Leakage in a converter tube
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Since the operation of one of our company’s conversion furnaces began, there have been 3 instances of tube leakage, all of which occurred at the lowest part of the furnace. The temperature control is normal; we would appreciate it if experts could analyze the reasons for this issue – could it be that the negative pressure is too low and thus heat cannot be removed, or is it possible that the ventilation openings in the refractory lining at the lower part are too small, leading to an accumulation of excessive heat?
Analysis of furnace tube temperature, water-to-carbon ratio, uneven burning of burners, catalyst condition, start-up and shutdown operations, etc
1. Quality of the furnace tube: Is it metallographically acceptable? Are there any pores, issues with thickness, or severe hydrogen embrittlement? 2. Converting back pressure to negative pressure, which is what you refer to as the heat accumulation issue.
1. If so: the negative pressure is too low, and heat cannot be removed. Check the furnace negative pressure control and instrument readings; this situation occurs three times in a row, so it is likely not due to negative pressure. 2. If the openings in the flue wall are too small, heat accumulates inside the furnace, and the most obvious consequence is an increase in the furnace temperature. Possible causes: 1. Issues with catalyst loading – such as insufficient catalyst in certain furnace tubes or bridging – which can lead to localized overheating in those tubes. 2. Poor stress relief in the furnace tubes, poor alignment, spring issues, etc