Systematic increase of the technological furnaces’ efficiency through an implementation of improvements during major overhaul and regular operational tuning tests

UDK: 66.041.012.1

DOI: 10.24887/0028-2448-2025-11-59-63

Key words: operational efficiency, technological furnaces, energy efficiency, organizational-technical solutions

Authors: Yu.V. Shevelev (Rosneft Oil Company, RF, Moscow); А.А. Tsupikov (Rosneft Oil Company, RF, Moscow); V.V. Putintsev (All-Russian Research Institute of Oil Refining JSC, RF, Moscow); D.A. Lenkevich (All-Russian Research Institute of Oil Refining JSC, RF, Moscow)

A systematic approach of Rosneft Oil Company to refining technological furnaces’ efficiency increase is described, encompassing organizational and technical measures. A key component of this approach is the organization of regular mode-adjustment tests enabling furnace operation monitoring, identifying and correcting deviations from optimal technological parameters, as well as a set of technical activities for increasing the efficiency of the equipment during repairs implementation. Individual mode maps and regulation algorithms were developed for more than 450 furnaces, considering fuel types and technological features, resulting in efficiency increase of up to 6 % above the initial level depending on the type of the equipment. An important aspect is the identification and replication of best practices for optimal furnace operation modes maintaining. Organizational and technical solutions such as fine-tuning of the fuel-air ratio, ensuring the tightness of the refractory sealing, changing the placement of steam and fuel oil collectors, burner replacements with modern models and periodic «on mode» cleaning of coils ensure maximum furnace efficiency sustain throughout the entire operational interval between overhauls. Special attention is given to implementing digital technologies for automating data collection, creating databases of effective modes and best practices, real-time deviation monitoring, and decision support systems. Future development of furnaces efficiency prospects include advanced big data tools for predictive analytics and proactive performance management application.

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