立式多层长圆筒容器气相区化爆压力波传播及壳体动态响应研究
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摘要
立式多层长圆筒厚壁容器广泛应用于大型化工生产装置中,在生产过程中此类容器爆破事故时有发生,造成了巨大的财产损失和严重的人员伤亡。但是有些事故原因定性存在较大的争议,特别是平阴尿塔爆破事故就存在化学爆炸和物理爆炸的争议,不利于采取有效措施预防此类事故的再次发生。为了探索此类设备爆破的真实原因,作者针对立式多层长圆筒容器塔体爆破的相关问题进行了研究,主要包括下面两个问题：一是立式长圆筒容器气相区化学爆炸压力波传播过程,包括对化爆压力波传播过程影响因素的研究；二是多层包扎圆筒在压力载荷作用下的力学响应,包括完整壳体在动态载荷作用下的响应和缺陷壳体在静载下的力学性能分析。只有弄清这两个问题,才能为明确尿塔爆破原因和分析其他类似容器爆破原因提供参考,也才能为类似设备采取针对性的防爆措施提供研究依据。
对典型立式长圆筒容器尿塔的结构和尿素生产工艺进行了分析,分析了尿塔中可燃气体化爆条件,总结了立式长圆筒容器气相空间化学爆炸的特点。研究表明,气相区内部容易聚集可燃气体和氧气,在静电火花等外界能量激励下存在发生化学爆炸的可能。尿塔类容器具有大长径比、空间密闭以及内部介质分为气相和液相等特点,使此类容器气相区化学爆炸具有空间密闭性、局部爆炸性和传播介质性质突变性等特点。
对立式长圆筒容器中气相区化爆压力波传播进行了研究。首先探讨了可燃气体爆源物理模型与凝聚相炸药爆源物理模型的异同,对两种爆源进行了等效性分析。计算了爆炸能量,介绍了爆炸模型和运动方程,建立了立式长圆筒容器有限元模型。在此基础上,利用LS-DYNA软件对立式长圆筒容器气相区化学爆炸压力波传播过程进行了模拟,获得了内部介质分为气相区和液相区的立式长圆筒容器气相区化学爆炸压力场演变规律、不同时刻器壁爆炸压力变化规律和不同位置器壁压力时间演化规律。研究结果表明,不同时刻介质内的压力场和器壁压力变化规律以及不同位置器壁压力演化规律清晰地描述了化爆压力波传播过程。气相区介质内压力场演化主要是由气体运动形成的,具有持续性和不规律性；上封头器壁压力曲线的首峰值即为最大峰值；压力最大值出现在上封头顶部位置,接近400MPa,远高于其他位置器壁压力最大值。液相区内的压力波是气体运动激励气液界面时产生的,具有不稳定性和持续性,在传播过程中会重复发生“叠加”和“分离”；筒体壁面压力曲线首峰值在多数时间内不是最大值,而且压力最大值出现的时间不固定；压力波被下封头反射后会向上传播,并在整个液相区的筒体范围内与后续向下传播的压力波相遇,叠加后的波强度有所增加。
对爆源位置、气相区体积变化、塔盘障碍物、爆炸能量和气相区形状等因素对立式长圆筒容器气相区化爆压力波传播过程的影响进行了研究分析。结果显示,整个筒体范围内的爆炸压力最大值出现在上封头顶部位置,是其他位置器壁压力最大值的5倍以上；液相区器壁压力最大值出现在靠近气液界面附近位置,比液相区其他位置器壁压力最大值高20MPa以上,出现的具体位置因变量不同稍有变化；液相区其他位置器壁压力最大值几乎相等。大多数情况下,上封头顶部位置压力比冲量曲线值在整个筒体范围内最大,只有爆源偏心设置时,靠近气液界面器壁压力“加强区”的比冲量曲线会超过上封头顶部位置比冲量曲线；随着与爆心距离的增加,不同位置比冲量曲线逐渐降低；设置塔盘后,塔盘上侧单元的比冲量曲线稍高于塔盘下侧相邻单元的比冲量曲线；气相区体积减小和爆炸能量增加时,不同位置比冲量曲线值增加,而气相区体积增加时比冲量曲线值减小。爆源位置变化影响上封头顶部压力最大值,对其他位置器壁压力最大值几乎无影响；气相区体积减小和爆源能量增加时,容器内压力场强度和器壁最大压力值变大；气相区体积增加时,压力场强度和器壁最大压力值减小；设置塔盘后,塔盘下侧器壁单元压力时间曲线趋于平缓。采用平封头结构时,器壁最大压力值分布和比冲量曲线变化规律与采用球封头时相似。
利用LS-DYNA软件对带间隙多层包扎圆筒在动态载荷作用下的力学响应进行了研究,分析过程中充分考虑了不同加载压力曲线、层板间隙以及平面应力和平面应变的影响,其中加载压力波形包括单波峰和两种双波峰情况,层板间隙包括0.02mm、O.1mm、0.2mm、0.3mm和0.4mm五种情况。计算结果显示,层板等效应力变化过程分成振荡变化阶段、屈服发展阶段、同步快速增加阶段和应力降低阶段：振荡变化阶段,层板等效应力振荡变化；屈服发展阶段,层板从内向外逐层屈服,屈服后等效应力增长减缓；同步快速增加阶段,最外层板屈服后,层板等效应力同步快速增加；等效应力降低阶段,内部层板应力降低速度大于外部层板等效应力降低速度。在整个加载过程中,层板间应力分布不连续；层板内应力分布不均匀；内层板应力不保证一直大于外层板应力,其中加载压力恢复至平衡压力后,间隙为0.02mm时,外层板应力高于内层板应力；层板运动速度发生变化。层板位移随加载压力降低而有所减小,等效塑性应变不随加载压力降低而减小。不同波峰加载下,次波峰作用时层板应力变化以首波峰结束时状态为基础开始发展,对恢复平衡压力时的等效应力、等效塑性应变和位移影响较小。间隙增加后,等效应力振荡变化阶段缩短；内部层板等效应力、等效塑性应变和位移增加,而外部层板的相关参量减小：加载压力恢复至平衡压力后,间隙为O.1mm时,内外层板等效应力几乎相等,间隙为0.2mm、0.3mm和0.4mm时,内部层板等效应力高于外部层板等效应力。相同层板间隙时,平面应力状态下的层板应力、等效塑性应变和位移值高于平面应变状态下的计算值。
对尿塔爆破机理进行了再分析。首先讨论了尿塔气相区化学爆炸引起塔体爆破的可能性,分析了尿塔中化爆压力波传播规律的原因,结果显示平阴尿塔的初始断裂并非由气相区化学爆炸引起。总结了尿塔中缺陷类型,分析了内层板上存在裂纹时对多层包扎圆筒产生的影响,结果显示,随着裂纹长度增加,内层板应力降低,外层板应力增加；外层板与裂纹自由边相接触的位置会出现应力“加强区”,会导致应力腐蚀裂纹优先在该位置产生。建立缺陷层板包扎圆筒结构的物理模型,提出考虑裂纹层板影响时其他层板应力和临界裂纹长度的计算方法。以平阴尿塔为算例,分析了考虑裂纹层板影响时其他层板应力和临界裂纹长度变化规律,结果显示,考虑内层板裂纹影响时,外层板应力增加,临界裂纹长度变短,增加了尿塔运行的危险性。
总之,通过对立式多层长圆筒容器内气相空间化学爆炸压力波传播过程的模拟,直观形象地展示了尿塔气相区化学爆炸压力波在尿塔中的传播过程。通过对尿塔中气相区化学爆炸引起塔体爆破的分析以及与化学爆炸观点关于爆炸波传播过程描述的比较,否定了平阴尿塔塔体初始断裂是由气相区化学爆炸引起的可能。通过对间隙多层包扎圆筒在动态载荷下的响应模拟研究,获得了间隙层板结构在动态载荷作用下的力学响应,为此类结构设备的防爆设计提供了直接的参考。对缺陷多层包扎圆筒的研究,很好地解释了尿塔层板中应力腐蚀裂纹分布规律。通过作者在本文中的研究,对明确尿素合成塔爆破原因和分析其他类似容器爆破原因提供了参考,对于采取有针对性的预防措施,保障此类容器的安全运行,具有重要的意义。此外,由于立式多层长圆筒容器事故非常复杂,要想彻底对尿塔爆破原因进行溯源研究,尚需对本文中的模拟结果进行容器爆破性实验验证。
The vessels with long vertical multilayer cylinder are widely used in large scale chemical plants. Explosion accidents of such vessels happen sometimes and cause serious loss of property and casualty. But, some accident causes have huge dispute, especially the dispute over Pingyin urea reactor accident is chemical explosion and physical explosion. And this situation goes against taking effective measures to prevent such accidents happening. In order to confirm the real explosion causes of such vessels, the author takes the relative study on the explosion accidents of vessels with long vertical multilayer cylinder. The main research topics are as follows:the first question is to study the pressure wave propagation in a vessel with long vertical multilayer cylinder resulting from the chemical explosion in gas space, including the influencing factors of the wave propagation process; the second one is the response of the multilayer cylinder structure, including the dynamic response under dynamic load and the mechanical response of defect shell under static load. Only these two questions are solved, the real causes of urea reactor explosion accidents can be confirmed and it can provide reference idea of similar accident analysis.
The structure of a urea reactor and the synthesis process of urea production are analyzed at first. And then, the chemical explosion conditions of combustive gases in the urea reactor are analyzed. The chemical explosion characters are summarized occurred in gas space of the urea rector. The results show that the gas space can gather these combustive gases and the oxygen gases easily. Under the excitation of external energies, such as electrostatic sparks, there exists the explosion possibility. Because of the characters of vessels like a urea reactor, the chemical explosion occured in gas space has following characters:space airtightness, local explosion and sudden change of media character in the vessel.
The pressure wave propagation process in a vessel with long vertical cylinder resulted from the gas space chemical explosion is studied. The combustive gas explosion source is compared with the solid explosive source at first. Equivalent analysis of two explosive sources is carried out. The explosive energy is calculated. The explosive model and the motion equations are introduced. The finite element model of such vessel is built. Based on these works, the pressure wave propagation process is simulated by using the LS-DYNA software. The chemical explosion pressure field evolution law is obtained. Meanwhile, the explosion pressure evolution law on vessel wall of different times and pressure evolution law versus time on vessel wall in different locations are obtained. The research results shows that the pressure wave propagation process can be described clearly by the pressure field evolution law, the explosion pressure evolution law on vessel wall of different times and pressure evolution law versus time on vessel wall in different locations. The explosion pressure evolution law of gas space is mainly formed by the gas motion. And it has persistence and irregularity. The first peak value of the pressure curve on the top of the top head is the maxim pressure value and the value is about400MPa. The pressure wave in the liquid space is formed by the gas-liquid interface vibration caused by the gas motion. It also has persistence and irregularity. Wave overlap and wave separation process will occur repeatedly during the pressure wave propagates in the liquid space. The first peak value of the pressure curve is no longer the maximum value for most of the time and the appearance time of the maximum pressure value is irregular. The pressure wave will propagate upward after it is reflected by the bottom head and it will superpose with the following pressure waves which propagate downward. The wave intensity increased after the wave superposition.
The effects on the pressure wave propagation process of the influencing factors, such as the volume change of the gas space, the trays, the explosive energy and the gas space shape, are studied. The results show that the maximum pressure value of the whole cylinder appears at the top of the top head and the value is five times the maximum value of other positions. The maximum pressure value of the liquid space appears at the position nears the gas-space interface and it is about20MPa bigger than the pressure value of other positions. The exact position of the maximum value of liquid space changes a little as the influencing factors change. The maximum value of other positions of liquid space is at the same level. In most situations, the specific impulse value at the top position of the top head is the maximum value of the whole vessel. The specific impulse value of the pressure of "strengthen area" is even larger than the one of the top position of the top head when the explosive source is eccentric settled. As the distance from the explosive center increases, the specific impulse value decreases gradually. The specific impulse value of the element on the upside of the tray is a little larger than the value of the adjacent element on the downside of the tray. As the gas space volume decreases and the explosive energy increases, the specific impulse value of different positions increases. As the gas space volume increases, the specific impulse value of different positions decreases. The maximum pressure value of the top position of the top head changes a lot with the explosive center changes, but the value of other positions is almost unchanged. The maximum pressure value increases with the increase of the explosive energy and the decrease of the gas space volume. The maximum pressure value decreases with the increase of the gas space volume. The pressure curve becomes flat after the trays are settled. The maximum pressure distribution law and the specific impulse curve when the top head is flat head are similar to the spherical head.
The dynamic response of multilayer cylinder vessel under dynamic load is simulated by the LS-DYNA. The effects of the load curve, the layer gaps and the plane stress state are considered during simulation. The load curves include a single peak curve and two kinds of double peak curve. The layer gaps include0.02mm,0.1mm,0.2mm,0.3mm and0.4mm. The results show that the layer stress increase process is divided into several stages such as oscillation change stage, yield development stage, quick increase simultaneously stage and stress decease stage. During the oscillation change stage, the layer stress shows a significantly change oscillation; at the yield development stage, the inner layer yield at first, and then the outer layers yield layer by layer, the stress increase rate of yield layers decrease a lot; at the quick increase simultaneously stage, all the layer stress increase simultaneously and quickly at the same time; during the stress decease stage, the stress decrease rate of inner layers is larger than the outer layers'. During the whole process, the layer stress show discontinuous distribution between layer and the layer stress is uneven distribution in a layer; the inner layer stress is not guarantee larger than the outer layer stress all the time, the outer layer stress is larger than the inner layer stress when the load returns to the balance pressure with the gap of0.02mm. The layer velocity changes during the loading. The final layer displacement decreases a little as the load decreases. The final plastic deformation does not change with the load decreases. Under the double peak load curve, the layer stress changes under the second pressure peak on the basis of the stress distribution when the first pressure peak comes to an end. The double peak pressure curve load has little influence on the final layer stress, the final plastic deformation and the final displacement. With the increase of gaps, the oscillation change stage time becomes shorter; the final layer stress and the final plastic deformation of inner layers grow larger, while the relative values of the outer layers grow smaller. The inner layer stress is almost equal to the outer layer stress while the load returns to the balance pressure with the gap of0.1mm, but the inner layer stress is still larger than the outer layer stress with gaps of0.2mm,0.3mm and0.4mm. With the same gaps, the layer stress and the plastic deformation under plane stress state are larger than those under plane strain state.
The mechanism of the explosion urea reactor is reanalyzed. The rupture possibility of urea reactor caused by the chemical explosion of gas space is discussed and the pressure wave propagation law is analyzed. The results show that the initial fracture of Pingyin urea reactor is not induced by the chemical explosion of gas space. The defects type is summarized in urea reactor. The effect caused by the inner layer cracks is analyzed. The results show that the inner layer stress grows smaller when the crack length grows and the outer layer stress grows larger. There is a stress strengthening area on the outer layer just behind the crack tip, where the stress corrosion cracks is priority to generate. The physical model of the multilayer cylinder with inner layer cracks is built. And the author proposes a method to calculate layer stress and critical crack length of other completed layers when the crack layers effect is considered. Take the Pingyin urea reactor as an example, the change law of the stress and the critical crack length of other completed layers is analyzed. The results show that the stresses of other completed layers grow larger and the critical crack length grow smaller when the inner crack is taken into consideration, which intensifies the risk of urea reactor running.
In a word, through the simulation of the pressure wave propagation process in a vessel with long vertical multilayer cylinder, the propagation process is shown intuitionisticly. The research results proved that the initial fracture of Pingyin urea reactor is not caused by the chemical explosion of gas space. The dynamic response of multilayer structures under dynamic load is obtained can provide direct reference for explosion-proof design of similar vessels. The research on the defect multilayer structures explains the distribution law of stress corrosion cracks. The research enhances the recognition level to the multilayer urea reactor explosion. It is meaningful for the explosion prevention and the vessel safety running. However, the mechanism of such vessels is so complicated that the small scale vessel explosion test with large aspect ratio is required to verify the analysis and the results in this paper.
对典型立式长圆筒容器尿塔的结构和尿素生产工艺进行了分析,分析了尿塔中可燃气体化爆条件,总结了立式长圆筒容器气相空间化学爆炸的特点。研究表明,气相区内部容易聚集可燃气体和氧气,在静电火花等外界能量激励下存在发生化学爆炸的可能。尿塔类容器具有大长径比、空间密闭以及内部介质分为气相和液相等特点,使此类容器气相区化学爆炸具有空间密闭性、局部爆炸性和传播介质性质突变性等特点。
对立式长圆筒容器中气相区化爆压力波传播进行了研究。首先探讨了可燃气体爆源物理模型与凝聚相炸药爆源物理模型的异同,对两种爆源进行了等效性分析。计算了爆炸能量,介绍了爆炸模型和运动方程,建立了立式长圆筒容器有限元模型。在此基础上,利用LS-DYNA软件对立式长圆筒容器气相区化学爆炸压力波传播过程进行了模拟,获得了内部介质分为气相区和液相区的立式长圆筒容器气相区化学爆炸压力场演变规律、不同时刻器壁爆炸压力变化规律和不同位置器壁压力时间演化规律。研究结果表明,不同时刻介质内的压力场和器壁压力变化规律以及不同位置器壁压力演化规律清晰地描述了化爆压力波传播过程。气相区介质内压力场演化主要是由气体运动形成的,具有持续性和不规律性；上封头器壁压力曲线的首峰值即为最大峰值；压力最大值出现在上封头顶部位置,接近400MPa,远高于其他位置器壁压力最大值。液相区内的压力波是气体运动激励气液界面时产生的,具有不稳定性和持续性,在传播过程中会重复发生“叠加”和“分离”；筒体壁面压力曲线首峰值在多数时间内不是最大值,而且压力最大值出现的时间不固定；压力波被下封头反射后会向上传播,并在整个液相区的筒体范围内与后续向下传播的压力波相遇,叠加后的波强度有所增加。
对爆源位置、气相区体积变化、塔盘障碍物、爆炸能量和气相区形状等因素对立式长圆筒容器气相区化爆压力波传播过程的影响进行了研究分析。结果显示,整个筒体范围内的爆炸压力最大值出现在上封头顶部位置,是其他位置器壁压力最大值的5倍以上；液相区器壁压力最大值出现在靠近气液界面附近位置,比液相区其他位置器壁压力最大值高20MPa以上,出现的具体位置因变量不同稍有变化；液相区其他位置器壁压力最大值几乎相等。大多数情况下,上封头顶部位置压力比冲量曲线值在整个筒体范围内最大,只有爆源偏心设置时,靠近气液界面器壁压力“加强区”的比冲量曲线会超过上封头顶部位置比冲量曲线；随着与爆心距离的增加,不同位置比冲量曲线逐渐降低；设置塔盘后,塔盘上侧单元的比冲量曲线稍高于塔盘下侧相邻单元的比冲量曲线；气相区体积减小和爆炸能量增加时,不同位置比冲量曲线值增加,而气相区体积增加时比冲量曲线值减小。爆源位置变化影响上封头顶部压力最大值,对其他位置器壁压力最大值几乎无影响；气相区体积减小和爆源能量增加时,容器内压力场强度和器壁最大压力值变大；气相区体积增加时,压力场强度和器壁最大压力值减小；设置塔盘后,塔盘下侧器壁单元压力时间曲线趋于平缓。采用平封头结构时,器壁最大压力值分布和比冲量曲线变化规律与采用球封头时相似。
利用LS-DYNA软件对带间隙多层包扎圆筒在动态载荷作用下的力学响应进行了研究,分析过程中充分考虑了不同加载压力曲线、层板间隙以及平面应力和平面应变的影响,其中加载压力波形包括单波峰和两种双波峰情况,层板间隙包括0.02mm、O.1mm、0.2mm、0.3mm和0.4mm五种情况。计算结果显示,层板等效应力变化过程分成振荡变化阶段、屈服发展阶段、同步快速增加阶段和应力降低阶段：振荡变化阶段,层板等效应力振荡变化；屈服发展阶段,层板从内向外逐层屈服,屈服后等效应力增长减缓；同步快速增加阶段,最外层板屈服后,层板等效应力同步快速增加；等效应力降低阶段,内部层板应力降低速度大于外部层板等效应力降低速度。在整个加载过程中,层板间应力分布不连续；层板内应力分布不均匀；内层板应力不保证一直大于外层板应力,其中加载压力恢复至平衡压力后,间隙为0.02mm时,外层板应力高于内层板应力；层板运动速度发生变化。层板位移随加载压力降低而有所减小,等效塑性应变不随加载压力降低而减小。不同波峰加载下,次波峰作用时层板应力变化以首波峰结束时状态为基础开始发展,对恢复平衡压力时的等效应力、等效塑性应变和位移影响较小。间隙增加后,等效应力振荡变化阶段缩短；内部层板等效应力、等效塑性应变和位移增加,而外部层板的相关参量减小：加载压力恢复至平衡压力后,间隙为O.1mm时,内外层板等效应力几乎相等,间隙为0.2mm、0.3mm和0.4mm时,内部层板等效应力高于外部层板等效应力。相同层板间隙时,平面应力状态下的层板应力、等效塑性应变和位移值高于平面应变状态下的计算值。
对尿塔爆破机理进行了再分析。首先讨论了尿塔气相区化学爆炸引起塔体爆破的可能性,分析了尿塔中化爆压力波传播规律的原因,结果显示平阴尿塔的初始断裂并非由气相区化学爆炸引起。总结了尿塔中缺陷类型,分析了内层板上存在裂纹时对多层包扎圆筒产生的影响,结果显示,随着裂纹长度增加,内层板应力降低,外层板应力增加；外层板与裂纹自由边相接触的位置会出现应力“加强区”,会导致应力腐蚀裂纹优先在该位置产生。建立缺陷层板包扎圆筒结构的物理模型,提出考虑裂纹层板影响时其他层板应力和临界裂纹长度的计算方法。以平阴尿塔为算例,分析了考虑裂纹层板影响时其他层板应力和临界裂纹长度变化规律,结果显示,考虑内层板裂纹影响时,外层板应力增加,临界裂纹长度变短,增加了尿塔运行的危险性。
总之,通过对立式多层长圆筒容器内气相空间化学爆炸压力波传播过程的模拟,直观形象地展示了尿塔气相区化学爆炸压力波在尿塔中的传播过程。通过对尿塔中气相区化学爆炸引起塔体爆破的分析以及与化学爆炸观点关于爆炸波传播过程描述的比较,否定了平阴尿塔塔体初始断裂是由气相区化学爆炸引起的可能。通过对间隙多层包扎圆筒在动态载荷下的响应模拟研究,获得了间隙层板结构在动态载荷作用下的力学响应,为此类结构设备的防爆设计提供了直接的参考。对缺陷多层包扎圆筒的研究,很好地解释了尿塔层板中应力腐蚀裂纹分布规律。通过作者在本文中的研究,对明确尿素合成塔爆破原因和分析其他类似容器爆破原因提供了参考,对于采取有针对性的预防措施,保障此类容器的安全运行,具有重要的意义。此外,由于立式多层长圆筒容器事故非常复杂,要想彻底对尿塔爆破原因进行溯源研究,尚需对本文中的模拟结果进行容器爆破性实验验证。
The vessels with long vertical multilayer cylinder are widely used in large scale chemical plants. Explosion accidents of such vessels happen sometimes and cause serious loss of property and casualty. But, some accident causes have huge dispute, especially the dispute over Pingyin urea reactor accident is chemical explosion and physical explosion. And this situation goes against taking effective measures to prevent such accidents happening. In order to confirm the real explosion causes of such vessels, the author takes the relative study on the explosion accidents of vessels with long vertical multilayer cylinder. The main research topics are as follows:the first question is to study the pressure wave propagation in a vessel with long vertical multilayer cylinder resulting from the chemical explosion in gas space, including the influencing factors of the wave propagation process; the second one is the response of the multilayer cylinder structure, including the dynamic response under dynamic load and the mechanical response of defect shell under static load. Only these two questions are solved, the real causes of urea reactor explosion accidents can be confirmed and it can provide reference idea of similar accident analysis.
The structure of a urea reactor and the synthesis process of urea production are analyzed at first. And then, the chemical explosion conditions of combustive gases in the urea reactor are analyzed. The chemical explosion characters are summarized occurred in gas space of the urea rector. The results show that the gas space can gather these combustive gases and the oxygen gases easily. Under the excitation of external energies, such as electrostatic sparks, there exists the explosion possibility. Because of the characters of vessels like a urea reactor, the chemical explosion occured in gas space has following characters:space airtightness, local explosion and sudden change of media character in the vessel.
The pressure wave propagation process in a vessel with long vertical cylinder resulted from the gas space chemical explosion is studied. The combustive gas explosion source is compared with the solid explosive source at first. Equivalent analysis of two explosive sources is carried out. The explosive energy is calculated. The explosive model and the motion equations are introduced. The finite element model of such vessel is built. Based on these works, the pressure wave propagation process is simulated by using the LS-DYNA software. The chemical explosion pressure field evolution law is obtained. Meanwhile, the explosion pressure evolution law on vessel wall of different times and pressure evolution law versus time on vessel wall in different locations are obtained. The research results shows that the pressure wave propagation process can be described clearly by the pressure field evolution law, the explosion pressure evolution law on vessel wall of different times and pressure evolution law versus time on vessel wall in different locations. The explosion pressure evolution law of gas space is mainly formed by the gas motion. And it has persistence and irregularity. The first peak value of the pressure curve on the top of the top head is the maxim pressure value and the value is about400MPa. The pressure wave in the liquid space is formed by the gas-liquid interface vibration caused by the gas motion. It also has persistence and irregularity. Wave overlap and wave separation process will occur repeatedly during the pressure wave propagates in the liquid space. The first peak value of the pressure curve is no longer the maximum value for most of the time and the appearance time of the maximum pressure value is irregular. The pressure wave will propagate upward after it is reflected by the bottom head and it will superpose with the following pressure waves which propagate downward. The wave intensity increased after the wave superposition.
The effects on the pressure wave propagation process of the influencing factors, such as the volume change of the gas space, the trays, the explosive energy and the gas space shape, are studied. The results show that the maximum pressure value of the whole cylinder appears at the top of the top head and the value is five times the maximum value of other positions. The maximum pressure value of the liquid space appears at the position nears the gas-space interface and it is about20MPa bigger than the pressure value of other positions. The exact position of the maximum value of liquid space changes a little as the influencing factors change. The maximum value of other positions of liquid space is at the same level. In most situations, the specific impulse value at the top position of the top head is the maximum value of the whole vessel. The specific impulse value of the pressure of "strengthen area" is even larger than the one of the top position of the top head when the explosive source is eccentric settled. As the distance from the explosive center increases, the specific impulse value decreases gradually. The specific impulse value of the element on the upside of the tray is a little larger than the value of the adjacent element on the downside of the tray. As the gas space volume decreases and the explosive energy increases, the specific impulse value of different positions increases. As the gas space volume increases, the specific impulse value of different positions decreases. The maximum pressure value of the top position of the top head changes a lot with the explosive center changes, but the value of other positions is almost unchanged. The maximum pressure value increases with the increase of the explosive energy and the decrease of the gas space volume. The maximum pressure value decreases with the increase of the gas space volume. The pressure curve becomes flat after the trays are settled. The maximum pressure distribution law and the specific impulse curve when the top head is flat head are similar to the spherical head.
The dynamic response of multilayer cylinder vessel under dynamic load is simulated by the LS-DYNA. The effects of the load curve, the layer gaps and the plane stress state are considered during simulation. The load curves include a single peak curve and two kinds of double peak curve. The layer gaps include0.02mm,0.1mm,0.2mm,0.3mm and0.4mm. The results show that the layer stress increase process is divided into several stages such as oscillation change stage, yield development stage, quick increase simultaneously stage and stress decease stage. During the oscillation change stage, the layer stress shows a significantly change oscillation; at the yield development stage, the inner layer yield at first, and then the outer layers yield layer by layer, the stress increase rate of yield layers decrease a lot; at the quick increase simultaneously stage, all the layer stress increase simultaneously and quickly at the same time; during the stress decease stage, the stress decrease rate of inner layers is larger than the outer layers'. During the whole process, the layer stress show discontinuous distribution between layer and the layer stress is uneven distribution in a layer; the inner layer stress is not guarantee larger than the outer layer stress all the time, the outer layer stress is larger than the inner layer stress when the load returns to the balance pressure with the gap of0.02mm. The layer velocity changes during the loading. The final layer displacement decreases a little as the load decreases. The final plastic deformation does not change with the load decreases. Under the double peak load curve, the layer stress changes under the second pressure peak on the basis of the stress distribution when the first pressure peak comes to an end. The double peak pressure curve load has little influence on the final layer stress, the final plastic deformation and the final displacement. With the increase of gaps, the oscillation change stage time becomes shorter; the final layer stress and the final plastic deformation of inner layers grow larger, while the relative values of the outer layers grow smaller. The inner layer stress is almost equal to the outer layer stress while the load returns to the balance pressure with the gap of0.1mm, but the inner layer stress is still larger than the outer layer stress with gaps of0.2mm,0.3mm and0.4mm. With the same gaps, the layer stress and the plastic deformation under plane stress state are larger than those under plane strain state.
The mechanism of the explosion urea reactor is reanalyzed. The rupture possibility of urea reactor caused by the chemical explosion of gas space is discussed and the pressure wave propagation law is analyzed. The results show that the initial fracture of Pingyin urea reactor is not induced by the chemical explosion of gas space. The defects type is summarized in urea reactor. The effect caused by the inner layer cracks is analyzed. The results show that the inner layer stress grows smaller when the crack length grows and the outer layer stress grows larger. There is a stress strengthening area on the outer layer just behind the crack tip, where the stress corrosion cracks is priority to generate. The physical model of the multilayer cylinder with inner layer cracks is built. And the author proposes a method to calculate layer stress and critical crack length of other completed layers when the crack layers effect is considered. Take the Pingyin urea reactor as an example, the change law of the stress and the critical crack length of other completed layers is analyzed. The results show that the stresses of other completed layers grow larger and the critical crack length grow smaller when the inner crack is taken into consideration, which intensifies the risk of urea reactor running.
In a word, through the simulation of the pressure wave propagation process in a vessel with long vertical multilayer cylinder, the propagation process is shown intuitionisticly. The research results proved that the initial fracture of Pingyin urea reactor is not caused by the chemical explosion of gas space. The dynamic response of multilayer structures under dynamic load is obtained can provide direct reference for explosion-proof design of similar vessels. The research on the defect multilayer structures explains the distribution law of stress corrosion cracks. The research enhances the recognition level to the multilayer urea reactor explosion. It is meaningful for the explosion prevention and the vessel safety running. However, the mechanism of such vessels is so complicated that the small scale vessel explosion test with large aspect ratio is required to verify the analysis and the results in this paper.
引文
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