Discussion on Reactor Tube Bundle Replacement in the Alkylation Unit (DuPont)
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In our alkylation unit, using the DuPont process, the reactor tube bundle developed leaks within less than three years of actual operation. Has anyone encountered such a situation? What steps are required when replacing the tube bundle? Everyone is welcome to discuss!
For tube bundle leaks, it depends on the situation; if the leakage is minor, it can be sealed up without the need for a complete replacement. If some of the tubes in the heat exchanger are leaking and need to be sealed, follow the procedures for sealing leaks in heat exchanger tubes, making sure to use materials resistant to acids and alkalis. If the amount of leakage is significant, the entire tube bundle needs to be replaced; it’s better to have the manufacturer come and assist with this process for the first time.
Have you found the cause of the leak? ?
Tube bundle corrosion thinning leakage···
Is it the normal corrosion rate? ?
Not really; it might be due to material issues, or erosion and corrosion caused by uneven flow inside the reactor
What are the main causes of flow deviation inside the reactor? ?
The rotation speed of the reaction stirrer, the internal structure of the reactor, and malfunctions in the equipment inside the reactor, such as corrosion of the feed pipe causing a short circuit
Factors such as the speed of the stirrer and the internal structure of the reactor are all due to the inherent design.
It’s true that it was designed from the start, but there are too many variables in actual operation
Three years of use is enough time for a leak to occur. Simply replace the tube bundle as a whole. After being in use for such a long time, the other parts have also thinned out; the leaks were repaired, and the tube bundle was put back into use. It might break down soon, and the costs would outweigh the benefits.