Fired Heater Efficiency

“Why is the efficiency of my

fired heater important?”
Because inefficient heaters cost you money!

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Measuring Fired
Heater Efficiency
This guide will teach you the
process of measuring and
calculating your heater’s
efficiency – so you can
optimize your plant and
save money.
• Based on method outlined in API 560
Annex G
• Procedure intended for fired heaters
burning liquid or gaseous fuels. Not
recommended for solid fuels.
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What do we mean by “efficiency”?
Thermal VS Fuel Efficiency
THERMAL EFFICIENCY
- total heat absorbed divided by total heat input
NOTE: this definition differs from the traditional definition of fired heater efficiency, which generally refers to fuel efficiency

FUEL EFFICIENCY
- total heat absorbed divided by heat input derived
from the combustion of the fuel only

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Equipment Needed
• Temperature-measuring devices, such as
thermocouples or thermometers, to
measure the temperature of:
• Fuel
• Ambient air
• Atomizing medium (if applicable)
• Flue gas
• Thermal fluid
• Flue-gas analytical devices to measure
oxygen and combustible gases

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Before the Test
Establish and maintain operating conditions
Perform any re-rating necessary to account for
differences between design and test conditions
Ensure fuel is acceptable for the test
Select and calibrate instrumentation
Ensure heater is operating properly with respect to
the size and shape of flame, excess air & draught
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Testing
Test procedure:
• The heater shall be operated at a uniform rate throughout the test
• Data shall be taken at the start of the test, and every 2 hours thereafter
• The duration of the test shall extend until three consecutive sets of
collected data fall within the prescribed limits
Measurements:
• Fuel gas quantity and heating value
• Flue-gas temperature and composition analysis

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Example
Hot oil heater for gas plant Ambient air temperature: 70°F
Relative humidity: 50%
Fuel gas composition (vol%):
• Nitrogen – 1.61
• Carbon dioxide – 0.15
• Methane – 98.17
• Ethane – 0.008
Fuel gas LHV Excess Oxygen: 3% (dry)
• 20,814 Btu/lb Radiation heat loss: 1.5%
Fuel gas HHV
• 23,115 Btu/lb
Fuel gas temperature
• 100°F
Fuel gas pressure
• 50 psig
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Thermal Efficiency
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎 − (𝒉𝒓 + 𝒉𝒔
𝒆= × 𝟏𝟎𝟎
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎

Where:
ℎ𝐿 lower heating value of the fuel (Btu/lb)
∆ℎ𝑎 heat correction due to air (Btu/lb)
∆ℎ𝑓 heat correction due to fuel (Btu/lb)
∆ℎ𝑚 heat correction due to atomizing medium (Btu/lb)
ℎ𝑟 assumed radiation heat loss (Btu/lb)
ℎ𝑠 calculated stack heat loss (Btu/lb)

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Need to solve for all variables
Step 1:
solve for heat loss through the stack (ℎ𝑠 )
Combustion Worksheet
Fuel
Component
Column 1
Volume
fraction
Insert fuel composition into
combustion worksheet
%

Nitrogen 1.61

Carbon
0.15
dioxide

Methane 98.17

Ethane 0.08

TOTAL -

Total per
pound of -
fuel

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Combustion Worksheet
Fuel
Component
Column 1
Volume
fraction
Column 2
Relative
molecular
Column 3
(1x2)
Total
Column 4
Net
heating
Column 5
(3x4)
Heating
Calculate total mass and
heating value of fuel
% mass mass value value
(lb) (Btu/lb) (Btu)

Nitrogen 1.61 28.0 0.4508 - -

Carbon
0.15 44.0 0.066 - -
dioxide

Methane 98.17 16.0 15.70 21,500 337,704.80

Ethane 0.08 30.1 0.02 20,420 491.71

TOTAL - - 16.25 - 338,196.51

Total per
pound of - - - - 20,814.55
fuel

(5)

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Combustion Worksheet Calculate products of
combustion for fuel
Fuel Column 1 Column 2 Column 3 Column 4 Column 5 Column 6 Column 7 Column 8 Column 9 Column 10 Column 11 Column 12 Column 13
Component Volume Relative (1x2) Net (3x4) Air (3x6) CO2 (3x8) H2O (3x10) N2 (3x12)
fraction molecular Total heating Heating required Air formed CO2 formed H2 O formed N2
% mass mass value value (lb air/lb) required (lbs CO2/lb) formed (lbs H2O/lb) formed (lbs N2/lb) formed
(lb) (Btu/lb) (Btu) (lbs) (lbs) (lbs) (lbs)

Nitrogen 1.61 28.0 0.4508 - - - - - - - - - -

Carbon
0.15 44.0 0.066 - - - - - - - - - -
dioxide

Methane 98.17 16.0 15.70 21,500 337,704.80 17.24 270.79 2.74 43.04 2.25 35.34 13.25 208.12

Ethane 0.08 30.1 0.02 20,420 491.71 16.09 0.39 2.93 0.07 1.80 0.04 12.37 0.30

TOTAL - - 16.25 - 338,196.51 - 271.18 - 43.11 - 35.38 - 208.42

Total per
pound of - - - - 20,814.55 - 16.69 - 2.65 - 2.18 - 12.83
fuel

(5) (7) (9) (11) (13)

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Completed Combustion Worksheet
Fuel Column 1 Column 2 Column 3 Column 4 Column 5 Column 6 Column 7 Column 8 Column 9 Column 10 Column 11 Column 12 Column 13
Component Volume Relative (1x2) Net (3x4) Air (3x6) CO2 (3x8) H2O (3x10) N2 (3x12)
fraction molecular Total heating Heating required Air formed CO2 formed H2 O formed N2
% mass mass value value (lb air/lb) required (lbs CO2/lb) formed (lbs H2O/lb) formed (lbs N2/lb) formed
(Btu/lb) (Btu) (lbs) (lbs) (lbs) (lbs)

Nitrogen 1.61 28.0 0.4508 - - - - - - - - - -

Carbon
0.15 44.0 0.066 - - - - - - - - - -
dioxide

Methane 98.17 16.0 15.70 21,500 337,704.80 17.24 270.79 2.74 43.04 2.25 35.34 13.25 208.12

Ethane 0.08 30.1 0.02 20,420 491.71 16.09 0.39 2.93 0.07 1.80 0.04 12.37 0.30

TOTAL - - 16.25 - 338,196.51 - 271.18 - 43.11 - 35.38 - 208.42

Total per
pound of - - - - 20,814.55 - 16.69 - 2.65 - 2.18 - 12.83
fuel

(5) (7) (9) (11) (13)

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 Relative Humidity
Correction for relative humidity:
𝑃vapor 𝑅𝐻 18
moisture in air = × ×
𝑃air 100 28.85

where:

𝑃vapor vapor pressure of water at ambient temperature

(from steam tables)
𝑃air 14.696 psi

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 0.364 50 18
Relative Humidity = × ×
14.696 100 28.85
= 0.0077 lbs of moisture per lb of air (a)

Correction for relative humidity:

𝑃vapor 𝑅𝐻 18
moisture in air = × ×
𝑃air 100 28.85

where:

𝑃vapor vapor pressure of water at ambient temperature

(from steam tables)
𝑃air 14.696 psi

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 0.364 50 18
Relative Humidity = × ×
14.696 100 28.85
= 0.0077 lbs of moisture per lb of air (a)

Correction for relative humidity:

𝑃vapor 𝑅𝐻 18 air required (7) 16.69
moisture in air = = =
× × 1 − moisture in air (a) 1 − 0.0077
𝑃air 100 28.85
= 16.82 lbs of wet air per lb of fuel (b)

where:

𝑃vapor vapor pressure of water at ambient temperature

(from steam tables)
𝑃air 14.696 psi

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 0.364 50 18
Relative Humidity = × ×
14.696 100 28.85
= 0.0077 lbs of moisture per lb of air (a)

Correction for relative humidity:

𝑃vapor 𝑅𝐻 18 air required (7) 16.69
moisture in air = = =
× × 1 − moisture in air (a) 1 − 0.0077
𝑃air 100 28.85
= 16.82 lbs of wet air per lb of fuel (b)

where:

𝑃vapor vapor pressure of water at ambient temperature = lbs wet air per lb of fuel(b) – air required(7)
(from steam tables) = 16.82 – 16.69
𝑃air 14.696 psi = 0.1295 lbs of moisture per lb of fuel (c)

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 0.364 50 18
Relative Humidity = × ×
14.696 100 28.85
= 0.0077 lbs of moisture per lb of air (a)

Correction for relative humidity:

𝑃vapor 𝑅𝐻 18 air required (7) 16.69
moisture in air = = =
× × 1 − moisture in air (a) 1 − 0.0077
𝑃air 100 28.85
= 16.82 lbs of wet air per lb of fuel (b)

where:

𝑃vapor vapor pressure of water at ambient temperature = lbs wet air per lb of fuel(b) – air required(7)
(from steam tables) = 16.82 – 16.69
𝑃air 14.696 psi = 0.1295 lbs of moisture per lb of fuel (c)

= H2O formed(11) + lbs of moisture per lb of fuel(c) +

atomizing steam
= 2.17 + 0.1295 + 0
= 2.31 lbs of H2O per lb of fuel (d)

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 Excess Air
Correction for excess air:
N2 formed CO2 formed H2 O formed
lb excess air (28.85 × %O 2 )( + + )
= 28 44 18
per lb of fuel lbs H2 O
20.95 − %O2 [ 1.6028 × + 1]
lbs air required

NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.

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 (13) (9) (d)

Excess Air =
N formed CO2 formed H2 O formed
(28.85 × %O2 )( 2
28
+

20.95 − %O2 [ 1.6028 ×

44
+
lbs H2 O (c)
lbs air required(7)
18
+ 1]
)

12.83 2.65 0
(28.85 × 3)( + + )
= 28 44 18
0
20.95 − 3[ 1.6028 × + 1]
Correction for excess air: 16.69
N2 formed CO2 formed H2 O formed = 2.50 lbs of excess air per lb of fuel (e)
lb excess air (28.85 × %O 2 )( + + )
= 28 44 18
per lb of fuel lbs H2 O
20.95 − %O2 [ 1.6028 × + 1]
lbs air required

NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.

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 (13) (9) (d)

Excess Air =
N formed CO2 formed H2 O formed
(28.85 × %O2 )( 2
28
+

20.95 − %O2 [ 1.6028 ×

44
+
lbs H2 O (c)
lbs air required(7)
18
+ 1]
)

12.83 2.65 0
(28.85 × 3)( + + )
= 28 44 18
0
20.95 − 3[ 1.6028 × + 1]
Correction for excess air: 16.69
N2 formed CO2 formed H2 O formed = 2.50 lbs of excess air per lb of fuel (e)
lb excess air (28.85 × %O 2 )( + + )
= 28 44 18
per lb of fuel lbs H2 O
20.95 − %O2 [ 1.6028 × + 1]
lbs air required
(e)
lb of excess air per lb of fuel
= × 100
air required (7)
2.50
= × 100
16.69
(f)
= 14.98 lbs excess air

NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted.

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 (13) (9) (d)

Excess Air =
N formed CO2 formed H2 O formed
(28.85 × %O2 )( 2
28
+

20.95 − %O2 [ 1.6028 ×

44
+
lbs H2 O (c)
lbs air required(7)
18
+ 1]
)

12.83 2.65 0
(28.85 × 3)( + + )
= 28 44 18
0
20.95 − 3[ 1.6028 × + 1]
Correction for excess air: 16.69
N2 formed CO2 formed H2 O formed = 2.50 lbs of excess air per lb of fuel (e)
lb excess air (28.85 × %O 2 )( + + )
= 28 44 18
per lb of fuel lbs H2 O
20.95 − %O2 [ 1.6028 × + 1]
lbs air required
(e)
lb of excess air per lb of fuel
= × 100
air required (7)
2.50
= × 100
16.69
(f)
= 14.98 lbs excess air

percent excess air (f) (c) (d)

= × lbs moisture per lb fuel + lb H2 O per lb fuel
100
14.98
= × 0.1295 + 2.31
NOTE: If oxygen samples are extracted on a dry basis, a value of zero shall be inserted for line (e) where 100
a value is required from lines (c) and (d). If oxygen samples are extracted on a wet basis, the
appropriate calculated value shall be inserted. = 2.33 total lbs H2O per lb of fuel (corrected for excess air) (g)

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Stack Loss
Column 1
Component Component formed
(lb per lb of fuel)
Carbon dioxide 2.65 (9) from combustion worksheet
Water vapor 2.33 (g) from excess air worksheet
Nitrogen 12.83 (13) from combustion worksheet
Air 2.50 (e) from excess air worksheet
Total 20.31

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Stack Loss
Exit flue-gas temperature, 𝑇𝑒 : 500°F
Column 1 Column 2
Component Component formed Enthalpy at T
(lb per lb of fuel) (Btu/lb formed)
Carbon dioxide 2.65 100
Values taken from enthalpy
Water vapor 2.33 192 tables in API 560, Figures G.6
Nitrogen 12.83 120 and G.7 for each flue-gas
component
Air 2.50 110
Total 20.31 -

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Stack Loss
Exit flue-gas temperature, 𝑇𝑒 : 500°F
Column 1 Column 2 Column 3
Component Component formed Enthalpy at T Heat content
(lb per lb of fuel) (Btu/lb formed) (Btu/lb of fuel)
Carbon dioxide 2.65 100 265.31
Water vapor 2.33 192 446.72
Nitrogen 12.83 120 1,539.27
Air 2.50 110 274.98
Total 20.31 - 2,526.28

ℎ𝑠 = heat content at 𝑇𝑒 = 2,526.28 Btu/lb of fuel

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Step 2:
solve for additional heat losses
Thermal Efficiency
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎 − (𝒉𝒓 + 𝒉𝒔
𝒆= × 𝟏𝟎𝟎
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎

Where:
ℎ𝐿 lower heating value of the fuel (Btu/lb)
∆ℎ𝑎 heat correction due to air (Btu/lb)
∆ℎ𝑓 heat correction due to fuel (Btu/lb)
∆ℎ𝑚 heat correction due to atomizing medium (Btu/lb)
ℎ𝑟 assumed radiation heat loss (Btu/lb)
ℎ𝑠 calculated stack heat loss (Btu/lb)

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 Heat Losses
Heat loss due to air:
∆ℎ𝑎 = 𝑐𝑝a × (𝑇𝑎 − 𝑇𝑑 ) × (𝑚𝑎 𝑚𝑓 ) = 𝑐𝑝a × (𝑇𝑎 − 𝑇𝑑 ) × (𝑚𝑎 𝑚𝑓 )
where:
= 0.24 × (70 − 60) × (16.81 + 2.50)
𝑐𝑝a specific heat of air
𝑇𝑎 temperature of air (°F) ∆ℎ𝑎 = 46.37 Btu/lb
𝑇𝑑 temperature of design air (°F)
𝑚𝑎 𝑚𝑓 the sum of 𝑚𝑎 and 𝑚𝑓 , expressed as
pounds of air per pound of fuel (from
lines (b) and (e) on the excess air and
relative humidity work sheet)

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 Heat Losses
Heat loss due to fuel gas:
∆ℎ𝑓 = 𝑐𝑝fuel × (𝑇𝑓 − 𝑇𝑑 ) = 𝑐𝑝fuel × (𝑇𝑓 − 𝑇𝑑 )
where:
= 0.587 × (100 − 60)
𝑐𝑝fuel specific heat of fuel gas
𝑇𝑓 temperature of fuel gas (°F) ∆ℎ𝑓 = 23.47 Btu/lb
𝑇𝑑 temperature of design fuel gas (°F)

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 Heat Losses
Heat loss due to atomization medium:
∆ℎ𝑚 = ∆𝐸 × (𝑚𝑠𝑡 𝑚𝑓 ) ∆ℎ𝑚 = 0
where: No atomization steam in this case.
∆𝐸 enthalpy difference
𝑚𝑠𝑡 mass of steam (lb)

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 Radiation Losses
Heat loss due to radiation:
ℎ𝑟 = ℎ𝐿 × %radiation loss ℎ𝑟 = 20,814 × 0.015
ℎ𝑟 = 312.24 Btu/lb

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Step 3:
solve for thermal and fuel efficiencies
Thermal Efficiency
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎 − (𝒉𝒓 + 𝒉𝒔
𝒆= × 𝟏𝟎𝟎
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎

Where:
ℎ𝐿 20,814 Btu/lb
∆ℎ𝑎 46.37 Btu/lb
∆ℎ𝑓 23.47 Btu/lb
∆ℎ𝑚 0 Btu/lb
ℎ𝑟 312.24 Btu/lb
ℎ𝑠 2,526.28 Btu/lb

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Thermal Efficiency
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎 − (𝒉𝒓 + 𝒉𝒔
𝒆= × 𝟏𝟎𝟎
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎

Where: 𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎 − (𝒉𝒓 + 𝒉𝒔

𝒆= × 𝟏𝟎𝟎
ℎ𝐿 20,814 Btu/lb 𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎
∆ℎ𝑎 46.37 Btu/lb
𝟐𝟎, 𝟖𝟏𝟒 + 𝟒𝟔. 𝟑𝟕 + 𝟐𝟑. 𝟒𝟕 + 𝟎 − (𝟑𝟏𝟐. 𝟐𝟒 + 𝟐, 𝟓𝟐𝟔. 𝟐𝟖)
∆ℎ𝑓 23.47 Btu/lb 𝒆= × 𝟏𝟎𝟎
𝟐𝟎, 𝟖𝟏𝟒 + 𝟒𝟔. 𝟑𝟕 + 𝟐𝟑. 𝟒𝟕 + 𝟎
∆ℎ𝑚 0 Btu/lb
ℎ𝑟 312.24 Btu/lb 𝒆 = 86.4%

ℎ𝑠 2,526.28 Btu/lb

Tulsa Heaters Midstream 38

Fuel Efficiency
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎 − (𝒉𝒓 + 𝒉𝒔
𝒆𝒇 = × 𝟏𝟎𝟎
𝒉𝑳

Where:
ℎ𝐿 20,814 Btu/lb
∆ℎ𝑎 46.37 Btu/lb
∆ℎ𝑓 23.47 Btu/lb
∆ℎ𝑚 0 Btu/lb
ℎ𝑟 312.24 Btu/lb
ℎ𝑠 2,526.28 Btu/lb

Tulsa Heaters Midstream 39

Fuel Efficiency
𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎 − (𝒉𝒓 + 𝒉𝒔
𝒆𝒇 = × 𝟏𝟎𝟎
𝒉𝑳

Where: 𝒉𝑳 + ∆𝒉𝒂 + ∆𝒉𝒇 + ∆𝒉𝒎 − (𝒉𝒓 + 𝒉𝒔

𝒆𝒇 = × 𝟏𝟎𝟎
ℎ𝐿 20,814 Btu/lb 𝒉𝑳
∆ℎ𝑎 46.37 Btu/lb
𝟐𝟎, 𝟖𝟏𝟒 + 𝟒𝟔. 𝟑𝟕 + 𝟐𝟑. 𝟒𝟕 + 𝟎 − (𝟑𝟏𝟐. 𝟐𝟒 + 𝟐, 𝟓𝟐𝟔. 𝟐𝟖)
∆ℎ𝑓 23.47 Btu/lb 𝒆𝒇 = × 𝟏𝟎𝟎
𝟐𝟎, 𝟖𝟏𝟒
∆ℎ𝑚 0 Btu/lb
ℎ𝑟 312.24 Btu/lb
𝒆𝒇 = 86.7%

ℎ𝑠 2,526.28 Btu/lb

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* Based on $2.75/MMBtu gas price
Conclusion
Knowing how to check your heater’s efficiency gives you the
knowledge and power to improve your facility and optimize
your heater. As we have seen, improving efficiency can help
save your facility a lot of money.

What are you waiting for? Go check and start saving now!

Tulsa Heaters Midstream 42

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