1

PERFORMANCE EVALUATION OF FURNACE

101
IN PROPYLENE OLEFINE COMPLEX OF
PERTAMINA

Agus Mundiyono1, Nur Azmi Faizah2, Mentari Ulfa

Nurhikmatulfalah3
1
agusmundiyono@gmail.com , 2nurazmifaiza@gmail.com ,
3
mentariulfa@gmail.com
Polytechnic STMI Jakarta, Ministry of Industry, Rep.Indonesia

ABSTRACT
Furnace, which used in petroleum industry, is an instrument to heat the fluids. Furnace or
heater, which is known as fired heater, is an equipment which is used in the heating process by using
fuel gas or fuel oil in controlled manner in the burner. The heating process is conducted to generate
the appropriate temperature. In order to have an optimum heating process, it is important to arrange
the furnace tubes properly. The design of furnace determines the heat loss. There is a correlation
between the heat loss with the refractory structure of the wall and flue gas temperature resulted from
the combustion and excess air. The higher of the stack temperature and the excess air, the higher of
the heat loss caused by the flue gas.
Keywords : furnace, fired heater, flue gas, refractory, stack

1. Introduction The heat is resulted from the

Chemical industries require combustion reaction of fuel which has
operating conditions at high the shape of gas or liquid contains of
temperatures, such as heating crued oil oxygen. The heat transffered to the fluids
petroleum before entering the through pipelines in combustion chamber
fractionation column in order to separate by the radiation and convection process.
chemical compound based on its boiling I order to get perfect heat transfer in
point. Oil and Gas Furnace used for combustion process, it is important to
high-temperature heating. Heat transfer have required condition such as
process occurs between heated fluids and sufficient fuel, oxygen, perfect
fuel combustion [1]. combustion, appropriate shape and
Furnace is an equipment used to temperature of flame and Cleanliness
heat crude oil or its fractions in the pipe surface must be cleaned [2].
processing of petroleum. The process Propylene Olefin Complex (POC)
heating system conducted in order to in PT PERTAMINA (Persero) RU VI
provide the temperature which is needed BALONGAN which started on January
in refining process. 2013. Its function is to process Ethylene
and Buthene into Propylene. In the POC

which is located in PT PERTAMINA
(Persero) RU VI BALONGAN, there is a
furnace 37-F-101 and it has performance
efficiency which possible to be
calculated.
2. Theoritical Concepts
2.1 Combustion
Combustion is a chemical reaction
between substances, usually including
oxygen and usually accompanied by the
generation of heat and light in the form
of flame.
Elements which required in the
combution process include:
a) Fuel: There are two types which
used as a fuel of the furnace, oil
and gas.
b) Air: The need of oxygen for
combustion is taken from the
surrounding air thus directly
affect to the combustion.
c) Fire: This element material is
used to achieve the conditions
in which combustion can take
place by itself.
There are three types of combustion :
Complete and perfect
combution. Complete
combution occurs if the
burning molecular of C
resulting in carbondioxyde
and the molecular of H2
transfered into hidro
molecular.
CH4 + 2 O2 CO2 + 2 H2O
Complete and imperfect
combustion. The process has
residual air from the oxygen
reaction.
CH4 + 3 O2 CO2 + 2 H2O
+ O2
Imperfect Combustion.
During incomplete
combustion part of the
carbon is not completely
oxidized producing soot or
carbon monooxide (CO).
3 CH4 + 5 O2 CO2 + 2 CO
+ 6 H2O
2
In order to make furnace works
efficiently, it requires some conditions as
follows [1]:
An appropriate burner system
Perfect combustion
Heats of combustion from gas and
fuel oil transffered properly to the
liquid burned.
Cleaning system of tube furnace
Reducing heat loss through the stack
or furnace wall.
2.2 Furnace Working Principle
Thermal radiation frequently used
to the processes of heat transfer. Radian
fire box is the place on the heater where
the fuel combustion occured. In this
process, liquid and fuel gas or its
combination mixed on furnace [7].
Feed the heated flowed through the
inside of the tube are arranged
horizontally or vertically along the floor ,
on the wall next to, or above the
combustion chamber, depending on the
configuration of the planning layout
which allows the planning of direct heat
radiation from the flame burning as well
as the reflection of heat from the wall
surface to the surface of the tube .
Heated fluid typically flows first
through convection section located
between the combustion chamber and
chimney , in order to utilize the heat
contained in the gases of combustion .
Furthermore, through the cross-over pipe
, fluid flowed into the radiant fire box .
Based on the size , capacity and
temperature required are a wide variety
of furnace design and type of
construction materials used . But
basically the furnace operated
bedasarkan same principles .
The amount of heat load that must
be provided by the furnace to the heated
fluid depending on the number of feeds
and the temperature difference inlet and
outlet feeds to be achieved . The greater
the temperature difference the more the
amount of feed , the higher the furnace
burden [7].
2.3 Furnace Efficiency

Thermal efficiency is an
important parameter for the furnace
performance. Thermal efficiency
indicates the use of heat generated from
the fuel combustion which is important
for fluids [7].
Factors affecting the furnace
efficiency explained as follows:
a. Excess air
It is important to inject the
excess air to the furnace as an preventive
effort to the imperfect combustion. The
low excess air will generate the
imperfect combustion. In the other side,
the high excess air will decrease the
furnace efficiency because of the fuel
gasl volume and the heat absorbed
during the combustion.
b. The Heat Loss
Factors which affected the heat loss
explained as follows:
Heat loss through furnace casing
Imperfect combustion generated from
the fuel gas.
The high temperature of fuel gas [7].
c. Furnace equipment
Furnace efficiency effected by the use
of its equipment.
In addition, furnace performance
affected by the condition as follows:
Damaged burner.
Exhaust gas (flue gas) smoky
High temperature of stack
The flame to flips
Short flame
Heat is not reached
The high temperatur of the tube
surface
Flame sloping
3.2. Data Processing Methods
Primary and secondary data
have been proccesed to get performance
furnace from its efficiency. Efficiency
value explained by the theoritical and
actual. Design efficiency processed by
the API Standar 560 method [5] ,
3
Currugated flame
Flame touching the tube
It is important to have periodic
maintenance by using the indicator in
order to solve problems related to the
furnace performance [7].
3. Research Methods
3.1 Data collection Methods Data
Data collection method conducted
by electronic data collection from the
internet, literature study, and discussion
to have knowledge regarding with the
furnace in POC PT PERTAMINA RU VI
Balongan). Information and data
collected from the sources are following
Process Flow Diagram Furnace
(PFD) 37-F-101 in POC
Sheet data of furnace 37-F 101
Results of the laboratorium analysis
Operational data of actual furnace 37-
F-101
Distributed Control System (DCS)
with consideration of the level of
accuracy.
Primary and secondary data
collection cunducted to get the
calculation of 37-F-101 furnace
efficiency in POC RU-VI Balongan.
3.1.1. Primary Data Collection
Primary Data Collection used to
calculate 37-F-101 furnace efficiency).
The data collected in September 2015.
3.1.2. Secondary Data Collection
Secondary data has been
collected from the sheet data of furnace
37-F-101 in Balongan, literature study,
and the composition of fuel gas as the
result of laboratorium analysis.
to determine the calori which generated
from heating value of fuel gas and fuel
oil based on the composition of fuel gas
in the data sheet of the company. In the
other side, actual data collected from the
operational condition.
 4

There are some methods which used to

calculate the efficiency value:

a. Calculation of total weight, heating value, air required, CO 2 formed, H2O formed
and N2 formed

The formulas (as described in Table 3.1) :

Total Weight = Molecular Weight Volume Fraction
Heating Value = Net Heating Value Total Weight
Air Required = Air Required per pound fuel Total Weight
CO2 Formed = CO2 Formed per pound fuel Total Weight
H2O Formed = H2O Formed per pound fuel Total Weight
N2 Formed = N2 Formed per pound fuel Total Weight

Tabel 3.1. Combustion Work Sheet

Fuel Gas Component Volume Molecular Total Net Heating
Fraction Weight Weight Heating Value
(1x2) Value (3x4)
(btu/lb)
(1) (2) (3) (4) (5)
Hydrogen 2.016 51600
Nitrogen 28 0
Methane 16 21500
Carbon Monoxide 28 4345
Carbon Dioxide 44 0
Ethane 30.1 20420
Ethylene 28.1 20290
Propane 44.1 19930
Propylene 42.1 19690
1-Butane 58.1
n-Butane 58.1 19670
1+i Butene 56.1 19420
Fuel Gas Component Volume Molecular Total Net Heating
Fraction Weight Weight Heating Value
(1x2) Value (3x4)
(btu/lb)
(1) (2) (3) (4) (5)
Trans-2-Butene 56.1
Cis-2-Butene 56.1
i-Pentane 72.1
n-Pentane 72.1 19500
Hexane 86.2 19390
 5

Fuel Gas Component Volume Molecular Total Net Heating

Fraction Weight Weight Heating Value
(1x2) Value (3x4)
(btu/lb)
(1) (2) (3) (4) (5)
Hidrogen Sulfide 34.1 6550
Total
Total/Pound of Fuel

Air Air CO2 CO2 H2O H2O N2 N2

Required Required Formed Formed Formed Formed Formed Formed
(lb/lbfuel) (3x6) (lb/lbfuel) (3x8) (lb/lbfuel) (3x10) (lb/lbfuel) (3x12)
(6) (7) (8) (9) (10) (11) (12) (13)
34.29 0 8.94 26.36
0 0 0 1
17.24 2.74 2.25 13.25
2.47 1.57 0 1.9
0 1 0 0
16.09 2.93 1.8 12.37
14.79 3.14 1.28 11.36
15.68 2.99 1.63 12.05
14.79 3.14 1.28 11.36
14.79 3.14 1.28 11.36
15.46 3.03 1.55 11.88
15.33 3.05 1.5 11.78
15.24 3.06 1.46 4.68
6.08 1.88 0.53 3.31

b. Calculation of relative humidity and excess air

relative humadity :
Moisture in air

............................................(a)

lb of wet air/lb of fuel required

....................................................................................(b)

lb of Moisture/lb fuel
lb of wet air/lb of fuel required air required...................................................(c)
lb of H2O/lb of fuel
H2O formed lb of moisture/lb fuel................................................................(d)
Excess Air correction :
lb of excess air/lb of fuel
 6

..........................(e)

Percent excess air

..........................................................(f)

Total lb of H2O/lb of fuel (corrected for excess air)

..............................................................................................................................(g)
c. Calculation of Heat Loss
Heat Loss Stack (Qs)
Heat loss stack calculated by using Table 3.2

Tabel 3.2. Stack Loss Work Sheet

Component Lb Comp Qr(RadianHeat Heat Loss Correction Calculation Efficiency
Formed/lb Loss)
fuel

(Totalx2) Ha Hf Hm
1 2 3 (btu/lbs (btu/lbs (btu/lbs
of fuel) of fuel) of fuel)
CO2
Water Vapor
N2
Air
Total Qs =

Enthalpy score resulted from the graphics (attached)

Qs = Total Heat Loss

LHV (Lower Heating Value) =

Radiation Heat Loss (Qr) = radiasi LHV

= 0.02 LHV

d. Calculating correction sensible heat air

Ha = Cp udara ( T ambient T datum ) ( lb of air/lb fuel )
lb of air/lb fuel = lb of wet air lb of excess air
e. Calculate fuel correction sensible heat
 7

Hf = Cp fuel (Tfuel-Tdatum)
f. The calculation of efficiency

Efficiency =

Efficiency =

e=

4. Result And Discussion

4.1. Calculation
According to the calculation of furnace 37-F-101 in Propylene Recovery Complex
(POC), it can be resumed as follows:

Comparison between Actual and Design Furnace Efficiency

Table 4.1. Design dan Actual Furnace Efficiency

By the date Design Actual
1/9/2015 83.56 85.577137
2/9/2015 83.56 85.480511
3/9/2015 83.56 85.535003
4/9/2015 83.56 85.404816
5/9/2015 83.56 85.421286
6/9/2015 83.56 85.678335
7/9/2015 83.56 85.707002
8/9/2015 83.56 85.594319
9/9/2015 83.56 85.700223
10/9/2015 83.56 85.608713
11/9/2015 83.56 85.458715
12/9/2015 83.56 85.051891
13/9/2015 83.56 85.270098
14/9/2015 83.56 85.040972
15/9/2015 83.56 85.300381
 8

By the date Design Actual

16/9/2015 83.56 85.755854
17/9/2015 83.56 85.439872
18/9/2015 83.56 85.254674
19/9/2015 83.56 85.210686
20/9/2015 83.56 85.850037
21/9/2015 83.56 85.796315

Average 85.482707

4.2. Discussion it can be resulted from the calculation of

4.2.1. Definition of Furnace Efficiency
Furnace efficiency is the heat
input minus absorbed heat by fluids with
heat loss through stack (Qs) and heat loss
due to radiation (Qr). It is divided by
heat input from the heat resulted from
combustion.
The heat absorbed by fluids is
possible to be generated with two
methods. First, it is resulted from the
difference of heat input and stack (Qs)
heat loss and radiation heat loss. Second,
its heat balances.
4.2.2. Factors affecting the Furnace
Efficiency
Furnace efficiency influenced
by stack heat loss (Qs) and radiation heat
loss (Qr). Qs value determined by stack
temperature (Ts). The higher the stack
temperature, the higher the Qs value. Qr
value determined by the radiation heat
loss which absorbed by fluids. It is
concluded that the higher the Qs and Qr
value, the lower the furnace efficiency.

Graphics 4.1. The Correlation between Qs Value (Heat Loss) and Efficiency

4.2.3. Design and Actual Efficiency

 9

Graphics 4.2. The Correlation between time and efficiency

Based on graphics 4.2., it is described Radiation (Qr). The higher the Qs

that actual furnace efficiency value is
higher than design efficiency. Furnace
37-F-101 can operate very well as POC
unit is the unit begins operations in 2013
until today.
and Qr value, the lower the furnace
efficiency.
3. The Furnace 37-F-101 in 37 units
(POC) has been using for three years
with a good performance.

5. Conclusion And Recommendation

5.1. Conclusion 5.2. Recommendation
Furnace Efficiency Calculation In order to control the furnace
37-F-101 in POC unit conducted by efficiency 37-F-101 in POC higher than
using operational data from September 1 design efficiency, the regular
September 21, 2015. Based on the maintenance is needed.
calculation, it can be resumed as:

1. The average of furnace efficiency 37-

F-101 (September 1 September 21,
2015) is 85.482707
2. Furnace efficieny influenced by the
heat loss from Stack (Qs) and
6. Reference

[1] Aulia, A. dan Chandra, D.H. 2012. Laporan Kerja Praktek PT PERTAMINA (Persero)
Refinery Unit VI Balongan-Indramayu (Periode 1 30 September 2012). Sekolah
Tinggi Manajemen Industri Kementerian Perindustrian. Jakarta
[2] Ryan Pratama. 2009. Diktat Furnace. Online
(https://www.academia.edu/10109818/DIKTAT_FURNACE) API Standart 560, 1995,
Fired Heaters for General Refinery Services , American Petroleum Institue,
Washington DC.
[3] API Standard 560,1995, Fired Heaters for General Refinery Services, American
Petroleum Institute, Washington DC.
 10

[4] Kern, D,Q., 1965, Process Heat Transfer, International Edition, Mc Graw Hill
Book Company, Singapore.
[5] Pertamina 2006, Furnace & Combustion, Pertamina RU VI Balongan, Indramayu.
[6] Smith, J.M. and H.C, Van Ness, 1987, Introduction to Chemical Engineering
Thermodynamics , 4thed., Mc Graw Hill Book Co., New York.
[7] Kemala, I. and Hashimoto, R. 2015.Laporan Kerja Praktek PT Pertamina (Persero)
Refinery Unit VI Balongan-Indramayu, Universitas Indonesia. Jakarta