催化裂化装置旋风分离器机械故障的原因分析
|
摘要
催化裂化工艺中旋风分离器被用来进行催化剂与油气或与烟气的分离,是保证催化裂化装置长周期安全稳定运行的主要设备。旋风分离器在高温和高浓度的环境下长时间工作有可能发生各种机械故障,例如冲蚀、磨损、断裂、堵塞等,这些故障是导致分离效率下降,催化剂跑损量增大,压力降减小等的主要原因之一。这些不同的机械故障所引起的操作参数变化和跑损催化剂的物性变化是有所不同的,有些参数是突变的,有些是渐变的,还有一些是波动变化的,这些变化与机械故障之间存在着密切联系。可以通过跑损催化剂的浓度和粒度的变化,旋风分离器入口速度和压力降的变化对旋风分离器产生机械故障的原因进行诊断和分析。
Cyclone is operated for separating the catalyst particles from oil vapor or from flue gas in fluid catalytic cracking unit(FCCU), which is key equipment for the long-term operation of the unit. As the cyclone works at high temperature and high concentration for a long time, various mechanical faults may occur, such as erosion, wear, fracture, blocking etc., which may result in the decrease of separation efficiency, the increase of catalyst loss and the fluctuation of pressure drop. But they are different from mechanical faults, and operating parameters changes and changes of physical properties of lost catalysts are different. Some parameters change abruptly, some parameters change gradually and some parameters change fluctuatingly. These changes are closely related to mechanical faults. The causes of mechanical faults of cyclones can be diagnosed and analyzed based upon the concentration and size distribution of lost catalysts and variations of inlet velocity of cyclone separator and pressure drop.
Cyclone is operated for separating the catalyst particles from oil vapor or from flue gas in fluid catalytic cracking unit(FCCU), which is key equipment for the long-term operation of the unit. As the cyclone works at high temperature and high concentration for a long time, various mechanical faults may occur, such as erosion, wear, fracture, blocking etc., which may result in the decrease of separation efficiency, the increase of catalyst loss and the fluctuation of pressure drop. But they are different from mechanical faults, and operating parameters changes and changes of physical properties of lost catalysts are different. Some parameters change abruptly, some parameters change gradually and some parameters change fluctuatingly. These changes are closely related to mechanical faults. The causes of mechanical faults of cyclones can be diagnosed and analyzed based upon the concentration and size distribution of lost catalysts and variations of inlet velocity of cyclone separator and pressure drop.
引文
[1] 宋健斐,王迪,孙立强,等.基于颗粒谱的FCC旋风分离器故障诊断技术的初步探索[J].石油学报(石油加工),2017,33(3):591.
[2] 罗勇,张瑞弛.荆门催化裂解装置催化剂磨损和跑剂的控制[J].石油炼制与化工,2001,32(12):26.
[3] 孔文文,严超宇,魏耀东.旋风分离器料腿漏风对压力降影响的实验分析[J].化工装备技术,2016,37(4):3.
[4] 魏耀东,刘仁桓,燕辉,等.蜗壳式旋风分离器的磨损实验和分析[J].化工机械,2001,28(3):72.
[5] 刘家海,袁红斌.旋风分离器磨损失效分析与对策[J].石油化工设备技术,2000,21(3):13.
[6] MCLEAN J B.FCC catalyst properties can affect cyclone erosion [J].Oil & Gas Journal,2000,98(1):34.
[7] 邓云山.催化裂化装置再生器旋风分离器失效原因分析及改进措施[J].石油化工设备技术,1999,20(4):62.
[8] 曹晖,刘雁.催化裂化装置再生器旋风分离器故障原因及措施[J].广东化工,2013,40(1):136.
[9] MCPHERSON L J.Causes of FCC reactor coke deposits identified[J].Oil & Gas Journal,1984,82(37):141.
[10] 关宏军,夏长斌,扈玉华,等.沉降器旋风分离器料腿堵塞原因分析[J].当代化工,2004,33(6):360.
[11] 翟军,李涛,徐辉,等.油浆固体含量高的原因分析及解决措施[J].石化技术,1997,4(3):151.
[12] 魏耀东,宋健斐,刘仁桓,等.一种抑制结焦的旋风分离器:200420058444.2[P].2004-12-14.
[13] 蔡香丽,李培,杨智勇,等.圆管内轴向旋转流切向速度湍流强度[J].化工学报,2014,65(11):4280.
[14] 蔡香丽,黄蕾,乔伟,等.FCCU旋风分离器壳体断裂失效的原因分析[J].炼油技术与工程,2014,44(9):29.
[15] 杨智勇,蔡香丽,仇鹏,等.催化裂化装置旋风分离器料腿断裂的原因分析[J].化工机械,2018,45(4):472.
[16] ZHENG Mianbin,CHEN Guohua,HAN Jianyu.Failure analysis on two austenitic stainless steels applied in cyclone separators of catalytic cracking unit[J].Engineering Failure Analysis,2011,18(1):94.
[17] 夏明川,常培廷,王建军,等.催化裂化装置再生器跑剂分析与对策[J].炼油技术与工程,2017,47(4):49.
[18] 程久联,郝永杰.催化裂化VQS改造探讨[J].炼油技术与工程,2013,43(2):40.
[19] 闫涛,张荣克,闻明科.旋风分离器用耐磨型翼阀的研制[J].石油化工设备,2009,38(2):19.
[20] 张峰,张爱琴,严超宇,等.FCC装置旋风分离器改进翼阀的防磨性能流场分析[J].炼油技术与工程,2012,42(10):35.
[2] 罗勇,张瑞弛.荆门催化裂解装置催化剂磨损和跑剂的控制[J].石油炼制与化工,2001,32(12):26.
[3] 孔文文,严超宇,魏耀东.旋风分离器料腿漏风对压力降影响的实验分析[J].化工装备技术,2016,37(4):3.
[4] 魏耀东,刘仁桓,燕辉,等.蜗壳式旋风分离器的磨损实验和分析[J].化工机械,2001,28(3):72.
[5] 刘家海,袁红斌.旋风分离器磨损失效分析与对策[J].石油化工设备技术,2000,21(3):13.
[6] MCLEAN J B.FCC catalyst properties can affect cyclone erosion [J].Oil & Gas Journal,2000,98(1):34.
[7] 邓云山.催化裂化装置再生器旋风分离器失效原因分析及改进措施[J].石油化工设备技术,1999,20(4):62.
[8] 曹晖,刘雁.催化裂化装置再生器旋风分离器故障原因及措施[J].广东化工,2013,40(1):136.
[9] MCPHERSON L J.Causes of FCC reactor coke deposits identified[J].Oil & Gas Journal,1984,82(37):141.
[10] 关宏军,夏长斌,扈玉华,等.沉降器旋风分离器料腿堵塞原因分析[J].当代化工,2004,33(6):360.
[11] 翟军,李涛,徐辉,等.油浆固体含量高的原因分析及解决措施[J].石化技术,1997,4(3):151.
[12] 魏耀东,宋健斐,刘仁桓,等.一种抑制结焦的旋风分离器:200420058444.2[P].2004-12-14.
[13] 蔡香丽,李培,杨智勇,等.圆管内轴向旋转流切向速度湍流强度[J].化工学报,2014,65(11):4280.
[14] 蔡香丽,黄蕾,乔伟,等.FCCU旋风分离器壳体断裂失效的原因分析[J].炼油技术与工程,2014,44(9):29.
[15] 杨智勇,蔡香丽,仇鹏,等.催化裂化装置旋风分离器料腿断裂的原因分析[J].化工机械,2018,45(4):472.
[16] ZHENG Mianbin,CHEN Guohua,HAN Jianyu.Failure analysis on two austenitic stainless steels applied in cyclone separators of catalytic cracking unit[J].Engineering Failure Analysis,2011,18(1):94.
[17] 夏明川,常培廷,王建军,等.催化裂化装置再生器跑剂分析与对策[J].炼油技术与工程,2017,47(4):49.
[18] 程久联,郝永杰.催化裂化VQS改造探讨[J].炼油技术与工程,2013,43(2):40.
[19] 闫涛,张荣克,闻明科.旋风分离器用耐磨型翼阀的研制[J].石油化工设备,2009,38(2):19.
[20] 张峰,张爱琴,严超宇,等.FCC装置旋风分离器改进翼阀的防磨性能流场分析[J].炼油技术与工程,2012,42(10):35.