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.

Pressure drop of the film-enlarged tube bundles in air-water two-phase cross flow in evaporative air cooler

An experiment was carried out to investigate the relation of the maximum velocity of air passing through narrowest passage, mass flux of spray water in one square meter in one hour and the pressure drop of tube bundles. Twelve equations were obtained for the relation. The results show that the pressure drop of the tube bundles increases with increase of the maximum velocity of air and the mass flux of spray water. Comparing the pressure drop of the bare tube bundles with that of the film-enhanced tube bundles, it is found that the pressure drop of the film-enhanced tube bundles is lower about 11% and the surface roughness of the film-enhanced plates is a main factor that influences the pressure drop. The data and method obtained in the paper can be used to compute the pressure drop of the film-enhanced tube bundles and is helpful for selection of fan.

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。

连续重整装置再接触空冷器管束泄漏分析

以某炼化企业连续重整装置再接触空冷器为研究对象,通过实际分析和模拟计算,对连续重整装置再接触空冷器管束泄漏原因进行分析并提出腐蚀防护措施。结果表明:连续重整装置再接触空冷器中的NH_(4)Cl结晶温度为80~100℃,处于再接触空冷器出入口温度区间内,NH_(4)Cl在再接触空冷器中间及出口部位会结晶沉积于管束内壁,停工期间会发生吸水潮解腐蚀。因此,停工期间可通过碳酸氢钠水溶液水洗、再接触空冷器管束充氮气保护等措施来防止产生NH_(4)Cl垢下腐蚀,同时还需对再接触空冷器管束进行打压,确保管束无泄漏。

基于逆布雷顿循环的空气制冷机的优化与性能分析

本文提出将传统空气制冷机的绝热压缩过程改进为多管束空气压缩机进行等温压缩,分析了改进后基于逆布雷顿循环的空气制冷机的压缩过程、制冷循环过程以及性能系数。结果表明:相较于传统的空气制冷机,改进的空气制冷机压缩机出口温度可降低144.55K,做功可以减少52.48kJ/kg,性能系数(COP)可以提高0.375。如果考虑回收膨胀功,改进的空气制冷机COP可以达到1.33。

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。

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.

吸收式溴化锂机组回收蒸汽凝液余热制冷技术改造分析

介绍了余热回收溴化锂制冷机组的工作原理,针对鑫润公司60万t/a草酸技改乙二醇装置存在的1.0 MPa(G)蒸汽冷凝液大量直排、所含余热未进行利用的问题,进行了技术改造,即在乙二醇冷冻站新增吸收式溴化锂制冷机组系统,利用凝液余热制取冷冻水。改造后,热能浪费问题得到了有效解决,每年可节约电能2740.53万kW·h,相当于节约标准煤3368.11 t、减少CO_(2)排放量15629.24 t。

高海拔特高压换流变压器冷却性能修正研究

川藏高原是我国的资源富矿,随着藏东南能源大开发,预计建设多个特高压直流工程,而特高压换流变压器是特高压输电工程中至关重要的设备,散热是保证其安全运行的关键。现有标准制定时工程未面临超高海拔特高压工程,为避免变压器的热设计裕量选择不当而影响设备安全稳定运行情况的发生,标准适用性可以继续深入论证。主要对强油循环风冷却器在不同海拔下冷却容量、换流变压器顶部油温升进行理论分析与仿真计算的对比验证。同时利用环境气候模拟实验室完成不同海拔高度下冷却容量的测试试验,通过对试验结果与理论计算的对比验证,给出了不同海拔条件下风冷却器冷却容量的修正建议,即海拔2000~5000m范围内,在2000m基础上,海拔每升高250 m温升限值降低0.75 K。这为高海拔环境下换流变压器的冷却系统设计和标准修订提供了参考依据,对用于高海拔环境下换流变压器的热设计和可靠性评估有一定指导意义。

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。

UNIPOL聚丙烯循环气冷却器换热效果差的原因分析及应对策略

某公司UNIPOL聚丙烯工艺生产装置的循环气冷却器换热效率降低,严重影响反应器的运行效果。对UNIPOL聚丙烯循环气冷却器换热效果差的危害影响进行阐述,分析循环气冷却器换热效果差的原因为循环水侧结垢、循环水供水温度高以及循环气侧管程积粉或堵塞,可通过清理循环气冷却器管程、壳程化学水清洗、投用循环冷却水副线、精细调整等手段降低冷却器换热效率低对装置运行的影响,为UNIPOL聚丙烯流化床的长周期稳定运行提供一定参考。

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。