Optimized Process Furnaces, Inc

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Air Preheat Systems

We specialize in designing and retrofitting process furnaces for optimal efficiency, and our Air Preheat Systems are an important part of that process.

We have designed and installed Air Preheat Systems in a wide variety of both new and in-service heaters to utilize hot flue gas from the combustion process to preheat the incoming combustion air.

Benefits of Air Preheat Systems

As a vital part of our nation's production and economy, heaters and furnaces are major consumers of energy. With energy consumption and crude oil prices on the rise, industry leaders are increasingly looking for ways to improve thermal efficiency and conserve fuel and energy.

One of the most potent ways to improve efficiency and productivity is to preheat the combustion air going to the burners. Because the air enters the furnace at a higher temperature, less energy must be supplied by the fuel.

OPF Advantage

Revamps and Upgrades

It's in our name: OPTIMIZED Process Furnaces, Inc. We specialize in designing and upgrading fired heating systems to perform at optimal capacity and efficiency.

With over 40 years of industry experience, OPF can evaluate new and retrofit solutions to determine the most effective, low cost solution.

Why Revamp or Upgrade Your Heater?

Fired heaters are major consumers of energy and fuel. With the rising cost of fuel, even small improvements to a heater's performance and/or efficiency can save thousands of dollars. We can upgrade, revamp, or repair your heater to:

  • Extend working life
  • Reduce emissions
  • Increase capacity & thermal efficiency
  • Increase run lengths between shutdowns
  • Decrease maintenance costs

Our Revamp / Upgrade Services:

  • Convection section replacement or modification
  • Coil modification or replacement
  • Coil metallurgy upgrades
  • Low emission burner retrofits
  • New air preheater installations
  • Existing air preheater repair
  • NOx reduction system installation
  • Stack modifications
  • Waste heat recovery unit design & repair
  • Natural to forced draft heater conversion
  • Heat transfer area expansion
  • Radiant box modifications
  • Selective catalytic reduction (SCR) systems for reduced emissions

Emissions Control

Our experienced engineers have custom-designed emission control systems for a broad spectrum of process heater designs and capacities.

One of the issues with the use of industrial fired heating systems is the amount of nitrogen oxides—or NOx—and other pollutants that these operations release into the atmosphere. It is important that emission levels are below federal and local mandates.

We offer a wide range of pre- and post-combustion options for reducing emissions, and we know how to maximize the contribution of each technology without sacrificing unit performance.

We can analyze each system to estimate NOx reduction potential, taking into account existing equipment design, current levels of NOx emissions, space and budget constraints, and potential downtime. OPF can provide process and emission guarantees on every emissions control project we manage.

Emission Control Options

Low-NOx Burners

The most common method—and often the first step—to control emissions is to install a Low or Ultra-low NOx Burner. These burners control the mix of fuel and air to lower flame temperature and reduce oxygen concentration, which results in lower NOx production. We custom-design each unit to maximize NOx reduction without sacrificing combustion performance or unit operation.

  • Cost-effective way to reduce emissions by 40-60%
  • Simplest NOx-control technology option to install
  • Won't increase operating costs or decrease efficiency
  • Reduce NOx emissions without a corresponding increase in CO emissions

Flue Gas Recirculation (FGR)

FGR units recirculate external flue gas into the combustion air stream, which lowers the peak flame temperature and cuts thermal NOx formation. The addition of flue gas also reduces the oxygen available to react with the nitrogen. FGR can cut NOx emissions on conventional burners by 50-70% and can also be used in conjunction with Low-NOx burners.

Selective Catalytic Reduction

Selective Catalytic Reduction (SCR) units provide an effective, affordable solution to NOx emissions restrictions for industrial furnace applications. SCR is a post-combustion NOx control option that uses a chemical reaction to separate the NOx into harmless nitrogen and water, thereby reducing overall NOx emissions.

OPF can design or retrofit your fired heating system with a highly integrated and optimized SCR unit. Our thorough understanding of fired heating applications allows us to maximize SCR performance while minimizing its impact on plant operations.

  • Custom designed for site-specific conditions
  • Flexibility and features to support day-to-day operations
  • Can be used alone or coupled with other OPF equipment
  • NOx reductions as high as 90 percent are possible
  • Low running and maintenance cost
  • Excellent reliability

System Optimization

Our Waste Heat Recovery Units, Air Preheat Systems and other Revamps and Upgrades are designed to reduce fuel consumption and increase system efficiency, which in turn reduces the amount of pollutants your fired heating system emits.

Contact Us About Your Project

If you have any questions about our Emissions Control options (or any of our products or services), please don't hesitate to contact us.

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One Company,
Everything You Need

Our goal at OPF is to be the only resource you need for direct-fired process furnace applications and waste heat recovery systems. From complete new system design, to replacement parts and field service, to instrumentation and controls, OPF is your complete equipment supplier.

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