高压空冷器入口管束内流动参数分布特性的数值模拟
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摘要
为揭示腐蚀性介质输送导致的高压空冷器入口管束的流动腐蚀失效机理,准确预测管束的高风险位置,提出了以传质系数和剪切应力作为空冷器入口管束流动腐蚀的关键表征参数。采用Mixture模型和SST k-ω湍流模型对空冷器入口管束段进行数值模拟,获得了入口管束内传质系数和剪切应力的分布特性。结果表明:空冷器入口配管存在偏流现象,引起管束内流动参数左右不对称。其中,传质系数与剪切应力的最大值重合位置位于a管排位号为a_(13)～a_(14)、a_(34)～a_(35)管束的R_1区域(即Z为11.5～26.4mm),为流动腐蚀失效的高风险区域。对比失效案例可知,传质系数、剪切应力分布的最大区域与管束腐蚀泄漏失效的区域基本一致,验证了表征参数和预测方法的准确性。研究成果有望为高压空冷器的耐流动腐蚀优化设计和在役风险检验提供理论支撑。
To reveal the flow-induced corrosion mechanism caused by the transportation of corrosive medium in high pressure air-cooler pipes,mass transfer coefficient and wall shear stress are utilized to represent the flow characteristics as the key parameters.The flow in air-cooler inlet pipe section has been numerically simulated based on the Mixture model and SST k-ω turbulent model,and the distributions of mass transfer coefficient and wall shear stress in the air-cooler pipes are analyzed.The result shows that there is a bias flow in the air-cooler inlet pipes,which causes an asymmetric distribution.Moreover,the coincide position of maximum mass transfer coefficient and wall shear stress is located at region R_1(Z=11.5-26.4mm)away from the liner pipe in pipeline numbered a_(13)-a_(14),a_(34)-a_(35),where there is a high risk of flow-induced corrosion failure.The result compared with a failure case shows that the coincide position of maximum mass transfer coefficient and wall shear stress is consistent with the area where there is a corrosion and leakage failure in the air-cooler pipes.The research results are expected to provide theoretical support for optimal designs and in-service risk tests based on the flow-induced corrosion in high pressure air-coolers.
To reveal the flow-induced corrosion mechanism caused by the transportation of corrosive medium in high pressure air-cooler pipes,mass transfer coefficient and wall shear stress are utilized to represent the flow characteristics as the key parameters.The flow in air-cooler inlet pipe section has been numerically simulated based on the Mixture model and SST k-ω turbulent model,and the distributions of mass transfer coefficient and wall shear stress in the air-cooler pipes are analyzed.The result shows that there is a bias flow in the air-cooler inlet pipes,which causes an asymmetric distribution.Moreover,the coincide position of maximum mass transfer coefficient and wall shear stress is located at region R_1(Z=11.5-26.4mm)away from the liner pipe in pipeline numbered a_(13)-a_(14),a_(34)-a_(35),where there is a high risk of flow-induced corrosion failure.The result compared with a failure case shows that the coincide position of maximum mass transfer coefficient and wall shear stress is consistent with the area where there is a corrosion and leakage failure in the air-cooler pipes.The research results are expected to provide theoretical support for optimal designs and in-service risk tests based on the flow-induced corrosion in high pressure air-coolers.
引文
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[3]KANE R D,HORVATH R J,CAYARD M S.Major improvements in reactor effluent air cooler reliability[J].Hydrocarbon Processing,2006,85(9):99-111.
[4]JIN H Z,OU G F,WANG Y P,et al.Failure analysis and structure optimization of hydrogenation air-cooler system based on imbalanced degree[C]//Prague:ASME PVP Conference,2010,(5):439-448.
[5]SCHERRER C,DURRIEU M,JARNO G.Distillate and resid hydroprocessing:Coping with high concentrations of ammonium bisulfide in the process water[J].Materials Performance,1980,19(11):25-31.
[6]HARVEY C,SINGH A.Mitigate failures for reactor effluent air coolers[J].Hydrocarbon Processing,1999,78(10):59-72.
[7]TOBA K,UEGAKI T,ASOTANI T,et al.A new approach to prevent corrosion of the reactor effluent system in HDS units[J].Corrosion,2003,7(4):455-472.
[8]OU G F,JIN H Z,XIE H P,et al.Prediction of ammonium salt deposition in hydroprocessing air cooler tubes[J].Engineering Failure Analysis,2011,18(6):1458-1464.
[9]金浩哲,陈小平,偶国富,等.加氢空冷器腐蚀产物漂移特性的数值模拟与分析[J].石油学报(石油加工),2016,32(4):754-761.(JIN Haozhe,CHEN Xiaoping,OU Guofu,et al.Numerical simulation and analysis of corrosion products drifting characteristics in hydrogenation reactor effluent air coolers[J].Acta Petrolei Sinica(Petroleum Processing Section),2016,32(4):754-761.)
[10]SUN L,ZHU M,OU G F,et al.Corrosion investigation of the inlet section of REAC pipes in the refinery[J].Engineering Failure Analysis,2016,66(1):468-478.
[11]ZHENG Y,YAO Z,WEI X,et al.The synergistic effect between erosion and corrosion in acidic slurry medium[J].Wear,1995,186-187(2):555-561.
[12]LOTZ U,HEITZ E.Flow-dependent corrosion I Current understanding of the mechanisms involved[J].Materials&Corrosion,2015,34(9):454-461.
[13]SHEMILT L W,CHA C Y,FIADZIGBE E,et al.Steel pipe corrosion under flow conditionsⅢEffect of sulphate ion[J].Corrosion Science,1980,20(3):443-455.
[14]EFRID K D.Effect of fluid dynamics on the corrosion of copper-base alloys in sea water[J].Corrosion,1977,33(1):3-8.
[15]SCHLICHTING H,GERSTEN K.Boundary Layer Theory[M].New York:McGraw-Hill.2003:176-201.
[16]MENTER F R.Two-equation eddy-viscosity turbulence models for engineering applications[J].AIAA,1994,32(8):1598-1605.
[17]WILCOX D C.Reassessment of the scale-determining equation for advanced turbulence models[J].Aiaa Journal,2012,26(11):1299-1310.
[18]WILCOX D C.Turbulence modeling for CFD[J].Dcw Industries La Canada California Usa,1993,11(3):363-367.
[19]ZHENG D,HE X,CHE D.CFD simulations of hydrodynamic characteristics in a gas-liquid vertical upward slug flow[J].International Journal of Heat&Mass Transfer,2007,50(21-22):4151-4165.
[20]RANJBAR K.Effect of flow induced corrosion and erosion on failure of a tubular heat exchanger[J].Materials&Design,2010,31(1):613-619.
[21]金浩哲,偶国富,王宽心,等.加氢处理系统NH4Cl结晶沉积预测及优化防控[J].石油学报(石油加工),2014,30(4):16-21.(JIN Haozhe,OU Guofu,WANGKuanxin,et al.The prediction of NH4Cl crystal deposition and optimized prevention method in the hydro treating units[J].Acta Pretrolei Sinica(Petroleum Processing Section),2014,30(4):16-21.)