Since 1985, THI has designed and built over dozens of new crude oil heaters and re-engineered/retrofitted over two dozen crude units for refineries and oil production facilities all over the world. Absorbed duties in these units range from 20 to 390 MM BTU/hr (6 to 120 MW). The designs represent heater styles that include single-cell and multi-cell horizontal cabins, vertical cylindricals and vertical boxes. Depending upon feed conditions and outlet requirements, a variety of coil metallurgies may be used, and process flow through the heater may be upward or downward. Every unit is custom-engineered and fabricated to strict industry standards. API Standard 560 is THI's minimum design criteria.
Since 1990, THI has designed and constructed, or revamped, dozens of vacuum charge heaters for refineries in several different countries. These units range from small single-cell horizontal cabins (5 to 25 MM BTU/hr (2 to 8 MW) absorbed duty) to large twin-cell cabin or box heaters with total duties up to 240 MM BTU/hr (70 MW). The high temperatures and heat fluxes, low outlet pressures and near-sonic velocities in the process coils make designing these special heaters an engineering challenge. Tulsa Heaters, Inc. has the tools and experience to do it right!
Hot Oil and Heat Medium Heaters
A common fired heater application, THI has designed and built over 100 new hot oil or heat medium heaters with duties ranging from < 5 to > 200 MM BTU/hr (< 1 to > 60 MW). THI units have been placed in both onshore and offshore applications in over a dozen different countries. THI's exacting engineering models allow close control of fluid film temperatures throughout the heater, which is critical to reliable performance and long life.
Regeneration Gas Heaters
This is another common fired heater application, but one usually requiring very high process pressures and flux rates. Again, THI's experience with design and fabrication of regeneration gas heaters in duties up to 180 MM BTU/hr (50 MW) and pressures up to 3000 psig (210 bar) allows THI to provide the very best product for each customer's application.
Reactor Feed Heaters
Whatever your process fluid requirements, THI can engineer a reactor feed heater to reliably meet those needs. These heaters usually feature 300-series stainless steel or other high-alloy coil materials. Among the > 70 reactor feed heaters that THI has engineered are many different styles: vertical cylindrical, horizontal cabin, vertical helical, double-fired horizontal box, single and twin-celled configurations. Absorbed duties range from 2 to > 100 MM BTU/hr (1 to > 30 MW). These heaters are key elements to hydrotreating or desulfurization units.
With over 60 new or revamped reboilers in our job list, THI has the skill and experience to provide optimum design and construction of these important vaporizing service heaters. Using tube segment-by-segment modeling, THI can predict with great accuracy vapor-liquid ratios, temperature, pressure, and velocity profiles (which are never linear) throughout the coil and tube metal temperatures. This is important so that the heater is not over-designed for pressure drop and will provide proper performance over the full desired turndown range.
Tulsa Heaters, Inc. is an approved manufacturer for UOP-licensed Platformer heaters. We also have experience with Ultraformers and other reformer heaters with up to four radiant cells and duties up to 250 MM BTU/hr (75 MW). THI has developed a proprietary computer program for wicket-style coil sections and can accurately model the heat transfer in these special high-temperature, low-pressure reformer reactor feed and interheaters.
Delayed Cokers and Visbreakers
Design and evaluation of delayed cokers and visbreakers is a THI specialty. THI has designed, fabricated and done troubleshooting and debottlenecking on both single and double-fired coker heaters in multi-cell configurations with duties up to 260 MM BTU/hr (76 MW). This engineering effort is supported by a unique proprietary complex computer model that accurately predicts key parameters such as % conversion to coke and cracked material and residence time in the coil.
- Crude Production
- Steam Superheaters
- Hot Oil Waste Heat Recovery
- Steam Waste Heat Recovery
- FCCU Regen Air
- Reactor Start-Up
- EDC Cracking