1.0 1.

INTRODUCTION Literature Review An industrial furnace or direct fired heater is equipment used to provide heat for a process or can serve as reactor which provides heats of reaction. Furnace designs vary as to its function, heating duty, type of fuel and method of introducing combustion air. However, most process furnaces have some common features. Fuel flows into the burner and is burnt with air provided from an air blower. There can be more than one burner in a particular furnace which can be arranged in cells which heat a particular set of tubes. Burners can also be floor mounted, wall mounted or roof mounted depending on design. The flames heat up the tubes, which in turn heat the fluid inside in the first part of the furnace known as the radiant section or firebox. In this chamber where combustion takes place, the heat is transferred mainly by radiation to tubes around the fire in the chamber. The heating fluid passes through the tubes and is thus heated to the desired temperature. The gases from the combustion are known as flue gas. After the flue gas leaves the firebox, most furnace designs include a convection section where more heat is recovered before venting to the atmosphere through the flue gas stack. (HTF=Heat Transfer Fluid. Industries commonly use their furnaces to heat a secondary fluid with special additives like antirust and high heat transfer efficiency. This heated fluid is then circulated round the whole plant to heat exchangers to be used wherever heat is needed instead of directly heating the product line as the product or material may be volatile or prone to cracking at the furnace temperature.) There are two major objectives for operation of the furnace. First, in order to minimize fuel costs, the furnace must be operated with proper oxygen composition to ensure complete combustion of the fuel (carbon monoxide is an undesired product). Second, the hydrocarbon feed stream must be delivered to the cracking unit at the desired temperature.

1.2

Theory The manipulated variables for the furnace are the Air Flow Rate and Fuel Gas Flow Rate. The controlled variables are the Hydrocarbon Outlet Temperature and Oxygen Exit Concentration. The system also has the disturbance variables that are Hydrocarbon Flow Rate and Fuel Gas Purity. This furnace is the first order system, so the system has system gain and time constant. This experiment represents a furnace fuelled by natural gas which is used to preheat a high molecular weight hydrocarbon feed (C16 C26) to a cracking unit at a petroleum refinery. The combustion of fuel is assumed to occur according to the following reaction equation: CH4 + 3/2 O2 CO + 2H2O CO + 1/2 O2 CO2

1.3

Objectives The purpose of this module is to demonstrate the properties of a first order system for various values of the system gain and time constant. This modules also illustrates the dynamic response of a first order to a different input signals.

2.0 2.1

METHODOLOGY Material MATLAB 7.0 software

2.2

Procedure 1) Started by selecting the Furnace from the Main Menu. This is done by clicking the left mouse button once on the Furnace button. This opens the menu window for the furnace modules. Clicked the left mouse button on the Furnace button. Two additional windows should open, one for the input and output graphs and one for the furnace process flow sheet. 2) Under the Simulation menu, selected Start. This command should be executed once during a lab session. It is a simulated equivalent to a perfect process start-up. The process output graphs are located on the window labelled Furnace Process Monitor. Notice how the outputs remain unchanged with time. 3) Next, try decreasing the fuel gas purity. This will act as a disturbance to the system. By double clicking on the Fuel Gas Purity Box, the value is changed from 1.0 to 0.95 by clicking on the value box and using the backspace key to erase the old value. When you have entered a new value, the Close button is clicked. Again, notice how the outputs on the process monitor are changing with time. Now return the Fuel Gas Purity to 1.0 by double clicking on the Fuel Gas Purity box and adjusting the value as done before. 4) The furnace is started. The initial steady state values for each of the inputs and outputs of the furnace are recorded. 5) The following sequence of increases in the air flow rate is made by double clicking the left mouse button on the Air Flow Rate box. The remaining inputs (the six other inputs) should be kept at their initial steady state values. After each change in the air flow rate, the system is allowed to reach a new steady state (approximately 40 simulation minutes) and then the values of the output variables obtained is recorded using the pointers on the output graphs. The steady state values are recorded. The Air Flow Rate is returned to its initial value and allows the furnace to reach steady state. 6) The following sequence of increases in the fuel gas flow rate by is made by clicking the left mouse button on the Fuel Gas Flow Rate box. The remaining
3

inputs (the six other inputs) should be kept at their initial steady state values. After each change in the fuel gas flow rate, the system is allowed to reach a new steady state (approximately 40 simulation minutes) and then the values of the output variables are recorded using the pointers on the output graphs. The steady state values are recorded. The Fuel Gas Flow Rate is returned to its initial value and the furnace is allowed to reach steady state. 7) The following sequence of increases in the hydrocarbon flow rate is made by double clicking the left mouse button on the Hydrocarbon Flow Rate box. The remaining inputs (the six other inputs) should be kept at their initial steady state values. After each change in the hydrocarbon flow rate, the system is allowed to reach a new steady state (approximately 40 simulation minutes) and then the values of the output variables obtained is recorded using the pointers on the output graphs. The steady state values are recorded. 8) The following sequence of increases in the fuel gas purity is made by double clicking the left mouse button on the Fuel Gas Purity box. The remaining inputs (the six other inputs) should be kept at their initial state values. After each change in the fuel gas purity, the system is allowed to reach a new steady state (approximately 40 simulation minutes) and then the values of the output variables obtained are recorded using the pointers on the output graphs. The steady state values are recorded. The Fuel Gas Purity is returned to its initial value and the furnace is allowed to reach steady state. 9) The nominal Air Flow Rate is increased by 20% and Procedure 4-8 is repeated. 10) To end the session, the simulation is stopped by selecting Stop under the Simulation menu, and then Yes is selected under the Quit menu from the main menu window. This will return you to the MATLAB prompt. At this prompt, type quit to exit MATLAB.

3.0 3.1

RESULT & DISCUSSION Result Initial steady state values a. t Inputs e Hydrocarbon Flow Rate b. F Hydrocarbon Inlet Temperature u Air e Flow Rate Air l Temperature Fuel Gas Flow Rate g Fuel Gas Temperature a Fuel Gas Purity s Outputs p Hydrocarbon Outlet Temperature u r Furnace Temperature i Exhaust Gas Flow Rate t Oxygen Exit Concentration y 609.8684 1426.8144 43.2896 0.92171 K K m3/min mol O2/min

0.035 310 17.9 310 1.21 310 1

m3/min K m3/min K m3/min K mol CH4/mol total

Table 1: Initial steady state values

Air flow rate Air Flow Rate 17.9 (nominal) 18.1 18.3 i) ii) 18.5 18.7 Hydrocarbon Outlet Temperature 609.8684 606.9737 604.6053 602.5000 599.0789 Table 2: Air flow rate Oxygen Exit Concentration 0.92069 0.95066 0.979697 1.6088 1.0343

Hydrocarbon Outlet Temp. 620 Pntr Val.= 608.0263 at t = 1726.0366 1460

Furnace Temp. Pntr Val.= 1428.3682 at t = 4575.4268

Temp. (K)

610 600 590 1.056

Temp. (K)

1440 1420 1400 1380 1.056 1.057 1.058

1.057

1.058

1.059 1.06 Time (min)

1.061

1.062

1.063 x 10
4

1.059 1.06 Time (min)

1.061

1.062

1.063 x 10
4

Exhaust Gas Flow Rate

O2 Concentration 1

Flow Rate (m3/min)

50

Conc. (mol/m3)

Pntr Val.= 43.2018 at t = 4808.313 45

0.95 0.9 0.85 1.056

Pntr Val.= 0.92171 at t = 4961.7683

40 1.056

1.057

1.058

1.059 1.06 Time (min)

1.061

1.062

1.063 x 10
4

1.057

1.058

1.059 1.06 Time (min)

1.061

1.062

1.063 x 10
4

Graph 1

Fuel flow rate Fuel Gas Flow Rate Hydrocarbon Outlet Temperature 609.6454 612.2368 614.3421 616.7196 618.8903 Increase 20% Oxygen Exit of air flow rate Concentration (21.48) 544.2943 545.7308 547.1674 548.6039 550.0404 Table 3: Fuel flow rate 0.92025 0.89983 0.87897 0.86043 0.83858 Increase 20% of air flow rate (21.48) 1.6013 1.5614 1.5347 1.5081 1.4814

1.21 (nominal) 1.22 1.23 1.24 1.25

Hydrocarbon Outlet Temp. 640 Pntr Val.= 609.6454 at t = 9818.313 1500 1450 1400 9820 9830 9840 9850 Time (min) 9860 9870 9880 9810 9820 9830

Furnace Temp. Pntr Val.= 1426.81 at t = 1981.4837

Temp. (K)

620 600 9810

Temp. (K)

9840 9850 Time (min)

9860

9870

9880

Exhaust Gas Flow Rate

O2 Concentration 1.1

Flow Rate (m3/min)

50

Conc. (mol/m3)

Pntr Val.= 43.2895 at t = 2119.6951 45

1 0.9 0.8 0.7 9810 9820 9830

Pntr Val.= 0.92025 at t = 9829.6951

40 9810

9820

9830

9840 9850 Time (min)

9860

9870

9880

9840 9850 Time (min)

9860

9870

9880

Graph 2a

Hydrocarbon Outlet Temp. 600 550 500 1.257 1.258 1.259 1.26 1.261 Time (min) 1.262 1.263 1.264 x 10
4

Furnace Temp. 1500 Pntr Val.= 71.1538 at t = 31.1881

Temp. (K)

Temp. (K)

Pntr Val.= 581.0167 at t = 11435.2642

1400 1300 1200 1100 1.257 1.258 1.259

1.26 1.261 Time (min)

1.262

1.263

1.264 x 10
4

Exhaust Gas Flow Rate

O2 Concentration

Flow Rate (m3/min)

50 40 30 1.257 1.258 1.259

Conc. (mol/m3)

Pntr Val.= 43.2895 at t = 2119.6951

2 1.5 1 1.257 1.258 1.259

Pntr Val.= 1.055 at t = 11423.0691

1.26 1.261 Time (min)

1.262

1.263

1.264 x 10
4

1.26 1.261 Time (min)

1.262

1.263

1.264 x 10
4

Graph 2b: Increase 20% of air flow rate

Hydrocarbon Flow Rate Hydrocarbon Flow Rate 0.0350 (nominal) 0.0355 0.0360 0.0365 0.0370 Hydrocarbon Outlet Temperature 609.5454 605.9474 602.7117 599.0138 595.7781 Increase 20% of air flow rate (21.48) 562.9691 560.096 577.223 552.9134 550.0404 Oxygen Exit Concentration 0.92025 0.92025 0.92025 0.92025 0.92025 Increase 20% of air flow rate (21.48) 1.4814 1.4947 1.4947 1.4947 1.4947

Table 4: Hydrocarbon flow rate

Hydrocarbon Outlet Temp. 640 Pntr Val.= 609.6454 at t = 9818.313 1500 1450 1400 9820 9830 9840 9850 Time (min) 9860 9870 9880 9810 9820 9830

Furnace Temp. Pntr Val.= 1426.81 at t = 1981.4837

Temp. (K)

620 600 9810

Temp. (K)

9840 9850 Time (min)

9860

9870

9880

Exhaust Gas Flow Rate

O2 Concentration 1.1

Flow Rate (m3/min)

50

Conc. (mol/m3)

Pntr Val.= 43.2895 at t = 2119.6951 45

1 0.9 0.8 0.7 9810 9820 9830

Pntr Val.= 0.92025 at t = 9829.6951

40 9810

9820

9830

9840 9850 Time (min)

9860

9870

9880

9840 9850 Time (min)

9860

9870

9880

Graph 3a

Hydrocarbon Outlet Temp. 600 550 500 1.257 1.258 1.259 1.26 1.261 Time (min) 1.262 1.263 1.264 x 10
4

Furnace Temp. 1500 Pntr Val.= 71.1538 at t = 31.1881

Temp. (K)

Temp. (K)

Pntr Val.= 581.0167 at t = 11435.2642

1400 1300 1200 1100 1.257 1.258 1.259

1.26 1.261 Time (min)

1.262

1.263

1.264 x 10
4

Exhaust Gas Flow Rate

O2 Concentration

Flow Rate (m3/min)

50 40 30 1.257 1.258 1.259

Conc. (mol/m3)

Pntr Val.= 43.2895 at t = 2119.6951

2 1.5 1 1.257 1.258 1.259

Pntr Val.= 1.055 at t = 11423.0691

1.26 1.261 Time (min)

1.262

1.263

1.264 x 10
4

1.26 1.261 Time (min)

1.262

1.263

1.264 x 10
4

Graph 3b: Increase 20% of air flow rate

Fuel Gas Purity Fuel Gas Purity 1.00 (nominal) 0.99 0.98 0.97 0.95 Hydrocarbon Outlet Temperature 595.7217 592.4539 590.0031 586.7353 581.0167 Increase 20% of air flow rate (21.48) 562.9691 560.096 558.6996 555.7865 550.0404 Table 5: Fuel gas purity Oxygen Exit Concentration 0.92025 0.94475 0.97334 0.99784 1.055 Increase 20% of air flow rate (21.48) 1.3349 1.3615 1.3882 1.4281 1.4814

Hydrocarbon Outlet Temp. 620 610 Pntr Val.= 595.5029 at t = 26844.0854 1450

Furnace Temp. Pntr Val.= 1428.3682 at t = 4575.4268

Temp. (K)

600 590 580 570 2.754 2.755 2.756 2.757 2.758 Time (min) 2.759 2.76 2.761 x 10
4

Temp. (K)

1400 1350 2.754 2.755 2.756 2.757 2.758 Time (min) 2.759 2.76 2.761 x 10
4

Exhaust Gas Flow Rate

O2 Concentration 1.1

Flow Rate (m3/min)

50

Conc. (mol/m3)

Pntr Val.= 43.2018 at t = 4808.313 45

Pntr Val.= 1.0352 at t = 26976.0772

1 0.9 2.754 2.755 2.756 2.757 2.758 Time (min) 2.759 2.76 2.761 x 10
4

40 2.754

2.755

2.756

2.757 2.758 Time (min)

2.759

2.76

2.761 x 10
4

Graph 4a

10

Hydrocarbon Outlet Temp. 600 550 500 1.302 1.303 1.304 1.305 1.306 Time (min) 1.307 1.308 1.309 x 10
4

Furnace Temp. 1500 Pntr Val.= 71.1538 at t = 31.1881

Temp. (K)

Temp. (K)

Pntr Val.= 550.0404 at t = 13016.8089

1400 1300 1200 1100 1.302 1.303 1.304

1.305 1.306 Time (min)

1.307

1.308

1.309 x 10
4

Exhaust Gas Flow Rate

O2 Concentration

Flow Rate (m3/min)

50 40 30 1.302 1.303 1.304

Conc. (mol/m3)

Pntr Val.= 43.2895 at t = 2119.6951

2 1.5 1 1.302 1.303 1.304

Pntr Val.= 1.4814 at t = 13020.061

1.305 1.306 Time (min)

1.307

1.308

1.309 x 10
4

1.305 1.306 Time (min)

1.307

1.308

1.309 x 10
4

Graph 4b

11

3.2

Discussion (Question) 1) Calculate the steady state gain for each of the following input-output pairings. i) Air Flow Rate

Graph 5: Hydrocarbon Outlet Temperature vs. air flow rate

1.06 oxygen exit concentration1.04 1.02 1 0.98 0.96 0.94 0.92 0.9 17.8 18 air flow 18.2

y = 0.1427x - 1.6322

18.4

18.6

18.8

Graph 6: Oxygen Exit Concentration vs. air flow rate

12

ii) Fuel Gas Flow Rate

Graph 7: Hydrocarbon Outlet Temperature vs. fuel gas flow rate

Graph 8: Oxygen Exit Temperature vs. fuel gas flow rate

13

iii) Hydrocarbon Flow Rate

Graph 9: Hydrocarbon Outlet Temperature vs. Hydrocarbon Flow Rate

Graph 10: Oxygen Exit Temperature vs. Hydrocarbon Flow Rate

14

iv) Fuel Gas Purity

Graph 11: Hydrocarbon outlet temperature vs. fuel gas purity

Graph 12: Oxygen exit temperature vs. fuel gas purity

2)

15

4.0

CONCLUSION & RECOMMENDATIONS We have achieved our objectives in the experiment that is to demonstrate the properties of a first order system for various values of the system gain and time constant. We also have successfully illustrates the dynamic response of a first order to different input signals. From the experiment we also have learned that some of the factors that influence to gain the value of steady state that are air flow rate, fuel gas flow rate, hydrocarbon flow rate, and fuel gas purity.

5.0

REFERENCES 1) Norman A. Anderson (1980). Instrumentation for Process Measurement and Control. 3th Edition. CRC Press. 2) Dale E. Seborg, Thomas F. Edgar, Duncan A. Mellichamp (2004). Process dynamics and control. Second Edition. 3) Brian Roffel and Ben Betlem. Process dynamics and control: modeling for control and prediction. 4) Raymond Jay Emrich (1981). Fluid Dynamics: Fluid Dynamics. Academic Press. 5) Marlin, T.E. Process Dynamic and Control Process Control: Designing Processes and Control Systems for Dynamic Performance

16