Analysis of the Erosion-Corrosion Mechanism of the Air Cooler in a Hydrocracking Unit:A Numerical and Experimental Study

Corrosion leakages often occur in the air cooler of a hydrocracking unit,with the failure sites mainly located in the entrance area of the tubes.An analysis of the macroscopic morphology and corrosion products confirmed that the damage was caused by erosion-corrosion(E-C).Numerical and experimental methods were applied to investigate the E-C mechanism in the air cooler.Computational fluid dynamics(CFD)was used to calculate the hydrodynamic parameters of the air cooler.The results showed that there was a biased flow in the air cooler,which led to a significant increase in velocity,turbulent kinetic energy and wall shear within 0.2 m of the tube entrance.A visualization experiment was then performed to determine the principles of migration and transformation of multiphase flow in the air cooler tubes.Various flow patterns(pure droplet flow,mist flow,and annular flow)and their evolutionary processes were clearly depicted experimentally.The initiation mechanism and processes leading to the development of E-C in the air cooler were also determined.This study provided a comprehensive explanation for the E-C failures that occur in air coolers during operation.

Ammonium Salt Deposition Characteristics in an Air Cooler System Based on the Coupling of Fluid Flow and Heat Transfer Simulation

The ammonium salt corrosion is a typical failure mode for the hydrogenation reaction effluent air cooler(REAC) system. In order to investigate the corrosion characteristics in the REAC system, numerical simulations were performed by using the mixture model, the heating transfer model, and the particles tracking model. The results show that the differences between the temperature and the velocity at each cross section of the first-row and second-row tubes are small. The inertia of the particles plays an important role in the particle’s deposition, and the smaller particles distribute more uniformly in the air cooler. However, for larger particles, they prefer falling from the inner side of the vertical elbow, and preferentially depositing at the inlet header and pipes before saturation. In the heat exchanger tubes, the particle deposition number is larger in the second-row tubes than that in the first-row tubes, and the high-risk tubes mainly concentrate on the middle and right side of the air cooler. The kinetic parameters of the particles are in accordance with the blocking-prone position in many real operating conditions.

Experimental and Numerical Investigation on Erosion Corrosion of the Air Cooler Tube Bundle in a Residue Hydrotreating Unit

Corrosion leakage occurred in the 14th tube bundle in the first row of a residual oil hydrotreating air cooler after operating for two years.The failure location was 0.5 m from the outlet header box.In this paper,the erosion corrosion of the air cooler tube bundle was investigated by experimental and numerical methods.Visual inspection,scanning electron microscopy(SEM),and X-ray diffraction(XRD)experiments were performed,and the failure morphology and material composition confirmed that the damage was caused by erosion corrosion.The shear stress transport k–ωturbulence model(SST-k–ω)was then used to investigate the flow and erosion corrosion characteristics,combined with mass transfer,corrosion rate,and ionization equilibrium models.The numerical simulation results revealed that the water phase volume fraction increased with flow and heat transfer in the fluid,which increased the mass flow rate and concentration of hydrogen sulfide.The mass transfer coefficient and corrosion rate were proposed as important parameters to characterize erosion corrosion.Moreover,the local concentration of wall shear stress was found to increase the risk of erosion corrosion.The predicted high-risk area was consistent with the actual failure area,which verified that this failure incident was attributable to erosion corrosion by the water phase.

Functional Link Neural Network for Predicting Crystallization Temperature of Ammonium Chloride in Air Cooler System

The air cooler is an important equipment in the petroleum refining industry.Ammonium chloride(NH4 Cl)deposition-induced corrosion is one of its main failure forms.In this study,the ammonium salt crystallization temperature is chosen as the key decision variable of NH4 Cl deposition-induced corrosion through in-depth mechanism research and experimental analysis.The functional link neural network(FLNN)is adopted as the basic algorithm for modeling because of its advantages in dealing with non-linear problems and its fast-computational ability.A hybrid FLNN attached to a small norm is built to improve the generalization performance of the model.Then,the trained model is used to predict the NH4 Cl salt crystallization temperature in the air cooler of a sour water stripper plant.Experimental results show the proposed improved FLNN algorithm can achieve better generalization performance than the PLS,the back propagation neural network,and the conventional FLNN models.

Application of Taguchi Method for the Optimization of System Parameters of Centrifugal Evaporative Air Cooler

A new evaporative cooling system based on the action of centrifugal forces is proposed.Such systems are suitable for cooling large air volumes in tropical climates.Effects of geometrical and operational parameters on system performance are optimized using Taguchi method.It is observed that disc speed,air flow rate and water flow rate are found to have major influence on system performance and other parameter,viz.,disc diameter,pin geometry,evaporation chamber length and orientation of pin have less influence.

干湿联合式蒸发空冷器管束腐蚀失效分析及预防措施

干湿联合式蒸发空冷器的传热管束包含预冷管束和蒸发管束,预冷管束采用翅片管,蒸发管束采用蛇形光管。该类型设备在某沿海石化企业使用过程中,蛇形光管U形弯部位出现不同程度的腐蚀穿孔泄漏,为了确定腐蚀泄漏原因,以石脑油加氢装置中石脑油分馏塔顶空冷器为例,采用多种试验手段对腐蚀失效原理进行分析。根据外观检查、水质分析、化学成分检测、力学性能及金相检测、腐蚀形貌观察和产物成分分析等分析结果判断,该空冷器的主要失效原因是浓差腐蚀及电化学腐蚀共同作用的结果,并对此提出了相应的预防措施。

基于响应面法的矿用翅片管空冷器参数优化

矿用空冷器是矿井降温系统常用的末端设备,优化矿用空冷器换热性能对提升矿井降温系统能效具有重要意义。采用Fluent建立了平直翅片管矿用空冷器模型,研究了翅片间距、翅片厚度、横向管间距和纵向管间距对传热因子、阻力因子和综合性能评价指标的影响规律;采用Box-Behnken响应面法,分析了双参数协同作用下传热因子、阻力因子和综合性能评价指标变化规律。结果表明:随着翅片间距、横向管间距的减小,以及翅片厚度增加,传热因子、阻力因子和综合性能评价指标逐渐增加;综合性能评价指标则随纵向管间距的增加而先增加后降低;横向管间距、翅片厚度是影响空冷器传热及流动性能最显著的两个参数,而翅片间距、纵向管间距的影响最小;得到了平直翅片管矿用空冷器的最优参数,传热因子提升16.3%、阻力因子增加26.3%、综合性能评价指标提升8.3%。研究结果可为矿用翅片空冷器设计参数优化提供指导。

传感器位置对大型冷库库内温度及风机运行规律的影响

目前,冷库多通过库内布置传感器所采集的温度信号控制冷风机启停,进而维持适宜贮存温度。为探索不同位置传感器对大型冷库库内温度及风机运行时长的影响,本文以一实际使用的大型冷库为为原型构建计算模型,模拟研究了不同传感器位置导致风机运行规律变化,进而引起冷库温度波动情况。结果表明,“冷库升温”过程中,传感器布置在侧墙中部响应效果最佳;“关门降温”过程,传感器平行侧墙布置在冷库中部时,所导致的风机能耗最小;“开门降温”过程,传感器平行布置在冷库中间可以实现风机最佳的响应时间。

板式湿式空气冷却器风机及喷淋系统试验研究与改造

板式湿式空气冷却器是一种综合空气侧增湿与高效低阻力降传热的新型模块化空冷产品。某炼油厂常减压装置板式湿式空气冷却器使用过程中,风机出口湿空气携带液体,形成空中飘水和地面积水,造成操作场地湿滑,成为工作安全隐患。结合板式湿式空气冷却器运行情况与工艺参数、风机性能、喷淋效果的关系以及夏季生产的实际需要,分析了产生此现象的可能原因,确定了关键影响因素。通过整机试验,开展了风量、风压、喷淋水量与空气携带液体的相关性研究,提出了产品改进措施。

采煤工作面空冷器位置及风流参数优化研究

针对济宁二号煤矿10303采煤工作面高温热害问题,采用数值分析方法,建立了工作面物理模型,分析了风筒长度、风筒的出风口距离及温度等多因素对降温系统的影响,确定了不同工况(生产和停产)的温度控制参数;通过自动启闭控温设施控制空冷器出风温度,实现了不同作业下采煤工作面所需的制冷量,解决了工作面高温热害问题。结果表明:100 m风筒长度、50m风筒出风距离的降温效果最好;当工作面正常开采作业时,出风温度设置应小于16.5℃,工作面的平均温度将降低3.7℃;当停采作业时,出风温度设置应小于20.5℃,此时工作面的平均温度将降低3.5℃;2种工况下的参数均能达到采煤工作面的温度控制目标。

钢厂CCPP发电机组提升负荷的研究与应用

为了提高CCPP发电机组负荷,根据不同环境温度采取不同的煤气热值,夏季利用空气冷却器降低空压机入口空气温度,采用水喷射系统降低燃气轮机入口燃料温度,上述措施实施后,能够降低燃烧温度,提高CCPP发电机组负荷。

塔河油田四号联轻烃后冷器设计探析

采用水作为冷却器的冷却介质已有多年的历史,由于水的换热系数较高,可使设备紧凑、投资低,因而受到重视,并成为一种最重要的冷却方式。由于工业用水量供不应求,人类环保意识不断增强,新型空冷器经济性不断提高,在过去的几十年中,有一部分水冷却器逐渐被空气冷却器所代替。空气冷却器是以环境空气作为冷却介质,依靠翅片管扩展传热面积来强化管外传热,借空气横掠翅片管后的空气温升带走热量,达到冷却、冷凝管内热流体的目的一种设备。空气冷却,不污染水源;空气腐蚀性低,不用特殊的清垢措施;空冷压降低,运行费用低;还具有维护费用低、运转安全可靠、使用寿命长等优点。塔河油田地处严重缺水的塔克拉玛干沙漠边缘,工业及生活用水来源主要依靠地下水,冷却水的供应有困难,为减少水资源浪费,提高水资源利用率,塔河油田油气站场广泛应用空气冷却器。为适应空冷器在塔河油田大面积应用的实际情况,提高空冷器性能,保证现场使用运行效果、扩大其在不同介质及工况情况下的用范围,需要从空冷器设计、制造及传热机理等方面进行不断改进。以塔河油田四号联混烃脱硫工程轻烃后冷器选型为例,详细介绍了空冷器的设计选型原则及具体计算过程,以供其他类似工程项目空冷器选型参考。

水泥窑纯低温余热锅炉常见问题及应对措施

随着水泥工业的飞速发展,水泥窑纯低温余热发电技术被广泛应用于水泥工业中。该技术利用窑头(AQC)和窑尾(SP)排出的废热烟气热量加热余热锅炉水,经过一系列转换后将锅炉水转变为过热蒸汽,进而推动汽轮机组发电。该技术的应用显著提高水泥制造企业的能源利用率,降低大气污染,是企业降本增效、节能减排的重要举措。该文主要介绍水泥窑纯低温余热锅炉的工作原理及其在运行过程中的常见问题,分析问题的形成原因,并提出相应的解决措施,以期为水泥窑纯低温余热锅炉的安全经济运行,维护保养、检修及定期检验提供科学指导。

冷库冷风机融霜方式对比分析

阐述用于冷库冷风机融霜的热气融霜、水冲霜、电热融霜的工作原理,在相同运行工况下,从初投资、运行成本、融霜效果等方面进行对比分析。结果表明,电热融霜冷风机初投资最低,约为热气融霜的60%,水冲霜的80%;热气融霜冷风机运行成本约为电热融霜冷风机的40%~50%,水冲霜冷风机的1.2~1.4倍;水冲霜融霜效果最好。最后针对不同类型冷库冷风机给出融霜方式的建议。

基于GA-BP神经网络的船舶空冷器状态预测

当前船舶空冷器的工作状态主要依靠空冷器冷却后的增压空气温度T_(A2)判断,通常按设定阈值触发报警,存在预警差和精度低等问题。对此,提出一种基于GA-BP(Genetic Algorithm-Back Propagation)神经网络的T_(A2)预测方法。利用BP神经网络构建空冷器状态预测模型,通过对比运行过程中T_(A2)实测值与预测值的偏差,及时发现空冷器的异常状态;引入GA解决BP神经网络存在的收敛速度慢和易于陷入局部最优解等问题。为验证基于GA-BP神经网络的预测方法的有效性,选取多组空冷器清洗前后的状态数据进行训练和验证,结果表明该方法能有效识别空冷器的异常状态。

炼油厂空气冷却器低温余热回收系统优化研究

针对炼油厂部分装置空气冷却器(空冷器)低温热回收及利用问题,对各装置空冷器低温热的热源品位、负荷及工艺介质特性、操作条件等因素进行了综合分析。根据季节变化考虑热阱的周期性波动特点优化设置热阱,进行热量的梯级回收利用,分别建立两套低温热回收利用系统,实现空冷器低温热合理利用。两套低温热回收利用系统可回收299.3 MW热量,回收后的低温热可用于发电、制冷、工艺单元加热、管道设备伴热、建筑物采暖等方面。冬季低温热可全部利用,夏季低温热过剩。

DCC装置稳定塔复合蒸发式空气冷却器管束泄漏原因分析及对策

某石化公司2.2 Mt/a催化裂解装置稳定塔复合蒸发式空气冷却器(空冷器)自装置首次开工以来多次出现管束泄漏的情况。在对空冷器管束外壁垢样成分进行鉴定的基础上,对空冷器管束泄漏的原因进行了详细分析,可以归结为垢下腐蚀、缝隙腐蚀和Cl-腐蚀。针对上述原因,采取加强水质控制、升级管束材质、定期进行腐蚀检测和优化操作条件等措施,可以减缓空冷器管束腐蚀速率,延长空冷器运行周期。另外,针对在役及发生泄漏的空冷器管束,制定合理的监控运行措施和应急处置方案,可有效减轻管束泄漏程度,保证安全生产。

基于工况参数和改进LSTM的空冷器热风温度预测

针对传统抽水蓄能电站技术供水系统存在的智能化水平偏低,供水对象的温度与许多参数变量之间相互耦合的问题,建立了基于工况参数和改进长短期记忆(LSTM)神经网络的发电机空气冷却器热风温度预测模型.首先对原始数据进行清洗,其次采用随机森林(RF)特征降维,对参与目标预测的诸多高维测点变量进行重要度排序,验证所提的工况参数与预测对象温度的相关性,最后再将其输入PSO-LSTM神经网络进行模型的求解.将所提的基于工况参数和改进LSTM方法与最小二乘法、BP神经网络以及原始的LSTM方法进行对比.结果表明,所提模型能有效预测发电机空气冷却器热风温度,相较其他的模型,预测误差能够下降50%左右,同时拥有更优的预测稳定性.