常顶系统流动腐蚀机理预测及防控措施优化
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摘要
国内某炼油厂常减压蒸馏装置的常压塔顶冷却系统换热器频繁出现腐蚀失效问题。基于物料衡算原理,采用逆向推导的方法及工艺过程模拟计算分析了该常压塔顶冷却系统的流动腐蚀失效机理,包括露点腐蚀、铵盐结晶沉积垢下腐蚀以及多相流冲刷腐蚀。注水是一种方便且非常有效的破除露点腐蚀和铵盐结晶沉积垢下腐蚀的工艺防护措施。但由于该炼油厂常压塔顶注水量有限,每台换热器采用不同的注水方式,依然出现了流动腐蚀失效问题。通过模拟计算,提出根据不同的注水量应选择不同的注水方式(总管注水、换热器定点注水和程控注水),从而实现该常顶冷却系统长周期稳定运行。
Corrosion failures often occur at the overhead cooling system in the atmospheric tower in a domestic oil refinery.Based on the material balance principle, this study uses the reverse derivation method and process simulation to analyze the flow corrosion failure mechanism of the atmospheric pressure overhead cooling system,including dew point corrosion, ammonium salt crystal deposition scale corrosion, and multiphase flow erosion.Generally,water injection is a convenient and efficient measure to eliminate dew-point corrosion and under-deposit corrosion caused by ammonium salt crystallization. Nevertheless, due to the restricted water injection flow rate and various water injection modes for the heat exchangers, corrosion failure still occurred in the overhead cooling system of the atmospheric tower. By simulating the overhead system, the suitable one of three water injection modes(in the main process pipe, in the heat exchangers and by a programming controller) can be determined to realize the longterm stable operation of the overhead cooling system in the atmospheric tower according to a given injected water flow rate.
Corrosion failures often occur at the overhead cooling system in the atmospheric tower in a domestic oil refinery.Based on the material balance principle, this study uses the reverse derivation method and process simulation to analyze the flow corrosion failure mechanism of the atmospheric pressure overhead cooling system,including dew point corrosion, ammonium salt crystal deposition scale corrosion, and multiphase flow erosion.Generally,water injection is a convenient and efficient measure to eliminate dew-point corrosion and under-deposit corrosion caused by ammonium salt crystallization. Nevertheless, due to the restricted water injection flow rate and various water injection modes for the heat exchangers, corrosion failure still occurred in the overhead cooling system of the atmospheric tower. By simulating the overhead system, the suitable one of three water injection modes(in the main process pipe, in the heat exchangers and by a programming controller) can be determined to realize the longterm stable operation of the overhead cooling system in the atmospheric tower according to a given injected water flow rate.
引文
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[25]Tang P,Yang J,Zheng Z J,et al.Failure analysis and prediction of pipes due to the interaction between multiphase flow and structure[J].Eng.Fail.Anal.,2009,16:1749-1756.
[26]张建文,苏国庆,姜爱国.液化气脱硫装置再生塔返塔管线弯头腐蚀失效机制分析[J].化工学报,2018,69(8):3537-3547.Zhang J W,Su G Q,Jiang A G.Corrosion failure mechanism of return pipeline elbow of regeneration tower in LPG desulfurization unit[J].CIESC Journal,2018,69(8):3537-3547.
[27]中华人民共和国工业和信息化部.高硫原油加工装置设备和管道设计选材导则:SH/T 3096-2012[S].北京:中石化出版社,2012.Ministry of Industry and Information Technology.Material selection guideline for design of equipment and piping in units processing sulfur crude oils:SH/T 3096-2012[S].Beijing:Sinopec Press,2012.
[28]中华人民共和国工业和信息化部.高酸原油加工装置设备和管道设计选材导则:SH/T 3129-2012[S].北京:中石化出版社,2012.Ministry of Industry and Information Technology.Material selection guideline for design of equipment and piping in units processing acid crude oils:SH/T 3129-2012[S].Beijing:Sinopec Press,2012.
[29]国家石油和化学工业局.石油化工设备和管道涂料防腐蚀技术规范:SH 3022-1999[S].北京:中石化出版社,1999.State Bureau of Petroleum and Chemical Industry.Technical specification for the coating anticorrosion of equipment and piping in petrochemical industry:SH/T 3022-1999[S].Beijing:Sinopec Press,1999.
[30]White R A.Materials Selection for Petroleum Refineries and Gathering Facilities[M].Houston:NACE International,1998:1-30.
[2]郭辉.常压蒸馏装置塔顶系统腐蚀机理分析及措施[J].石油化工腐蚀与防护,2017,34(4):62-64Guo H.Mechanic analysis and countermeasures of corrosion in overhead system of atmospheric distillation unit[J].Corrosions&Protection in Petrochemical Industry,2017,34(4):62-64.
[3]侯芙生.中国炼油技术[M].北京:中国石化出版社,2011:53-98.Hou F S.China Oil Refining Technology[M].Beijing:Sinopec Press,2011:53-98.
[4]Slavcheva E,Shone B,Turnbull A.Review of naphthenic acid corrosion in oil refining[J].Brit.Corros.J.,1999,34(2):125-131.
[5]Schempp P.Preu?K.Tr?ger M.About the correlation between crude oil corrosiveness and results from corrosion monitoring in an oil refinery[J].Corrosion,2016,72(6):843-855.
[6]Johnson D,Mcateer G,Zuk H.The safe process of high naphthenic acid content crude oils-refinery experience and mitigation studies[J].NACE Corrosion,2003,03645.
[7]Wu X Q,Jing H M,Zheng Y G,et al.Erosion-corrosion of various oil-refining materials in naphthenic acid[J].Wear,2004,256:133-144.
[8]Shargay C A.Effect of nonextractable chlorides on refinery corrosion and fouling[R].NACE Publication 34105,Houston,TX,2005.
[9]Cayard M S.Crude distillation unit-distillation tower overhead system corrosion[R].NACE Publication 34109,Houston,TX,2009.
[10]Wu B,Li X,Li Y,et al.Hydrolysis reaction tendency of lowboiling organic chlorides to generate hydrogen chloride in crude oil distillation.Energy Fuels,2016,30(2):1524-1530.
[11]关乐.常压塔顶系统露点腐蚀控制研究[D].西安:西安石油大学,2014.Guan L.The controlling research on dew point corrosion at the top system of the atmospheric tower[D].Xi'an:Xi'an Shiyou University,2014.
[12]段永锋,于凤昌,崔中强,等.蒸馏塔顶系统露点腐蚀与控制[J].石油化工腐蚀与防护,2014,31(5):29-33.Duan Y F,Yu F C,Cui Z Q,et al.Dew-point corrosion in crude distillation unit overhead system and prevention[J].Corrosion&Protection in Petrochemical Industry,2014,31(5):29-33.
[13]王凯.HCl-H2O体系露点腐蚀规律及预测方法研究[D].杭州:浙江理工大学,2013Wang K.Research of HCl-H2O system dew-point corrosion law and prediction method[D].Hangzhou:Zhejiang Sci-Tech University,2013.
[14]王海博,李云,欧阳文彬,等.Aspen Plus模拟预测常压塔顶冷凝系统露点及pH值[J].石油学报(石油加工),2018,34(3):629-633.Wang H B,Li Y,Ouyang W B,et al.Aspen Plus predict water dew point and pH value of the overhead condensing system of crude atmospheric distillation unit[J].Acta Petrolei Sinica(Petroleum Processing Section),2018,34(3):629-633.
[15]Wu Y M.Calculations estimate process stream depositions[J].Oil Gas J.,1994,92(1):38-41.
[16]金浩哲,叶浩杰,偶国富,等.基于偏最小二乘法的加氢换热器NH4Cl结晶温度预测模型[J].石油学报(石油加工),2017,33(6):1176-1182.Jin H Z,Ye H J,Ou G F,et al.Predicting model of ammonium salt crystallization temperature based on partial least squares approach in a hydrogenation heat-exchanger[J].Acta Petrolei Sinica(Petroleum Processing Section),2017,33(6):1176-1182.
[17]Munson B R,Cayard M S.Thermodynamic derivations of various ammonium salt deposition equations common to the refinery industry[J].Corrosion,2018,74(10):1158-1163.
[18]Sun A,Fan D.Prediction,monitoring,and control of ammonium chloride corrosion in refining processes[J].Corrosion,2010,10359.
[19]Karimi A,Verdon C,Martin J L,et al.Slurry erosion behavior of thermally sprayed WC-M coatings[J].Wear,1995,186-197:480-486.
[20]Rogers P M,Hutchings I M,Little J A.Coatings and surface treatments for protection against low-velocity erosion-corrosion in fluidized beds[J].Wear,1995,186-197:238-246.
[21]Piehl R L,Singh A,Harvey C.Corrosion of reactor effluent air coolers[C]//NACE Corrosion.1997:97490.
[22]Horvath R J,Cayard M S,Kane R D.Prediction and assessment of ammonium bisulfide corrosion under refinery sour water service conditions[C]//NACE Corrosion.2006:06576.
[23]Horvath R J,Lagad V V,Srinivasan S,et al.Prediction and assessment of ammonium bisulfide corrosion under refinery sour water service conditons-part 2[C]//NACE Corrosion.2010:10349.
[24]American Petroleum Institute.Design,materials,fabrication,operation,and inspection guidelines for corrosion control in hydroprocessing reactor effluent air cooler(REAC)systems:APIRP 932-B-2012(2014)[S].Washington D C:API Publishing Services,2014.
[25]Tang P,Yang J,Zheng Z J,et al.Failure analysis and prediction of pipes due to the interaction between multiphase flow and structure[J].Eng.Fail.Anal.,2009,16:1749-1756.
[26]张建文,苏国庆,姜爱国.液化气脱硫装置再生塔返塔管线弯头腐蚀失效机制分析[J].化工学报,2018,69(8):3537-3547.Zhang J W,Su G Q,Jiang A G.Corrosion failure mechanism of return pipeline elbow of regeneration tower in LPG desulfurization unit[J].CIESC Journal,2018,69(8):3537-3547.
[27]中华人民共和国工业和信息化部.高硫原油加工装置设备和管道设计选材导则:SH/T 3096-2012[S].北京:中石化出版社,2012.Ministry of Industry and Information Technology.Material selection guideline for design of equipment and piping in units processing sulfur crude oils:SH/T 3096-2012[S].Beijing:Sinopec Press,2012.
[28]中华人民共和国工业和信息化部.高酸原油加工装置设备和管道设计选材导则:SH/T 3129-2012[S].北京:中石化出版社,2012.Ministry of Industry and Information Technology.Material selection guideline for design of equipment and piping in units processing acid crude oils:SH/T 3129-2012[S].Beijing:Sinopec Press,2012.
[29]国家石油和化学工业局.石油化工设备和管道涂料防腐蚀技术规范:SH 3022-1999[S].北京:中石化出版社,1999.State Bureau of Petroleum and Chemical Industry.Technical specification for the coating anticorrosion of equipment and piping in petrochemical industry:SH/T 3022-1999[S].Beijing:Sinopec Press,1999.
[30]White R A.Materials Selection for Petroleum Refineries and Gathering Facilities[M].Houston:NACE International,1998:1-30.