Potential failure analysis and prediction of multiphase flow corrosion thinning behavior in the reaction effluent air cooler system. (January 2020)

• Record Type: Journal Article
• Authors: Jin, Haozhe; Chen, Xiaoping; Ou, Guofu; Zhang, Jianqiang
• Is Part Of: Engineering failure analysis. Volume 109(2020)
• Publication Date: 2020-01
• Subjects: REAC system -- Corrosion thinning -- Multiphase flow -- CFD -- Prediction; System failures (Engineering) -- Periodicals; Fracture mechanics -- Periodicals; Reliability (Engineering) -- Periodicals; Pannes -- Périodiques; Rupture, Mécanique de la -- Périodiques; Fiabilité -- Périodiques; Fracture mechanics; Reliability (Engineering); System failures (Engineering); Periodicals; Electronic journals; 620.112
• DOI: 10.1016/j.engfailanal.2019.104274
• Languages: English
• ISSNs: 1350-6307

Abstract

Graphical abstract: Highlights: Failure investigation was conducted to identify the corrosion thinning of pipes. The high liquid fraction and high particle mass flow rate is the main reason. The high risk area has a good qualitative agreement with the CFD simulation. Abstract: The corrosion-thinning failure of tubes caused by ammonium salt remains a longstanding challenge in reaction effluent air cooler (REAC) systems and in other industries. During the quadrennial period of overall maintenance, the area of corrosion thinning is mainly found in the second tube side of the air cooler system, and the carbon steel in these pipes is in multiphase flow condition. Based on the relevant technological process flow, the inner flow field is simulated by using the mixture model and the discrete phase model, and its flow corrosion thinning regulation is revealed. The computational fluid dynamics (CFD) results indicate that the tube area with high liquid fraction and high particle mass flow rate is at higher risk of localized corrosion thinning, as the separated ammonium salt particles easily absorb moisture, deliquesce in the presence of water and form the corrosive environment. The potential failure analysis and prediction basically agree with the inspection results of eddy current testing instruments on the spot. Therefore, it verifies the CFD simulation can be utilized for predicting the multiphase flow corrosion thinning areas in REAC systems.