How to deal with internal leakage in the methanol water cooler for methanol synthesis
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It was recently discovered that there is a leak inside the water cooler. There are several methods for detection; what should be done during operation and after the machine is shut down?
Are you encountering leaks while it’s running? We missed it before as well, but we noticed it before even starting the car
It depends on the degree of internal leakage. If it is only a minor leak, it can continue to operate until maintenance is carried out for treatment. If a leak has been detected based on the temperature and pressure in the heat exchanger, then the heat exchanger should be switched to bypass mode so that the leak can be identified and sealed as soon as possible. Minor leaks can be detected by measuring the methanol content in the circulating cooling water ； In the case of a major leak, the temperature and pressure of the heat exchanger may no longer be at normal operating levels.
Can detecting leaks by testing the pressure in circulating water identify all the leakage points?
Remove the equipment’s head and use water pressure to check for leaks; the appropriate treatment method will depend on where the leak is located, and a plan will need to be formulated accordingly
If there is a leak in the heat exchanger for methanol, it is possible to determine the methanol content by taking samples from the return water of the circulating water for analysis. If the leakage is severe, the operating parameters will change; in serious cases, the return water temperature on the circulating water side may rise, there may be sounds similar to water hammer in the pipes, and even overpressure or rupture of the pressure relief valves may occur. Generally, synthetic water coolers do not have bypass systems; if there is a significant leak, the unit must be shut down to identify and repair the leak. If a slight leakage is detected during regular inspections, strengthen monitoring; the leakage amount may gradually increase, so it is necessary to have emergency plans in place for when the leakage becomes more severe. Additionally, pay attention to adding more bactericides and algaecides to the circulating water in order to maintain good water quality. Last year, our plant had to shut down for over ten days for repairs due to internal leakage in the methanol water cooler that was synthesized there.
If the leakage is small, it’s impossible to determine the methanol content; it’s better to measure COD at the water inlet and outlet. Address the issue promptly once pressure build-up is detected, as large-scale leaks can damage the other tubes in the surrounding area.