When refineries look to reduce energy use and operating costs, they often focus on equipment upgrades or fuel switching. But one of the biggest opportunities is frequently hiding in plain sight: fired heaters.
In this short Q&A, Eberhard Lucke explains why fired heaters are often the largest source of energy loss in refineries. Issues such as excess air, fouling, poor flame control, outdated instrumentation, and misaligned operating targets can quietly drive fuel consumption far above what’s necessary.
At LCTS, we approach fired heater performance from a system perspective. Using process simulation, heat balance analysis, and field data, we evaluate combustion efficiency, heat recovery, tube metal temperatures, and operating margins. Small adjustments in operating strategy or design configuration can lead to significant fuel savings and emissions reduction—without major capital spending.
Optimizing fired heaters can deliver:
• Lower fuel consumption and operating costs
• Reduced CO₂ and NOₓ emissions
• Improved heater reliability and tube life
• Better heat integration with downstream units
• Increased operating flexibility and throughput
Energy efficiency improvements don’t always require new technology. Often, they start with understanding how existing equipment is truly performing.
Want to reduce energy losses where they matter most? Let’s take a closer look at your fired heaters.
📨 Got questions? Message us here on LinkedIn—we’re ready to help.
📌 Contact us:
📞 +1 (281) 366-1306 | +1 (713) 302-7805
📧 elucke@luckeconsulting.com | sspears@luckeconsulting.com
🌐 www.luckeconsulting.com
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