Blockage in the transformation heat exchanger

It is recommended that the feed gas flow through the tube side, while the shift gas flows through the shell side

It is likely caused by the deposition of mechanical impurities from the gaseous process gas, which leads to blockages. This problem is difficult to resolve; it’s best to find ways to reduce the amount of solids introduced at the source

We have also considered what was mentioned upstairs, but based on previous inspections of the bubble caps in the gasification scrubber tower and the process pipelines exiting the scrubber tower, no dust accumulation or blockages were found in the bubble caps after 160 days of operation； Apart from a layer of tar-like substance, the process gas pipeline is relatively clean otherwise ； Furthermore, the separator and filter before the heat exchanger should be able to remove most of the solidified substances. Could the mechanical impurities that enter the heat exchanger cause obstruction in its flow paths? If such failures occur frequently, isn’t it necessary to add a spare heat exchanger, with one in use and another as a backup? (Similar to a parallel filter)

Since there is a filter in front of the heat exchanger, if no problems are found during the cleaning of the filter, then the heat exchanger certainly won’t get clogged!

Then it’s probably not a blockage, but a leak! If there is a leak in the heat exchanger, the raw gas enters the shift gas at a lower pressure, which naturally results in an increased pressure difference and a reduced flow rate of gas!

Does the poster mean an increase in the pressure difference of the raw gas flowing in and out of the heat exchanger, or an increase in the pressure difference of the shifted gas flowing in and out of the heat exchanger? If it is the latter case, may I ask which converter catalyst your manufacturer uses? If the quality of the conversion catalyst is not good enough, especially if its strength is insufficient, it is prone to crumbling. When these fine particles end up in the heat exchanger, it naturally leads to an increase in pressure difference; this could be one of the reasons. 1# xuqinger

For 7# zaizuo, it is mainly due to an increase in the pressure difference of the raw materials. Some colleagues upstairs suggested that there might be a leak in the heat exchange tubes. We tried to drain water by opening the sewage outlet of the heat exchanger, and as a result the pressure difference decreased slightly; the carbon monoxide level also dropped from 20% to 11% after that. However, the pressure difference gradually increased again. It indicates that there is mainly blockage in the raw gas section.

The brother on the sixth floor said that a leak in the tubes could cause an increase in pressure difference, and this is indeed one of the possible causes. But based on what the poster has described, it’s likely that there is blockage as the feed gas passes through the shell side. From the previous analysis, it’s unlikely that dust is causing the blockage, as no dust accumulation or blockage occurred after 160 days of operation of the bubble column ； Apart from a layer of tar-like substance, the process gas pipeline is relatively clean otherwise. Is it possible that the water condensed from the feed gas increases in the shell side, resulting in a reduction in the volume of gas flowing through the shell side and thus an increase in the pressure difference? How much water does your heat exchanger discharge as waste water? How often does it take to get a queue? So, check what the temperature of your feed gas entering the heat exchanger is How high is the pressure? How high is the vapor pressure? What is the operating pressure of the converter? Also, what is the temperature of the conversion gas coming out of the conversion furnace? Taking all these factors into account, it is necessary to consider whether it is possible for steam to condense in the pipes ahead of the heat exchanger as well as within its shell side. 8# xuqinger

Upon inspection, it was found that the powder resulting from the fragmentation of ceramic balls had accumulated in the heat exchanger, causing the channels to narrow and increasing the pressure difference between the inlet and outlet

Does the transformed gas flow through the tube side? It’s the breakdown and blockage of the ceramic balls at the bottom of the converter; that should lead to an increase in the pressure difference on the tube side, right? 10# xuqinger