High-pressure air cooling offset problem in hydrogenation units
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After the high-pressure air coolers I installed were put into operation, a phenomenon of uneven flow was observed. There are 4 air coolers in total, arranged in two groups symmetrically; at times, the temperature difference between the two groups reached 20°C. I would like to know if anyone has encountered a similar situation – what could be the possible causes?
It’s possible that the installation wasn’t level to begin with, resulting in uneven distribution of the material as it enters the pipes.
Consider whether ammonium salt crystallization blockage in the air cooling system is causing deviation in flow
Can the unit’s processing capacity ensure the minimum load? Is the amount of circulating hydrogen sufficient? Check for ammonium salt blockages or issues with the levelness of the air coolers
Let’s check if it’s a problem with the thermocouples; we encountered similar issues, and in the end it turned out that the electrical signals generated by the two thermocouples were different, resulting in different temperature readings.
It should be the ammonium salt crystals that are blocking the tube bundle
Are there louvers on the air cooler? If so, check whether the angles of the louvers on both sides are the same
The phenomenon of off-flow due to high-pressure air cooling is quite common. I’m not aware of the age of your equipment; the further away from the center, the more severe the off-flow tends to be. It is recommended to measure the wall thickness of the inlet liner if possible, in order to prevent tube rupture.
Deviation currents are most likely to occur in winter, as well as due to water injection or an insufficient processing capacity of the equipment. It is necessary to regularly monitor the temperature of each branch during production; the air coolers should be operated symmetrically, and the air cooler covers should also be adjusted accordingly