Crystallization Behavior of Ammonium Chloride in High-Pressure Heat Exchanger of Hydrotreating Unit

In view of the corrosion failure of a high-pressure heat exchanger in a diesel hydrogenation unit, the formation mechanism of ammonium chloride in a multiphase flow system is investigated in this article. Numerical simulation is carried out by user defined function (UDF) on the process of adding source of mass transfer in computational fluid dynamics (CFD) solvers. The distribution characteristics of ammonium chloride are illustrated by the parameters including crystallization temperature of ammonium chloride, volume fraction of ammonium chloride, and mass transfer rates of NH3 and HCl, and the causes of corrosion cracking in the U-shaped bend of the heat exchanger are discussed. The results show that there is a great risk of ammonium chloride deposition in the heat exchanger from 4.5 m away from the outlet of the second pass. The crystallization area in the tube gradually expands from the wall to the center along the flow direction, and the crystallization rate is higher near the tube wall. The field sampling test results show that the corrosion cracking is hydrogen-induced cracking, which is due to the existence of large amount of hydrogen, high impacting force, excessive flow rate, and the risk of ammonium chloride particle erosion at the U-bend. In order to alleviate the corrosion of ammonium chloride deposition, some improvement measures are put forward, such as raising the inlet temperature of the tube side to 215 °C and increasing the water injection by 30%, which play an important role in decreasing the formation of ammonium chloride in the heat exchange system.

Analysis of Multiphase Flow and Heat and Mass Transfer for Ammonium Chloride Crystallization of the High-Pressure Heat Exchanger in Hydrogenation Unit

The corrosion failure of the high-pressure heat exchanger in a petrochemical enterprise was simulated. A multiphase flow and heat and mass transfer simulation shows that the vortex core with a higher gas phase content and lower temperature is the region of easy crystallization, located on both sides of the center of the tube. The crystallization process occurs in the gas phase. As the reaction progresses, the crystallization range spreads from the tube wall to the center of the tube bundle, and the inner diameter of the tube bundle decreases continuously. In Fluent, a user-defined function, based on the ammonium chloride crystallization reaction, is loaded. The results show that crystallization first occurs in the tube bundles on both sides of the center of the tube and that the corrosion is aggravated by the erosion wall surface of crystal particles at the elbow, which is consistent with the actual corrosion failure location.

Anchorage length of patented wire cables in prestressed bridge girders

This paper briefly describes the methodology, performance and the obtained results of unique experiments performed on original I-73 precast bridge girders. The main objective of the experiments was to determine the actual anchorage length of corroded-through fully grouted prestressing reinforcement (prestressing wires), which is important for determination of the residual load-bearing capacity of prestressed structures. Observation probes leading all the way to the prestressing wires were drilled on selected sections of the girders along the length of the prestressing reinforcement. Optical image acquisition devices were then installed at these probes. Subsequently, controlled breakage of the patented wires (corrosion failure simulation) and observation of the changes that occurred in the prestressing wires after relief of stress were carried out. Evaluation of the experiments was then performed by analyzing the images obtained before and after the prestressing reinforcement failure.

Influence of Super Absorbent Polymer on the Sulfate Resistance of Cement Mortar

Structures are easily corroded in the Salt Lake areas of China, especially in sulfate solution. This study was intended to settle the problem of sulfate corrosion failure of concrete structures, the influences of different contents of super absorbent polymer (abbreviated as SAP) on the working performance, mechanical properties, corrosion resistance and expansion performance of cement mortar were studied. The mechanism of SAP in mortar was analyzed and studied by SEM. The results showed that although SAP could slightly decrease the fluidity and strength of cement mortar, but it could remarkably improve the coefficient of resistance erosion of specimens and the inflation coefficient of cement paste. When the content of SAP was 0.3%, the sulfate corrosion resistance and expansion performance of specimens showed the best (the coefficient of resistance erosion and inflation coefficient of mortar specimens were 0.95 and 0.97, respectively). Besides, SAP could release much water in the hydration process, form irregular holes, and increase the porosity of mortar specimens. There would more hydration products generated and filled in the pores during the hydration process, thereby improving the sulfate resistance of mortar specimens. Therefore, this research provides theoretical guidance and basis for the study of sulfate corrosion damage of concrete structures in the future.

Hot corrosion behaviour of CNT-reinforced ZrO2-Y2O3 composite coatings on boiler tube steel at 900°C

Purpose In Indian thermal power plants, the main cause of boiler tube failure is the presence of molten sulphates and vanadates, which deteriorate the tube material at high temperatures. To combat the hot corrosion failure of metals, thermal spray technology is adopted. This study aims to investigate and study the effect of hot corrosion behaviour of carbon nanotube (CNT)-reinforced ZrO2-Y2O3 composite coatings on T-91 boiler tube steel in a molten salt environment at 900 °C for 50 cycles. Design/methodology/approach A plasma spray technique was used for development of the coatings. The samples were exposed to hot corrosion in a silicon tube furnace at 900 °C for 50 cycles. After testing, the test coupons were analysed by X-ray diffraction, scanning electron microscopy/energy dispersive spectroscopy and cross-sectional analysis techniques to aid understanding the kinetics of the corrosion reaction. Findings CNT-based reinforced coatings showed lower weight gain along with the formation of protective oxide scales during the experimentation. Improvement in protection against hot corrosion was observed with increase in CNT content in the coating matrix. Originality/value It is pertinent to mention here that the high temperature behaviour of CNT-reinforced ZrO2-Y2O3 composite on T-91 steel at 900°C temperature in molten salt environment has never been studied. Thus, the present research was conducted to provide useful results for the application of CNT-reinforced composite coatings at elevated temperature.