The heat exchange efficiency of the three-stage cooler in the air separation booster is poor
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The heat exchange efficiency of the third-stage cooler in the air separation booster is poor. Since March 2015, even though the inlet air temperature of this cooler has not increased, the outlet air temperature has risen from 38°C to 62°C, preventing the unit from operating at full capacity. The reason for this decline in heat exchange efficiency remains unknown. After draining the water flowing through the coolant channels on the circulation water side, no significant impurities or issues with the circulation water fillers were found. Our factory initially suspects scaling of the heat exchanger; please experts provide some analysis.
Firstly, if it is described that there are no obvious impurities or fillers on the water side, scaling should not be the main factor, after all, the outlet gas temperature is too high. Furthermore, you mentioned the period from March 2015 to the present; can it be understood that this refers to new equipment that has been in use for less than half a year? If this is the case, then it’s necessary to start with the equipment design. As the ambient temperature rises and the humidity in the air increases, as well as when the pressure of the air compressor goes up, under the same temperature difference in the air, the thermal load on the third stage should be the greatest; perhaps insufficient heat exchange area was not taken into account from the beginning of the design. Secondly, the poster’s claim that “the device cannot operate at full capacity” can also be explained by the problems that existed from the very beginning of its design. Finally, if there is no obvious scaling on the water side, what about the gas side? You can use the gas pressure drop to determine whether there is a scaling issue.
What material is the heat exchanger core made of? If it is copper, then the impact of patina formation on the heat exchange efficiency also needs to be taken into consideration~~
1. First, check whether the outlet temperature sensor is functioning properly. 2. Exhaust the air from the waterway’s exhaust valve. 3. Cooling water quality report: check the water composition to see if it is severely contaminated. Many factories do not pay enough attention to the management of cooling water, resulting in serious damage to many equipment components. It poses a serious threat to the safe and stable operation of the equipment. 4. Verify the operational data from a design perspective – what is the difference from the actual values? 5. Inspect the core of the cooler during the maintenance period.
Measure the temperature of the return water at the upper part of the third-stage cooler and compare it with the outlet temperature on the gas side; also compare it with similar equipment. Through comprehensive analysis, it is indeed concluded that scaling in the heat exchanger affects its heat exchange efficiency. Online cleaning can be tried to see if it works, but it is essential to assess the risks associated with such online cleaning. I have installed an online cleaning system for the ammonia cooler.
This post was last edited by xhkf on 2015-8-12 at 11:37. The pressure of the third stage of the supercharger’s gas phase should be higher than that of the cooling water; also check whether there is air in the return pipeline If gas presence affects the heat exchange area, the cooling effect changes significantly.
I agree with you; if this happens, just imagine how much leakage there would be. It’s also possible to detect whether there is any leaking gas through the exhaust valve of the cooler.
Everyone should pay more attention to scaling on the gas side. Check the change in the differential pressure on the gas side; if conditions permit and core extraction is carried out, observe more closely whether there is any scaling on the gas side. If scaling occurs on the water side, all of your coolers should have poor heat exchange performance. Another possibility is that there is a problem with the water side of the heat exchanger; the water inside takes a bypass route, resulting in poor heat exchange
Measure whether the temperature of this return water has increased significantly； Are the circulating water pressure and temperature normal? ； Open it and check if there is any stolen goods blocking it ； Is there a problem with the end plate baffle, causing a short circuit? ； Is the water quality poor and is scaling severe? ； Wait...
1. Scaling. But usually, it involves several heat exchangers working together. Additionally, check the end caps for any blocked tubes or short circuits in the circulating water. 2. Are there any dead corners in the exhaust system that cause heating problems? 3. The design might be unreasonable, but this shouldn’t happen generally – there shouldn’t be any leaks. After all, with three stages of pressure, water hammer effects should be significant enough, so leaks shouldn’t occur
Is it the partition of the heat exchanger that’s leaking?