transfer intensification from the combustion products to the heat-receiving walls (using rings-turbulators) and the product coil (using a finned tube), and thereby significantly reduce the dimensions and weight of the heater.

The burner with aerodynamic control used in the heater design allows to optimize the thermal performance due to:

·         Increasing the radiant component of heat transfer from the flue gases to the furnace wall due to offset of the flame combustion core;

·         Increasing the convective component of heat transfer due to increase in the axial  velocity and the degree of flow turbulence;

·         The possibility of regulating the torch length;

·         Reduction of nitrogen oxides in flue gases to 65-70 mg / m2;

·         Reduction of energy costs for blasting by 2-32 times;

·         Increase the overhaul life of the furnaces by 10-12 months.

Automation

Possible to supply the heater with various control systems. Oil heaters PNK-0.73 (Zh); 1.9 (Zh); 3.5  (Zh) are commonly completed with the control systems BUK-5PUR, on request -SA-PNG.M based on the Direct Logic DL-05 controller. Control systems provide the ability to exchange information with the upper control level and remote control using various industrial protocols (MODBUS RTU, etc.), RS-232 and RS-485 interfaces which makes it easy to integrate the heater into the process control system.

On request the heater can be designed for work with gas or liquid fuel as well as on combined fuel  (oil, mazut, diesel fuel, gas), in this case the index "Zh" is used in the designation.  

All furnaces and heaters depending on the modification can be equipped with both standard  automation and control systems (BUK-5PUR, USA-1TK) and on request with a microprocessor-based control system based on Direct  Logic controllers and other analogues which will make easier to integrate the heater into the process  control system as well as organize remote monitoring and control, in this case the index "M" or "E" (tubular block heaters) is used in the of the product marking.


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Parameter

PNK-0,73 (Zh)

PNK-1,9 (Zh)

PNK-3,5 (Zh)

Nominal heat capacity, mW (gcal / h)

0.73 (0.63)

1.9 (1.6)

3.5 (3.0)

Heated fluid

Oil - viscosity at 20 ° C max 50 cSt,

Acid gas content: H2S - max 0.002%

CO2 - max 1.0 wt %

Coil operating pressure, MPa

6.3

Pressure drop in the coil, MPa, max

0.25

0.3

0.2

Temperature:

 

 

 

- of the product at the inlet/outlet of the heater, + °C

10/110

- of the intermediate heating agent (fresh water) heating, + ° C, max

95

Volume of heating agent (fresh water), m³

4.7

4.9

7.6

fuel

Natural or associated gas, liquid fuel

(oil, mazut, diesel fuel)

specifications of fuel gas:

- hydrogen sulphide content, wt %, max

 pressure at the inlet to the fuel preparation unit, MPa, within

- pressure at burner, MPa, within

0.002

0.3…1.2

0.07…0.15

Consumption of fuel gas (Q = 35 mJ/sm³), sm3/h

91.5

225.2

422.3

Fuel oil characteristics:

- density, kg/m³, max

- viscosity, (cst)

- hydrogen sulphide H2S, mol %, max

- Carbon dioxide CO2, mol %, max

- operating temperature, ºC, max

- inlet pressure at the heater, MPa, within

- pressure before burner, MPa, max


887

20

0.01

1.0

50

4,0…6,2

3.5

- fuel oil consumption, kg/h, within

100

200

400

Efficiency, %

85%

Power of ignition system, control, signaling, protection devices and

valves with electric drive from an AC network, V/Hz

220/50

Overall dimensions, m, max

8.35 × 2.05 × 3.62

10.6 × 2.55 × 5.55

13.85 × 2.96 × 5.55

Weight, kg, max

4.6

11

22.5

 





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