Haozhe Jin

Numerical simulation and factor analysis of petrochemical pipe erosion-corrosion failure

Based on the behavior of carbon steel outlet tube in REAC pipes of Zhenhai Refining & Chemical Company, the mathematical model of fluid-solid interaction was established according to the mechanism of erosion-corrosion damage. The interaction between corrosion products protecting film and multiphase liquid was analyzed by numerical simulation method. The distribution of shearing stress on the inwall of elbow bend, and the distribution of principal displacement, stress and strain of corrosion products protecting film were disclosed, while the erosion-corrosion failure processes was studied. The simulation result coincides with that of the positioned thickness gauging which validated the reliability and feasibility of the finite element analysis software simulation method. The obtained results can be used in the erosion-corrosion failure analysis, structural optimization, in-service testing positioning, life prediction, risk assessment, safety and other security projects for multiphase flow pipeline.

Hydrocracking air coolers real-time diagnosis system development based on failure analysis of flow induced corrosion

The frequent flow induced corrosion of hydrocracking air cooler system always results in a significant economic loss of the petroleum enterprise. Aimed at the issue, the design of hydrocracking air coolers real-time system is completed on the basis of the frame of the corrosion control system. Aspen Plus software is embedded in the system for the modeling and simulation of the corresponding parameters. The databases of the distribute control system (DCS) and laboratory information management system (LIMS) of the hydrocracking plant are linked with the software to the further calculation, monitoring and management. The corresponding anti-corrosion methodology is put forward according to the specific running situation, which can optimize the service operation and enhance the security of the hydrocracking air coolers system essentially.

Investigation on the Flow Induced Erosion-Corrosion Failure of Hydrocracking Air Cooler Systems and Optimization Study

The flow induced erosion-corrosion of a hydrocracking reactor effluent air cooler (REAC) system normally occurs locally and abruptly, which leads to the high risk of unplanned shutdown and even catastrophic accidents. To study the typical failure cases induced by the high-sulfur and chloride-containing raw oil in the process of refining, numerical simulation of technical process and fluid dynamics parameters are performed on softwares of HYSYS and CFD, and the rules of multiphase flow erosion and ammonium salts deposition are analyzed. Analytical results are in good agreement with actual failure instance and thus the reliability of the predictive method is validated. A corrosion-control research system, consisting of mechanism research, numerical simulation, experimental verification and similarity theory correction, is established. The critical characteristics of multiphase flow deposition and erosion are obtained. And the system to control the flow induced erosion-corrosion, which can be widely applied in various conditions, is formed on the basis of “avoiding blockage and controlling erosion” conception. Moreover, this paper proposes an optimum design based on the degree of unbalancedness and a frame of the REAC Real-time Diagnosis Expert Software for guiding the optimum design. The method above will be beneficial to the promotion and modification of related criteria and regulations in the future.Copyright