How to deal with a leak at an outlet during conversion?

In the sulfuric acid production process, gas leakage at the outlet of the conversion section is indeed a technical challenge. Here are a few possible solutions: 1. **Inspect and repair the equipment**: First, the sealing condition of the converter and related pipes should be checked. Any damaged seals or corroded parts should be replaced or repaired promptly. 2. **Enhance monitoring systems**: Install high-quality gas detection systems to detect leaks promptly and take action to address them. These systems can help you identify problem areas more quickly. 3. **Use high-quality materials**: Consider using corrosion-resistant and high-temperature materials to manufacture converters and pipes. For example, using titanium or special alloys can improve the durability of the system and reduce the risk of leaks. 4. **Regular maintenance and inspection**: Establish a strict maintenance plan to regularly check the condition of all key components. This not only reduces the risk of leaks but also extends the equipment’s lifespan. 5. **Technical improvements**: Research and adopt new technologies, such as advanced sealing techniques and improved design solutions, to reduce the likelihood of leaks. 6. **Employee Training**: Ensure that all operators and maintenance staff receive appropriate training to understand how to operate the equipment correctly and take the right emergency actions in case of leaks. I hope these suggestions will be helpful to you. If there are more specific circumstances or further technical details are needed, feel free to ask. .

Finding the leak point: Leaks in areas without insulation can be seen with the naked eye, while leaks in areas with insulation are harder to detect and require careful searching. The method for finding the leak point is to proceed section by section from bottom to top; generally, the area where smoke is coming from is first disassembled to determine whether the smoke rises from below or emerges directly from that spot. If it is determined that the smoke is coming from below, small holes should be made vertically at the smoking area, starting from the bottom, to check for any smoke. If no smoke is present, holes should be made at intervals of 1–2 meters higher up, and this process should be continued upward. The insulation material near the leak site has been exposed to smoke; when the insulation bricks are pried open, significant smoking is observed. As further prying continues, the smoking gradually subsides, only to reappear if more movement is made. This phenomenon does not indicate that the source of the leak has been found; it is necessary to pay attention to whether there is smoke flow in the gaps between the observer’s wall and the insulation layer, as well as to observe the direction of that smoke flow. If the smoke emerges in large quantities, it indicates that the entrance is near; simply expanding the entrance in the direction of the smoke will allow one to quickly locate the area where air is leaking. Conversely, if the smoke flow is weak, additional holes need to be drilled, and finally the area where air is leaking must be identified. Check the location of the leak: Once the area where the leak is located has been identified, use a pointed tool to examine the thickness and size of the steel plate surrounding the leak, so as to determine the appropriate method for repair. Repair method: Direct welding repair: If the steel plate is thick and the weld has cracked or suffered pitting corrosion, it is generally repaired by directly welding it using welding rods. Small cracks or holes can be welded shut without stopping the machine; however, if the cracks or holes are larger, it is usually necessary to stop the machine first in order to repair them properly. Patch method: In areas where there is air leakage, the steel plate is thinner, and welding it directly results in an immediate connection; therefore, it is necessary to add additional steel plates to cover the area where the thickness of the plate has decreased, depending on the size and shape of that area. When applying a patch, it is possible to stop the vehicle or not, depending on the extent of the leak and the pressure level at that location. In most cases, it is not necessary to stop the vehicle when providing a subsidy. The method involves applying a layer of paste prepared from asbestos, water glass, or dolomite powder, with a certain thickness and size, onto the plate intended for patching, roughly at the location of the leak. This paste is then pressed tightly against the leak site and fixed using spot welding, after which it is welded shut in all surrounding areas using welding rods. Patch repair method: In cases where the area of thinning in the steel plate around the leak site is large or its shape is unusual, it is necessary to burn away the old steel plate at the leak location and then replace it with a new one. This repair method is thorough and does not leave any risk of the old steel plates falling off. Plugging method: In the absence of welders and in areas where welding repairs are not possible, acid-resistant putty is generally used for plugging. The method of sealing it involves first cleaning the leaky area and the steel plates surrounding it, washing them with water glass, then stuffing white asbestos rope into the leaky spot or using a soft metal such as aluminum or lead to push it into that area. Finally, a mortar that is resistant to both acids and high temperatures is applied to seal the gap and secured in place; once it has cured, the task is complete. Other methods: If there is a leak at the bottom of the converter or heat exchanger and the above methods cannot be used to seal it, it is necessary to first remove the corrosive substances from the bottom of the device, fill it with damp asbestos ash and compact it. A trench 100 mm wide and 200 mm deep should be dug around the equipment, steel plates inserted into this trench, and it filled with acid-resistant cement (the trench is then leveled off with cement on the outside), after which a cover plate is used to weld the inserted steel plates shut in place relative to the equipment. Acid-resistant mortar can be used for sealing leaks, and the treatment of the base material at the weld site is of utmost importance during welding. For negative-pressure leakage points, high-alumina cement and water glass can be used for sealing, with good results. When the leakage is severe, the method of applying resin followed by attaching glass cloth can be used (suitable for areas with not too high temperatures). In gas pipelines, whether made of carbon steel or plastic, when the leak is small, a short section with flanges can be welded to the location of the leak during operation; after welding, a blind flange can be used to seal off the flanges. This is a common method for sealing leaks during operation. If a negative-pressure steel pipe is leaking, it can be sealed by mixing yarn ends with butter; welding can then be used to repair the leak when the opportunity arises. If it’s a leak in the acid pipe, it can be sealed with polytetrafluoroethylene and then tightened with a clamp; if the acid pipe isn’t too thin, it will last for a long time. If the perforation in the acid pipe is too large, it can be filled by mixing limestone powder with water glass and sodium fluosilicate; to speed up the process, more sodium fluosilicate should be used, and it generally sets in half an hour.

Should the transformation layer be on top or at the bottom?

First, find a way to seal the leak, then weld in steel plates for repair

Is it a pipeline leak or a heat exchanger leak?

It’s indeed difficult to handle; it can’t be welded, so the only option is to wrap it in a box

The outlet flue of a conversion unit is the part of the conversion system where the flue temperature is highest; in systems of a certain scale, stainless steel is generally used for this purpose. In smaller systems or those that were not built on a large scale initially, stainless steel was not used, after all, the cost is a factor to consider； Generally, a section is placed at the top of the converter; due to the insulating effects, thermal expansion and contraction can occur, which may lead to leaks at the welds ； Effective measures include ensuring proper insulation of areas such as the weld joints at the bends in high-temperature flues, and taking additional rain protection measures for that insulation. Think about it: doesn’t this problem tend to occur frequently after heavy rain? Next is the issue of welding quality; the vehicle must be stopped to address it properly. I won’t go into detail on those points mentioned below. Heat-resistant materials can be replaced under certain conditions, which solves the problem once and for all as mentioned above.

The explanation on the third floor is excellent and worth learning*