Repair of the discharge port of the adiabatic conversion furnace
Thread Content
An adiabatic converter experienced a leak in the short pipe at the discharge port during operation. Upon shutdown for inspection, it was found that there was a through-crack in the discharge short pipe, with the crack extending into the reinforcement tube of the head. Repairing the discharge port proved to be difficult; therefore, it was decided to block the discharge port from inside the converter, and vacuum extraction would be used for catalyst discharge in the future. Preliminary diagnosis of the cause of the leakage: The discharge port is a dead zone in the converter; the connection pipe at this port is relatively long and lacks heating. During operation, the process gas from the converter condenses and causes corrosion at the discharge port, and the alternating hot and cold conditions during startup and shutdown further damage this port.
Based on the phenomena you described and the analysis conducted, the following repair suggestions are provided: 1. Clog in the discharge short pipe: – Thoroughly clean the catalyst around the discharge port inside the furnace. - Clean the area of the cracked leak to a location where the base metal is intact; after grinding it clean, apply a reliable seal at the discharge port on the inside of the converter (such as by welding a thick-walled blind plate). - After welding is completed, flaw detection checks are carried out to ensure the quality of the welds and prevent further leaks. 2. Subsequent catalyst unloading measures: – Use vacuum suction or top extraction methods to unload the catalyst. - Revise the operating procedures and equip them with dedicated vacuum evacuation equipment. 3. Preventive measures: – Add heat tracing and insulation to other similar discharge ports and dead zones to reduce the risk of high-temperature gas condensation and corrosion. - Regular anti-corrosion testing, thickness measurement, and inspection of the outer surfaces of the furnace and equipment are carried out to prevent accidents. - Optimize the start-up and shutdown processes to reduce the intensity of temperature fluctuations, thereby preventing damage caused by thermal fatigue. Through the aforementioned adjustments and improvements, the safe, stable, and long-term operation of the equipment can be effectively ensured. .
To address this situation, it is recommended to take the following measures for repair and improvement: 1. Leak repair: – Thoroughly remove the catalyst and rust deposits from the area where the leak occurs inside the furnace, and polish it clean. - Reliable welding sealing is achieved using welding seal plates inside the furnace, and non-destructive testing is performed on the welds to ensure a secure seal. 2. Improve the catalyst unloading method: - Switch to vacuum extraction for unloading the catalyst, in order to avoid repeated damage to the original unloading port due to condensation and corrosion in the dead zone. 3. Measures to prevent further leaks: – Improve the insulation and heating measures for the residual piping to avoid the formation of dead zones and the condensation of corrosive gases. - Modify the process pipeline structure as necessary, add insulation or heat tracing to areas prone to condensation corrosion, in order to reduce the impact of temperature differences. - During operation and maintenance, strict control is exercised over the start-up and shutdown rates to reduce the risk of thermal shock and extend the equipment’s service life. By combining the above measures, the leakage issue at the discharge port of the adiabatic converter can be effectively resolved, ensuring the long-term safe operation of the equipment. .