Hybrid furnace with fuel and/or electricity

1 . An apparatus for heating petroleum, petrochemical, chemical process fluids, and boiler feed water or steam generation with a combination, or individual operation, of electrical elements and fired burners comprising:

a radiant heating section and a flue gas stack for exhausting a combustion gas to the atmosphere;

one or more process coils disposed within the radiant heating section;

one or more fuel-fired burners disposed within the radiant heating section, the one or more fuel-fired burners configured for combusting a fuel and producing the combustion gas, wherein the one or more fuel-fired burners are arranged to provide a first radiant energy to an upper elevation of the one or more process coils;

one or more electrical heating elements disposed within the radiant heating section, the one or more electrical heating elements arranged to provide a second radiant energy to a lower elevation of the one or more process coils; and

an internal baffle located at an elevation between the upper elevation and the lower elevation, the internal baffle arranged to provide shielding of the one or more electrical heating elements from flame and combustion gases from the one or more fuel-fired burners;

wherein the one or more electrical heating elements are configured to provide 5% or more of a combined maximum energy output of the one or more fuel-fired burners and the one or more electrical heating elements.

2 . The apparatus of claim 1 , wherein the one or more fuel-fired burners include one or more floor burners, one or more wall burners, or a combination of floor and wall burners.

3 . The apparatus of claim 1 , further comprising a refractory material disposed between the one or more electrical heating elements and an internal surface of an exterior wall of the radiant heating section.

4 . The apparatus of claim 3 , further comprising a refractory coating disposed between the one or more electrical heating elements and the refractory material.

5 . The apparatus of claim 1 , wherein the internal baffle is configured to provide an opening between the upper elevation and the lower elevation.

6 . The apparatus of claim 1 , wherein the internal baffle is configured to close the upper elevation from the lower elevation.

7 . The apparatus of claim 1 , wherein the one or more electrical hearting elements further comprise one or more electrical connections, wherein the one or more electrical connections are located on an exterior of the radiant heating section.

8 . The apparatus of claim 7 , further comprising an external baffle configured to direct a combustion air over at least one of the one or more electrical connections and provide the combustion air to the one or more fuel-fired burners.

9 . The apparatus of claim 1 , further comprising a second refractory material disposed on the internal baffle.

10 . The apparatus of claim 1 , wherein the one or more electrical heating elements are located between 12 and 18 inches from the one or more process coils.

11 . The apparatus of claim 1 , further comprising one or more purge gas inlets disposed in the lower elevation of the radiant heating section, the one or more purge gas inlets configured to maintain a working environment within the lower elevation.

12 . A process for retrofitting a fuel-fired heater, having a radiant heating section, one or more process coils in the radiant heating section, and a flue gas stack, for heating petroleum, petrochemical, chemical process fluids, and boiler feed water or steam generation to include a combination of electrical heating elements and fuel-fired burners, the process comprising:

removing one or more fuel-fired burners disposed at a lower elevation in the radiant heating section;

retaining one or more fuel-fired burners disposed at an upper elevation in the radiant heating section;

disposing one or more layers of refractory material in the lower elevation in the radiant heating section;

disposing one or more electrical heating elements in the lower elevation in the radiant heating section proximate a surface of the one or more layers of refractory material, wherein the one or more electrical heating elements are disposed at a distance of 12 to 18 inches from the one or more process coils; and

disposing an internal baffle between the upper elevation and the lower elevation, the internal baffle configured to provide shielding of the one or more electrical heating elements from flame and combustion gases from the one or more fuel-fired burners.

13 . The process of claim 12 , further comprising providing a refractory shielding material between the one or more electrical heating elements and the one or more layers of refractory material.

14 . The process of claim 12 , further comprising disposing one or more purge gas inlets in the lower elevation of the radiant heating section, the one or more purge gas inlets configured to maintain a working environment within the lower elevation.

15 . A method of retrofitting a cracking heater comprising a radiant heating zone and a convective heating zone, wherein the radiant heating zone comprises a floor, floor burners disposed in the floor, a refractory wall including a first wall opposite a second wall, wall burners disposed along a height of the first wall and the second wall, and a radiant coil disposed within the radiant heating zone intermediate the first wall and the second wall, the method comprising:

installing an intermediate floor at an elevation below a wall burner;

installing a second refractory wall from the floor to the intermediate floor;

moving a floor burner from the floor to the intermediate floor;

installing one or more electrical heating elements along a height of the second refractory wall.

16 . The method of claim 15 , wherein the second refractory wall is closer to the radiant coil than the refractory wall.

17 . The method of claim 15 , wherein the intermediate floor and the second refractory define a bull nose above the one or more electrical heating elements, the bull nose separating a lower elevation of the radiant heating zone from an upper elevation of the radiant heating zone.

18 . The method of claim 15 , further comprising installing a purge air inlet proximate the floor.