甲烷化水冷器管束泄漏原因分析及处理
中国石化九江分公司, 江西九江 332004
| 摘 要： | 煤制氢净化装置甲烷化水冷器1240E002壳程为循环水，管程（介质侧）为工业氢/凝水，该换热器自2015年投用至2021年未见异常；在2022年3月~8月，连续出现3次泄漏，给装置安稳生产带来较大的风险隐患和不必要的经济损失。本文主要分析运行过程中频繁出现泄漏的原因，从循环水腐蚀机理及形成原因等方面进行研究，针对循环水中钙镁等离子及悬浮物较多、水流速不达标、管束结构缺陷产生流动死区等问题提出可行性应对措施，并通过理论分析及实际应用予以验证，如减缓结垢可增加反冲洗流程、增加钐钴流体处理器、提高水流速、优化折流板分布减少流动死区、定期排污、改善水质降低悬浮物和粘泥量；如减缓腐蚀可对管束外壁涂层防腐（如循环水走管程则对管束进行内防腐）、降低循环水中氯离子和溶解氧的含量、抑制微生物生产、严格控制循环水进出口温度、采用牺牲阳极保护技术来保护管束等，最终达到减缓垢下腐蚀的发生，从而避免泄漏，保障装置的安全稳定运行。 |
| 关 键 词： | 水冷器泄漏; 循环水腐蚀机理; 反冲洗; 钐钴流体处理器; 垢下腐蚀 |
| DOI： | 10.57237/j.cse.2024.01.001 |
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收稿日期: 2023-10-25
接受日期: 2023-11-11
在线出版日期: 2023-12-27
Analysis and Treatment of Methanation Water Cooler Tube Bundle Leakage
Jiujiang Petrochemical Company, Jiujiang 332004, China
| Abstract: | Shell 1240E002 is circulating water, and the pipe (medium side) is industrial hydrogen / condensate. The heat exchanger has not been in operation from 2015 to 2021; from March to August 2022, there were three consecutive leaks, which brought great risks and unnecessary economic losses to the stable production of the device. This paper mainly analyzes the reasons for frequent leakage during operation, and studies the corrosion mechanism and formation reasons of circulating water, In view of the problems such as more calcium and magnesium plasma and suspended matter in circulating water, substandard water velocity, and flow dead zone caused by structural defects of tube bundles, feasible countermeasures were proposed, and verified by theoretical analysis and practical application. For example, reducing scaling can increase the backwash process, increase the samarium cobalt fluid processor, increase the water flow rate, optimize the baffle distribution to reduce the flow dead zone, regular sewage, improve the water quality to reduce the amount of suspended solids and mud; For example, to slow down the corrosion of the outer wall coating of the tube bundle (such as the internal anticorrosive process of the tube bundle for circulating water), reduce the content of chloride ions and dissolved oxygen in the circulating water, inhibit the production of microorganisms, strictly control the temperature of the inlet and outlet of circulating water, and adopt sacrificative anode protection technology to protect the tube bundle, etc., and finally reduce the occurrence of scale corrosion, so as to avoid leakage. Ensure the safe and stable operation of the device. |
| Keywords: | Leakage of Water Cooler; Corrosion Mechanism of Circulating Water; Backwashing; Samarium Cobalt Fluid Processor; Under-Deposit Corrosion |
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