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| 題 名 | 新反應器進出料換熱器破漏原因追查技術與應用推廣=Novel Technique to Investigate the Cause of the Reactor Combined Feed-Effluent Exchanger's Leak and Its Application |
|---|---|
| 作 者 | 蕭秀雄; 洪正宗; | 書刊名 | 石油季刊 |
| 卷 期 | 54:1 2018.03[民107.03] |
| 頁 次 | 頁11-21 |
| 分類號 | 460.027 |
| 關鍵詞 | 轉烷化; 反應器進出料換熱器; 洩漏; 規整差壓; 觸媒重組; Transalkylation; Combined feed-effluent exchanger; Leak; Normalized pressure drop; Catalytic reforming; |
| 語 文 | 中文(Chinese) |
| 中文摘要 | 台灣中油公司林園廠第一轉烷化工場改造後操作不久，發生新反應器進出料板式換熱器嚴重破漏。原製造廠家在封掉20%流道的檢修後，宣稱是進料中的物質造成不均勻積污，引發熱應力造成破損。由於該板式換熱器在啟用不久即發生破漏，而且操作上並沒有違反任何保固排除事項，台灣中油公司認為應該是原廠製做瑕疵所造成的。反應器進出料板式換熱器內為兩相流動並發生汽化相轉變，不易由其差壓等資料追查破漏發生的時間點。如果反應器進出料板式換熱器發生破漏，流往下游反應器進料加熱爐與反應器的流體流量會下降，加熱爐與反應器之操作資料應該會有相應跡象。由於操作條件的變動，反應進料加熱爐與反應器的差壓數據資料相當發散，無法解析出有用資料。根據流體力學原理，反應進料加熱爐與反應器之差壓除以流體密度與流體體積流量平方之乘積，即ΔP/ρQ^2，在湍流下，為一定值。規整差壓ΔP/ρQ^2對時間作圖正常大致上呈現水平走勢，如果曲線均呈現下滑走勢，表示反應器進出料換熱器不但發生破漏而且破漏持續擴大中。反應進料加熱爐與反應器之原本頗為發散的差壓數據資料，經過轉換，可以得到相當收斂的規整差壓曲線。加熱爐與反應器之規整差壓曲線走勢相當平行一致，下滑與保持水平時段的起始與終止時間非常穩合。以反應進料加熱爐與反應器之規整差壓曲線所估算的換熱器的洩漏量，與由樣品分析所估算的洩漏量相當穩合，說明以規整差壓曲線來解析是相當可靠。2010年12月下旬～2011年2月中旬間，加熱爐與反應器的規整差壓曲線均呈現下滑走勢，表示反應器進出料換熱器從初始操作起就發生破漏且破損持續逐漸擴大，該期間換熱器內沒有積污(Fouling)，有力反駁換熱器原製造廠家之先有2011年3月底開始發生的積污才有破漏發生的說法；同時也有力地證實製做瑕疵是破漏原因，一如台灣中油公司所認定的。加熱爐與反應器規整差壓技術可以應用至許多煉油與石化產業之製程工場，不過有兩項條件必須滿足，一是進入加熱爐與反應器流體須為單一氣相，另一是流經反應器流體在反應前後莫耳數必須沒有增減。觸媒重組反應過程產生氫氣，因此反應器規整差壓技術便不能運用；但可以利用進料加熱爐差壓規整化數據來解析反應器進出料換熱器狀況。 |
| 英文摘要 | After revamp of No. 1 transalkylation unit in Linyuan plant owned by CPC Corporation Taiwan, its new reactor combined feed - effluent heat exchanger encountered serious leakage. The plate exchanger vendor repaired it by welding seal 20% channels and declared that the breakage of the plate exchanger came from thermal stresses which were established from uneven fouling of substance in feed. Since the new heat exchanger occured leaking soon after initial run, and there was not any operation to violate any warranty exclusions, CPC Corporation Taiwan believes it should be attributed to manufacture defects. Due to two phase flow and vaporization of feed in cold side of the heat exchanger, it is not easy to find out the time when leaking occurred by using pressure drop data of the heat exchanger. If the reactor combined feed - effluent heat exchanger encounters leaking, the flow through the furnace and the reactor will decrease and operating data of them should reflect some signs. Due to continuous fluctuation in operating conditions, the pressure drop data of the reactor feed furnace and reactor are so divergent that it is unable to provide the useful information. According to principles of the fluid mechanics, the pressure drop of the reactor feed furnace or reactor divided by the product of the fluid density and the square of the volume of fluid flow, i.e., ΔP/ρQ^2, under turbulent flow, are constant values respectively. Normalized pressure drop ΔP/ρQ^2 versus time in normal cases presents the horizontal trend curve. If the curve showed a declining trend, it means that the reactor combined feed - effluent heat exchanger encounters leaking and the extent of leaking is expanding. Originally quite divergent pressure data of the reactor feed furnace and reactor can be converted into quite convergent normalized pressure drop curves. The trend of normalized pressure drop curve of the furnace and the reactor behave fairly consistent, the start time and end time of both the declining or the level sections match very well. The estimated leakage rate of the heat exchanger from normalized pressure drop curves of the furnace and the reactor are quite consistent with the leakage rate calculated based on the analytical result of samples, that indicates the information extracted from normalized pressure drop curves of the furnace and the reactor is quite reliable. Between late December 2010 to mid-February 2011, the normalized pressure drops of both the furnace and the reactor have the downward trend, indicating the heat exchanger encountered leaking from the initial operation and the extent of leaking was expanding continuously. In addition, there was no sign of fouling during this period. It totally refuted the vender's argument that leaking came from fouling starting from the end of March, 2011. It also powerfully confirms that leaking of heat exchanger resulted from manufacture defects, as recognized by CPC Corporation Taiwan. The analytical technique with normalized pressure drop curves of the furnace and the reactor can be applied to oil refining and petrochemical processes. But the fluid to the furnace and the reactor should be gas phase, and there should be no molar change when flowing through the reactor. Due to net hydrogen production in the catalyst reforming reactor, the technique with normalized pressure drop curves of the reactor can not be used; but can be applied with normalized pressure drop curves of the feed furnace. |
本系統中英文摘要資訊取自各篇刊載內容。