Comparison on conventional and digital technology assisted design methodologies of process heater radiant section

Unawareness of appropriate process heater design method leads to insufficient accuracy in calculations or overlook of important design parameters. It consequently results in occasional maintenance or failures of heaters. There are number of radiant section design methodologies available, however which method to be used and under what conditions are not well summarized. The paper explains reliability and accuracy of industrial code method, conventional methods, research methods and CFD methods by comparison with data available from the literature. The results show heat flux from modified plug flow method has good agreement with measured values. To obtain heater flue gas radiant exit temperature ‘Lobo-Evans’ method provides reliable output. The study presented is based on selected distinct cases to provide good criteria to heater engineers to select appropriate method based on its advantages. The outcome of application of correct method will result in smooth heater operations and commercial benefits.