加氢反应器2.25Cr-1Mo-0.25V钢堆焊不锈钢应用研究
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摘要
加氢反应器是现代炼油工业的重大关键设备,该设备主要用于石油炼制或重质油的加氢裂化、加氢精制以及催化重整、脱硫、脱除重金属等工艺过程。随着国际石油工业设备向自动化、大型化的方向发展,所用加氢反应器设备的尺寸也愈来愈大,原来一直被广泛采用的2.25Cr-1Mo钢难以满足需求。而且采用2.25Cr-1Mo钢制造的反应器在长期使用中也曾暴露出如高温回火脆化、不锈钢焊缝的氢脆以及不锈钢堆焊层氢致剥离现象等损伤问题。发达国家新的加氢反应器近年来已开始使用新的钢种——2.25Cr-1Mo-0.25V钢,新钢种在强度、韧性较传统钢种有较大提高,并且具有优秀的抗高温回火脆化、抗氢脆、抗不锈钢堆焊层氢致剥离性能。因此,研究2.25Cr-1Mo-0.25V钢的组织性能、焊接性以及在2.25Cr-1Mo-0.25V钢堆焊0Cr20Ni10Nb钢的堆焊工艺研究和工程应用中堆焊质量控制,对于开发研究大型的2.25Cr-1Mo-0.25V钢加氢反应器具有重要的理论价值和实际应用意义。
国内2.25Cr-1Mo-0.25V钢加氢反应器的产品制造在国内还刚刚起步,仅有少数公司能够制造该钢种的大型反应器。本论文以开发研究应用该钢种的反应器制造技术为目标,特别是在加氢设备生产的关键加工方法——2.25Cr-1Mo-0.25V钢堆焊0Cr20Ni10Nb不锈钢的工程应用理论及加工方法还进行了较细致的应用研究。
论文具体针对加氢反应器的制造技术,分别就2.25Cr-1Mo-0.25V的理化性能、不同热处理工艺对材料力学性能的影响机理、回火脆化倾向的评定数据及技术、2.25Cr-1Mo-0.25V钢的焊接性理论分析以及模拟样件的斜Y型坡口焊接裂纹试验、焊接热影响区最高硬度试验、抗再热裂纹试验、进行了较深入的探讨,并结合生产实际进行了2.25Cr-1Mo-0.25V钢的堆焊工艺评定,具体对60mm、90mm带极堆焊进行了相关焊接试验,经过试验分析和工艺优化获得了满足技术条件要求的化学成分均匀的堆焊层组织,同时分析了堆焊缺陷的影响要素,制定出了较为合理的堆焊工艺,为该产品工程现场生产应用和质量控制提供了技术支撑。
Hydroprocessing reactor, which is the significant key equipment of modern petroleum refining industry, is mainly used in technical processes such as refining of fossil oil, hydrocracking, hydrofining, catalytic reforming, desulphurizing and depriving of heavy metals from heavy oil. With the developing trend of automatization and large scale of international oil industry, the dimensions of the existing hydroprocessing equipment become bigger and bigger, thus, the extensively adopted 2.25Cr-1Mo steel cannot meet the need any longer. Meanwhile, the hydroprocessing reactor made of the 2.25Cr-1Mo steel used to expose many problems, such as high-temperature temper embrittlement, hydrogen brittleness of stainless steel welds, and hydrogen-induced stripping of stainless steel claddings, etc. In recent years, many developed countries have begun to make hydroprocessing reactors with the new material-----the 2.25Cr-1Mo-0.25V steel, whose strength and malleability have been greatly improved comparing with traditional steels. Additionally, the 2.25Cr-1Mo-0.25V steel boasts the features of high-temperature temper embrittlement resistance, hydrogen embrittlement resistance, and hydrogen-induced stripping resistance of stainless steel claddings. Therefore, the research on the structure property and weldability of the 2.25Cr-1Mo-0.25V steel and the quality control during technical research of cladding 2.25Cr-1Mo-0.25V on 0Cr20Ni10Nb and project application will provide important theoretical value and practical meaning for researching and exploiting hydroprocessing reactors made of the 2.25Cr-1Mo-0.25V steel.
China is just at the beginning of manufacturing hydroprocessing reactor with the 2.25Cr-1Mo-0.25V steel. And only a few companies are able to manufacture hydroprocessing reactors with it. This thesis paper aims at exploiting and researching on the techniques, particularly the key method of producing hydroprocessing reactor with the 2.25Cr-1Mo-0.25V steel, i.e. applicable theory of cladding.
In accordance with the techniques of manufacturing hydroprocessing reactor, this thesis paper thoroughly probed into the physicochemical properties, influential mechanics of material mechanics properties under different heat-treatment processes, estimation data and technology of the inclination of temper and embrittlement, theoretical analysis of the weldability of 2.25Cr-1Mo-0.25V steel, welding crack test on Y-shaped samples, test of maximum hardness on welding heat-affected zone, and test of reheat-resistant cracks, respectively. Meanwhile, on the basis of relevant experiments on 60mm and 90mm electrode-banded cladding, this thesis paper made technical estimation on 2.25Cr-1Mo-0.25V steel cladding according to actual production, obtained cladding structure with uniform chemical constitution, which can meet the technical requirement, through experimental analysis and technical optimization. At the same time, the thesis paper analyzed factors resulting in cladding deficiency, established appropriate technical process of cladding, and provided technical gist for production application and quality demonstration.
国内2.25Cr-1Mo-0.25V钢加氢反应器的产品制造在国内还刚刚起步,仅有少数公司能够制造该钢种的大型反应器。本论文以开发研究应用该钢种的反应器制造技术为目标,特别是在加氢设备生产的关键加工方法——2.25Cr-1Mo-0.25V钢堆焊0Cr20Ni10Nb不锈钢的工程应用理论及加工方法还进行了较细致的应用研究。
论文具体针对加氢反应器的制造技术,分别就2.25Cr-1Mo-0.25V的理化性能、不同热处理工艺对材料力学性能的影响机理、回火脆化倾向的评定数据及技术、2.25Cr-1Mo-0.25V钢的焊接性理论分析以及模拟样件的斜Y型坡口焊接裂纹试验、焊接热影响区最高硬度试验、抗再热裂纹试验、进行了较深入的探讨,并结合生产实际进行了2.25Cr-1Mo-0.25V钢的堆焊工艺评定,具体对60mm、90mm带极堆焊进行了相关焊接试验,经过试验分析和工艺优化获得了满足技术条件要求的化学成分均匀的堆焊层组织,同时分析了堆焊缺陷的影响要素,制定出了较为合理的堆焊工艺,为该产品工程现场生产应用和质量控制提供了技术支撑。
Hydroprocessing reactor, which is the significant key equipment of modern petroleum refining industry, is mainly used in technical processes such as refining of fossil oil, hydrocracking, hydrofining, catalytic reforming, desulphurizing and depriving of heavy metals from heavy oil. With the developing trend of automatization and large scale of international oil industry, the dimensions of the existing hydroprocessing equipment become bigger and bigger, thus, the extensively adopted 2.25Cr-1Mo steel cannot meet the need any longer. Meanwhile, the hydroprocessing reactor made of the 2.25Cr-1Mo steel used to expose many problems, such as high-temperature temper embrittlement, hydrogen brittleness of stainless steel welds, and hydrogen-induced stripping of stainless steel claddings, etc. In recent years, many developed countries have begun to make hydroprocessing reactors with the new material-----the 2.25Cr-1Mo-0.25V steel, whose strength and malleability have been greatly improved comparing with traditional steels. Additionally, the 2.25Cr-1Mo-0.25V steel boasts the features of high-temperature temper embrittlement resistance, hydrogen embrittlement resistance, and hydrogen-induced stripping resistance of stainless steel claddings. Therefore, the research on the structure property and weldability of the 2.25Cr-1Mo-0.25V steel and the quality control during technical research of cladding 2.25Cr-1Mo-0.25V on 0Cr20Ni10Nb and project application will provide important theoretical value and practical meaning for researching and exploiting hydroprocessing reactors made of the 2.25Cr-1Mo-0.25V steel.
China is just at the beginning of manufacturing hydroprocessing reactor with the 2.25Cr-1Mo-0.25V steel. And only a few companies are able to manufacture hydroprocessing reactors with it. This thesis paper aims at exploiting and researching on the techniques, particularly the key method of producing hydroprocessing reactor with the 2.25Cr-1Mo-0.25V steel, i.e. applicable theory of cladding.
In accordance with the techniques of manufacturing hydroprocessing reactor, this thesis paper thoroughly probed into the physicochemical properties, influential mechanics of material mechanics properties under different heat-treatment processes, estimation data and technology of the inclination of temper and embrittlement, theoretical analysis of the weldability of 2.25Cr-1Mo-0.25V steel, welding crack test on Y-shaped samples, test of maximum hardness on welding heat-affected zone, and test of reheat-resistant cracks, respectively. Meanwhile, on the basis of relevant experiments on 60mm and 90mm electrode-banded cladding, this thesis paper made technical estimation on 2.25Cr-1Mo-0.25V steel cladding according to actual production, obtained cladding structure with uniform chemical constitution, which can meet the technical requirement, through experimental analysis and technical optimization. At the same time, the thesis paper analyzed factors resulting in cladding deficiency, established appropriate technical process of cladding, and provided technical gist for production application and quality demonstration.
引文
[1]仇恩沧.国产2.25Cr-1Mo-0.25V钢加氢反应器的开发.石油化工设备技术,2000,21(4): 36-44.
[2]董苏中译.用高强度Cr-Mo钢制造石油精炼高压容器.大型铸锻件.1992,55(1): 57-59.
[3]肖福仁,胡怡,张乐欣,等.3Cr-1Mo-1/4V钢的组织与性能.钢铁,2001,36(10): 47-50.
[4] Hyun Kwon, Seung-Se Baek, Hyo-Sun Yu. The use of electrochemical propert.
[5]中国机械工程学会压力容器学会代表团.赴美参加第五届国际压力容器技术会议和技术考察报告.压力容器,1985,2(3):1.2.
[6]罗兴宏.微合金化对抗氢蚀钢1.25Cr-0.5Mo钢使用性能的影响.[博士学位论文].沈阳:中国科学院金属研究所,1997:1.15.
[7] D. L. Newhouse and H. G. Heltz. Temper embrittlement in steel. ASTM. STP407,1968:106.
[8]梅丽华,魏刚. 2.25Cr-1Mo-0.25V钢加氢反应器的研制.压力容器. 2003 Vol20.No11.
[9]李金连.石油炼制用热壁加氢反应器.一重技术,1990,3:77-83.
[10] Jianhong Lin, Zhengdong Wang,Cengdian Liu, et al.A New Method to Evaluate Hydrogen Induced Disbonding Susceptibility in Stainless Steel Weld Overlay.In:Transactions of the 12th International Conference in Structural Mechanics in Reactor Technology.Vol G.STUTTGART, Germany:[s n] 1993.G14/6.
[11] J. Andersson, R. George and T. Ishiguro. Manufacturing of advanced Cr-Mo steel pressure.
[12] vessels. Proceeding of the seventh international conference, 1992:847-856.
[13]李丽茹.热壁加氢精制反应器异种钢焊接金相组织及分析.沈阳工业大学学报. 2003年第25卷第4期.
[14]黄嗣罗. 2.25Cr-1Mo不锈钢带极堆焊工艺研究及应用.压力容器. 1996年第13卷第5期.
[15]龙杰,王福明.抗氢2.25Cr-1Mo钢热处理工艺与性能研究.宽厚板. 2006年第12卷第3期.
[16]崔忠圻.金属学与热处理(铸造、焊接专业用).机械工业出版社. 1989年11月.
[17]郭传江刘晓书等.关于不锈钢堆焊层铁素体测算方法的研究.压力容器. Vol17. No3 2000.
[18] ASME Boiler and Pressure Vessel Code, Section III and VI-II-2, 1986 Versio.
[19]张文钺周振丰主编.焊接冶金与金属焊接性.机械工业出版社.
[20]张浩.堆焊层层下裂纹产生原因分析.压力容器.1999年第4期.
[21]贾小斌,张峥,李定孝.热壁加氢反应器材料及焊接技术.石油化工设备.第31卷第四期.
[22]张璞临徐笑梅李晓耀.加氢反应器带极堆焊的质量控制.压力容器.1999年第四期.
[23]周维海,王存宇,张文辉等. 2. 25Cr-1Mo-0. 25V钢的晶粒长大规律.《金属热处理》2005年第30卷第11期.
[24] Palmiere E J. Compositional Microstructural Changes WhichAttend Reheating and Grain Coarsening in Steel ContainingNiobium[J]. Metallurgical and Materials Transactions A,1994,25A:277-286.
[25]李晓清,刘志颖,张堃. 90 mm宽带极不锈钢双层电渣堆焊工艺试验研究.压力容器. Vol23 .No5 2006.
[26] Dipl . - ing .R. Paschold . Electroslag Strip Cladding for CorrosionResistance[R].A Welding Review by ESAB,2001 .2 .62. 67 .
[27]张良成,等.工艺参数对带极电渣堆焊的影响[J].中国化工装备,2002,(1):22 - 32.
[28]牛庆伟. Cr - Mo - V抗氢钢的焊接性.压力容器. Vol21,No5,2004.
[29]李辉,等.2.2 5Cr-1M o-0.2 5V钢的焊接性能和抗氢试验.石油化工设备.第34卷第一期.2005年1月.
[30]齐树柏2.25Cr-1Mo一0.25V钢板工业化的试验研究北京:机械工业出版社,2001.
[31]张文辉,刘同湖,戴世杰.2.25 Cr -1M o-0.25 V钢锻件的研制.压力容器,2001,18(增刊):42
[32]陈崇刚,黎国磊.我国2 1/4Cr-1Mo-1/4V抗氢钢的开发.石油化工设备技术,2002,23(5):38-48.
[33] J. H. Bulloch. The small punch toughness test: some detailed fractographic information. Pressure vessels and piping, 1995:177-194.
[34]蔡连重,谷文,廖巨智.国产热壁加氢反应器制造技术的新近展.压力容器,2000,17(1):69-75.
[35] E.C.Bain:Principles of Heat Treatment,ASM,1962.
[36] R.E.Reed-Hill:Physical Metallurgy Princinless,Van Norstrand Co.,New York,1964.
[37]林建鸿.热壁加氢反应器运行安全问题及其保障技术.压力容器,1994,11(3): 237-240.
[38]周兆圻,章炳华.加氢反应器的使用检验及其试板分析.压力容器, 1997,14(3): 242.246.
[39] Peter Hassen:Pyhsical Metallururgy,Cambridge Univ.Press,1978.
[40]季建新,陆磐谷,顾雪东.热壁加氢反应器制造质量控制要点探讨.石油化工技术,1999,20(6):16-19.
[2]董苏中译.用高强度Cr-Mo钢制造石油精炼高压容器.大型铸锻件.1992,55(1): 57-59.
[3]肖福仁,胡怡,张乐欣,等.3Cr-1Mo-1/4V钢的组织与性能.钢铁,2001,36(10): 47-50.
[4] Hyun Kwon, Seung-Se Baek, Hyo-Sun Yu. The use of electrochemical propert.
[5]中国机械工程学会压力容器学会代表团.赴美参加第五届国际压力容器技术会议和技术考察报告.压力容器,1985,2(3):1.2.
[6]罗兴宏.微合金化对抗氢蚀钢1.25Cr-0.5Mo钢使用性能的影响.[博士学位论文].沈阳:中国科学院金属研究所,1997:1.15.
[7] D. L. Newhouse and H. G. Heltz. Temper embrittlement in steel. ASTM. STP407,1968:106.
[8]梅丽华,魏刚. 2.25Cr-1Mo-0.25V钢加氢反应器的研制.压力容器. 2003 Vol20.No11.
[9]李金连.石油炼制用热壁加氢反应器.一重技术,1990,3:77-83.
[10] Jianhong Lin, Zhengdong Wang,Cengdian Liu, et al.A New Method to Evaluate Hydrogen Induced Disbonding Susceptibility in Stainless Steel Weld Overlay.In:Transactions of the 12th International Conference in Structural Mechanics in Reactor Technology.Vol G.STUTTGART, Germany:[s n] 1993.G14/6.
[11] J. Andersson, R. George and T. Ishiguro. Manufacturing of advanced Cr-Mo steel pressure.
[12] vessels. Proceeding of the seventh international conference, 1992:847-856.
[13]李丽茹.热壁加氢精制反应器异种钢焊接金相组织及分析.沈阳工业大学学报. 2003年第25卷第4期.
[14]黄嗣罗. 2.25Cr-1Mo不锈钢带极堆焊工艺研究及应用.压力容器. 1996年第13卷第5期.
[15]龙杰,王福明.抗氢2.25Cr-1Mo钢热处理工艺与性能研究.宽厚板. 2006年第12卷第3期.
[16]崔忠圻.金属学与热处理(铸造、焊接专业用).机械工业出版社. 1989年11月.
[17]郭传江刘晓书等.关于不锈钢堆焊层铁素体测算方法的研究.压力容器. Vol17. No3 2000.
[18] ASME Boiler and Pressure Vessel Code, Section III and VI-II-2, 1986 Versio.
[19]张文钺周振丰主编.焊接冶金与金属焊接性.机械工业出版社.
[20]张浩.堆焊层层下裂纹产生原因分析.压力容器.1999年第4期.
[21]贾小斌,张峥,李定孝.热壁加氢反应器材料及焊接技术.石油化工设备.第31卷第四期.
[22]张璞临徐笑梅李晓耀.加氢反应器带极堆焊的质量控制.压力容器.1999年第四期.
[23]周维海,王存宇,张文辉等. 2. 25Cr-1Mo-0. 25V钢的晶粒长大规律.《金属热处理》2005年第30卷第11期.
[24] Palmiere E J. Compositional Microstructural Changes WhichAttend Reheating and Grain Coarsening in Steel ContainingNiobium[J]. Metallurgical and Materials Transactions A,1994,25A:277-286.
[25]李晓清,刘志颖,张堃. 90 mm宽带极不锈钢双层电渣堆焊工艺试验研究.压力容器. Vol23 .No5 2006.
[26] Dipl . - ing .R. Paschold . Electroslag Strip Cladding for CorrosionResistance[R].A Welding Review by ESAB,2001 .2 .62. 67 .
[27]张良成,等.工艺参数对带极电渣堆焊的影响[J].中国化工装备,2002,(1):22 - 32.
[28]牛庆伟. Cr - Mo - V抗氢钢的焊接性.压力容器. Vol21,No5,2004.
[29]李辉,等.2.2 5Cr-1M o-0.2 5V钢的焊接性能和抗氢试验.石油化工设备.第34卷第一期.2005年1月.
[30]齐树柏2.25Cr-1Mo一0.25V钢板工业化的试验研究北京:机械工业出版社,2001.
[31]张文辉,刘同湖,戴世杰.2.25 Cr -1M o-0.25 V钢锻件的研制.压力容器,2001,18(增刊):42
[32]陈崇刚,黎国磊.我国2 1/4Cr-1Mo-1/4V抗氢钢的开发.石油化工设备技术,2002,23(5):38-48.
[33] J. H. Bulloch. The small punch toughness test: some detailed fractographic information. Pressure vessels and piping, 1995:177-194.
[34]蔡连重,谷文,廖巨智.国产热壁加氢反应器制造技术的新近展.压力容器,2000,17(1):69-75.
[35] E.C.Bain:Principles of Heat Treatment,ASM,1962.
[36] R.E.Reed-Hill:Physical Metallurgy Princinless,Van Norstrand Co.,New York,1964.
[37]林建鸿.热壁加氢反应器运行安全问题及其保障技术.压力容器,1994,11(3): 237-240.
[38]周兆圻,章炳华.加氢反应器的使用检验及其试板分析.压力容器, 1997,14(3): 242.246.
[39] Peter Hassen:Pyhsical Metallururgy,Cambridge Univ.Press,1978.
[40]季建新,陆磐谷,顾雪东.热壁加氢反应器制造质量控制要点探讨.石油化工技术,1999,20(6):16-19.