加氢空冷器流动腐蚀失效分析与智能防控完整性解决方案  

Failure Analysis on Flow Corrosion of Hydrogenation Air Cooler and Integrity Solution of Intelligent Prevention and Control

作　　者：偶国富 俞晨炀 黄本清 OU Guofu;YU Chenyang;HUANG Benqing(Institute of Flow-Induced Corrosion and Intelligent Prevention and Control,Changzhou University,Changzhou 213164,China)

机构地区：[1]常州大学流动腐蚀与智能防控研究所,江苏常州213164

出　　处：《化学反应工程与工艺》2021年第3期244-252,共9页Chemical Reaction Engineering and Technology

基　　金：国家自然科学基金-重点项目(U19092016);国家自然科学基金-面上项目(51876194,U1261124,50976106,20576125)。

摘　　要：针对原油劣质化程度高、加工负荷波动大、原料切换性质多变、腐蚀事故频繁出现的某渣油加氢空冷器的流动腐蚀失效情况,进行了反应流出物空冷器系统的工艺过程分析、腐蚀流分布研究以及流动腐蚀高风险区域预测。通过对失效案例的解剖研究,验证了流动腐蚀预测分析的准确性,明确了反应流出物系统的失效机理、过程与条件。失效研究表明:反应流出物空冷器的结构设计不合理,运行过程缺少流动腐蚀的状态监测,工艺防护缺少针对性,最终导致了腐蚀失效的发生。基于流动腐蚀失效分析结果,提出了复合衬管空冷器的制造和校核方案,以及流动腐蚀状态监测方案。研发了工艺防护优化技术以及流动腐蚀智能防控成套技术,基于高风险设备的本质安全与运行安全,提出了REAC系统智能防控的完整性解决方案。In view of the flow corrosion failure of a residue hydrotreating air cooler with high degree of crude oil deterioration,large fluctuation of processing load,changeable raw material switching properties and frequent corrosion accidents,the process analysis of reaction effluents air cooler(REAC)system,corrosion flow distribution research and flow induced corrosion risk area prediction were carried out.Through the anatomic study of failure cases,the accuracy of flow induced corrosion prediction analysis was verified.At the same time,the failure mechanism,process and conditions of the reactive effluent system were clarified.The failure studies showed that the structural design of REAC was unreasonable,the state monitoring of flow corrosion was lacking in the operation process,and the process protection was not targeted,which ultimately leaded to the occurrence of corrosion failure.Based on the results of flow induced corrosion failure analysis,the manufacturing and checking scheme of composite liner air cooler,and a monitoring scheme of flow induced corrosion state were proposed.The optimization technology of process protection and the complete set technology of intelligent flow induced corrosion prevention and control were developed.Based on the intrinsic safety and operation safety of high-risk equipment,the integrity solution of intelligent prevention and control of REAC system was proposed.

关 键 词：反应流出物系统空冷器 流动腐蚀 失效分析 智能防控 

分 类 号：TQ022.4[化学工程]