Numerical Simulation of Multiphase Erosion-corrosion of Tubes Bundles of Hydrocracking Air Cooler

doi:10.11902/1005.4537.2018.003

Journal of Chinese Society for Corrosion and protection

2019, Vol. 39

Issue (2): 192-200 DOI: 10.11902/1005.4537.2018.003

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Numerical Simulation of Multiphase Erosion-corrosion of Tubes Bundles of Hydrocracking Air Cooler

Aiguo JIANG¹,Jianwen ZHANG¹(

),Yanan XIN¹,Xiaoming CONG²,Shi DONG³

1. College of Chemical Engineering, Beijing University of Chemical Technology, Beijing 100029, China
2. Qinghai Geology Mineral Surveying Institute, Xining 810012, China
3. Shanxi Orchid Coalbed Methane Co., Ltd., Jincheng 030006，China

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Abstract

Air cooler is the key equipment in the process of hydrocracking. The corrosion of air cooler becomes a prominent problem in the safe and stable operation of equipment. In this paper, a numerical simulation model is established based on the analysis of the erosion corrosion of the air cooler tubes in a hydrocracking unit. The mixture model and the standard k-ε model of CFD simulation software is used to simulate the whole flow field of the tube box and tube bundle of the air cooler. The corrosion position of the air cooler is predicted by the turbulent kinetic energy distribution. The corrosion amount of erosion corrosion and electrochemical corrosion are predicted as well. According to the simulation, the maximum erosion amount is 4.76 mm/a, and it is concentrated at the inlet of the tube bundle of air cooler. The simulation results are consistent with the actual corrosion of the air cooler. Comparing with electrochemical corrosion, erosion corrosion is the main cause of corrosion of air cooler. The amount of erosion and corrosion of the tube bundle of air cooler has been greatly reduced after the retrofit of the air cooler structure, therewith, the safety and stability of the air cooler have been greatly improved.

Key words: air cooler CFD turbulent kinetic energy erosion corrosion

Received: 08 January 2018

ZTFLH:

TE986

Fund: National Key Technology R&D Program of China(2015BAK39B02);Key Technology R&D Program of Qinghai(2018-SF-138)

Corresponding Authors: Jianwen ZHANG E-mail: zhangjw@mail.buct.edu.cn

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	Aiguo JIANG
	Jianwen ZHANG
	Yanan XIN
	Xiaoming CONG
	Shi DONG

Cite this article:

Aiguo JIANG,Jianwen ZHANG,Yanan XIN,Xiaoming CONG,Shi DONG. Numerical Simulation of Multiphase Erosion-corrosion of Tubes Bundles of Hydrocracking Air Cooler. Journal of Chinese Society for Corrosion and protection, 2019, 39(2): 192-200.

URL:

https://www.jcscp.org/EN/10.11902/1005.4537.2018.003 OR https://www.jcscp.org/EN/Y2019/V39/I2/192

Fig.1 Process diagram for droplet to impact metal wall

Fig.2 Function F(α) of ductile metals and brittle metals

Table 1 Physical parameters of multiphase flow in the inlet of air cooler

Fig.3 Distribution of corrosion of tube bundles of air cooler

Fig.4 Mesh independence

Fig.5 Normal velocity distributions of the fluid in the first (a), second (b) and third (c) row tube bundles

Fig.6 Tangential velocity distributions of the fluid in the first (a), second (b) and third (c) row tube bundles

Fig.7 Distribution of bias current ratio for each tube bundle

Fig.8 Turbulent kinetic energy distributions of the fluid in the first (a), second (b) and third (c) row tube bundles

Fig.9 Distribution of erosion rate

Fig.10 Distribution of electrochemical corrosion rate

Fig.11 Improved structure diagram of air cooler

Fig.12 Normal velocity distributions for the fluid in the first (a), second (b) and third (c) row tube bundles after structure optimization of air cooler

Fig.13 Tangential velocity distributions of the fluid in the first (a), second (b) and third (c) row tube bundles after structure optimization of air cooler

Fig.14 Distribution of bias current ratio of each tube bundle after structure optimization of air cooler

Fig.15 Turbulent kinetic energy distributions of the fluid in the first (a), second (b) and third (c) row tube bundles after structure optimization of air cooler

Fig.16 Distribution of erosion rate after structure optimiza-tion of air cooler

Fig.17 Distribution of electrochemical corrosion rate after structure optimization of air cooler

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