The water flow at the drain port on the shell side of the water-cooled heat exchanger in the ammonia synthesis system is high
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Our plant’s ammonia synthesis process also makes extensive use of water-cooled heat exchangers. Recently, it was observed that in some of the second-stage horizontal water-cooled heat exchangers (with a heat exchange area of 240 m2), there is a large amount of water flowing through the drainage ports located between the tubes and the shell; approximately dozens of liters of water are discharged per shift. In these heat exchangers, water flows inside the tubes, under a pressure of 0.58 MPa and at temperatures ranging from 20 to 80 degrees℃； A water cooler in which a medium (H2, N2) flows between tubes, at a pressure of 0.58 MPa and a temperature of 200–100°C). Excuse me, expert: is there a leak in the heat exchanger tubes? Water brought by the medium gas?
Based on the phenomenon, it should be gas condensation water; it doesn’t seem like a leak. You can also analyze the water quality; that’s enough
If it is cooling water that has seeped in, which indicator should be analyzed to confirm it? Thanks, OP of floor 2!
Analyze the mineral content or other ion components of the two types of water, such as chlorine, calcium, etc
If that doesn’t work, add tracking calibrators to the cooling water, and then check to see if they are there; if they are, there is a leak, and if not, there is no leak
Additionally, it is possible to calculate the amount of saturated water vapor brought in per shift at the inlet pressure and temperature of stage 2, as well as the amount of saturated water vapor in the gas at the outlet pressure and condensation temperature of stage 2. The difference between these amounts of water vapor at the two dew points represents the normal amount of condensate produced.
The pressure of water and air in this device is roughly equal, so the possibility of a leak in the device cannot be ruled out. If the air pressure is slightly high, air leaks into the water, causing the pH value of the returning water to drop (when there is CO2), and bubbles form in the water. If the water pressure is slightly high, the air pressure can be reduced slightly to see if the waste discharge increases. If the unit is shut down but water flow is not stopped, can it not be completely drained? Additionally, compare it with other units to see if the second-stage inlet temperature is high, or if it is caused by an excessively high liquid level in the first-stage separator.