CN104271309A - 用于池式反应器或池式冷凝器的管板和热交换器组件的制造方法;相应的管板和热交换器组件 - Google Patents

用于池式反应器或池式冷凝器的管板和热交换器组件的制造方法;相应的管板和热交换器组件 Download PDF

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CN104271309A
CN104271309A CN201380023333.XA CN201380023333A CN104271309A CN 104271309 A CN104271309 A CN 104271309A CN 201380023333 A CN201380023333 A CN 201380023333A CN 104271309 A CN104271309 A CN 104271309A
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A·A·A·希尔德尔
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
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    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/04—Arrangements for sealing elements into header boxes or end plates
    • F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
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    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
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    • F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
    • F28F9/18—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
    • F28F9/185—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding with additional preformed parts
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    • B23K2101/04—Tubular or hollow articles
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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Abstract

本申请涉及用于在由氨和二氧化碳制备尿素中使用的池式反应器或池式冷凝器的管板(7)和热交换器组件的方法，其中该方法包括由碳钢材料级制造管板(7)并对该管板(7)设置奥氏体-铁素体双相不锈钢级腐蚀防护层(8、9)，其中热交换器包括至少一个奥氏体-铁素体双相不锈钢级U形管(13)，该方法还包括通过管板(7)***至少两个奥氏体-铁素体双相不锈钢级套管(11)，使得套管(11)的两端沿远离管板(7)的方向而延伸，该方法还包括将套管(11)，至少其相反两端，至少连接至管板(7)的防护层(8、9)，且最后将至少一个U形管(13)的两端连接至各个套管(11)。

Description

用于池式反应器或池式冷凝器的管板和热交换器组件的制造方法;相应的管板和热交换器组件
技术领域
本发明涉及在包含高压合成部的尿素设备中由氨和二氧化碳制备尿素的领域。具体而言，本发明涉及制造用于池式反应器或池式冷凝器的管板和热交换器组件以用于在尿素设备中由氨和二氧化碳制备尿素的领域。
背景技术
对于尿素设备中尿素和二氧化碳的制备，这样的设备可以包括高压汽提器、高压氨基甲酸盐冷凝器、池式冷凝器或池式反应器。这样的池式冷凝器或池式反应器可以是壳管式，其包括经管板延伸的基本上u形的管束。这样的尿素设备例如记载在WO 2009/141346中。已知的池式反应器或池式冷凝器的壳侧填充有高压工序介质。设置在反应器或冷凝器中的U形管束填充有用于产生低压蒸汽的蒸汽冷凝物。因为在壳侧与管侧之间存在较高的压力差，管板必须设计成足够牢固以承受两侧之间的压力差。此外，对于制造这样的池式反应器或池式冷凝器，管束的各个U形管必须与反应器或冷凝器的管板连接。由于管为U形，各个管与管板的连接包括较难且耗时的操作，这使得反应器或冷凝器难以构建。更加地，因为各个U形管束包括多个管，例如约500～5000个，优选地为1000～4000个，更优选地为1500～3000个管。结果，因较难的构建，这样的池式反应器或池式冷凝器的制造成本较高。
因此，本发明的目的是提供在尿素设备中用来制备尿素的这类池式反应器或池式冷凝器的改进制造方法。更具体而言，本发明的目的是提供用于这类池式反应器或池式冷凝器的管板和热交换器组件的制造方法，其使得各个管能够以高效的方式与管板连接。
发明内容
根据本发明的一个方面，提供一种用于壳管式热交换器例如池式反应器或池式冷凝器的管板和热交换器组件的制造方法，其中该壳管式热交换器用在由氨和二氧化碳制备尿素的装置中。该方法包括由碳钢材料级制造管板并对所述管板在其壳侧和管侧设置奥氏体-铁素体双相不锈钢级腐蚀防护层。热交换器包括至少一个奥氏体-铁素体双相不锈钢级U形管。该方法还包括通过管板***至少两个奥氏体-铁素体双相不锈钢级套管，使得套管的两端沿远离管板的方向延伸。该方法包括将套管(至少其相反的两端)至少与管板的防护层连接，然后将至少一个U形管的两端与套管的各端连接。使用根据本发明的方法，束的U形管的连接包括两个步骤。通过首先将套管***到管板中，套管在其两端与设于管板两个表面的防护层进行连接是相对简单的。归根结底，可以容易地触及套管的两端，与U形管需要与管板直接连接的情况相反。U形管端部与套管端部的连接也可以相对简单地获得。为将U形管的端部与套管的端部连接，U形管的端部位靠于套管的各个端部，使得U形管的两个管与各个套管成一线。随后，套管的各个端部与管的端部相互连接，例如通过内孔焊接的方式。
通过制造碳钢材料级的管板以及奥氏体-铁素体双相不锈钢材料级的将要***所述管板的套管，能够防止在使用池式反应器或池式冷凝器过程中热膨胀的问题。因为奥氏体-铁素体双相不锈钢材料级的热膨胀系数与碳钢材料级的热膨胀系数近似相同，可以将套管连接至包括两个奥氏体-铁素体不锈钢材料级外层的碳钢材料级管板，而没有尿素制备过程中提升温度时的产品失效风险。特别是在池式反应器或池式冷凝器中热循环的开始和停止过程中，由于该特定的构造，在密封焊接中产生最小的热应力。
此外，由于碳钢材料级管板以及与其连接的奥氏体-铁素体双相不锈钢级腐蚀防护层的构造，管板的累积热(heat history)沿管板的整个厚度是相等的。然而，这在整个管板均由奥氏体-铁素体双相不锈钢级制造的情况下是不可能的。此外，由于厚度大于300mm，仅仅奥氏体-铁素体双相不锈钢制得的管板无法锻造成在整个厚度上均具有合适的抗腐蚀性，因此也无法使通过整个管板延伸的孔的内部具有合适的抗腐蚀性。另外，这将是较为昂贵的替代方式。
通过首先将套管焊接至腐蚀防护层并随后使U形管与套管的端部相互连接，管板完全被防腐蚀材料包围。在管板和热交换组件的各个部件之间不存在裂隙。这较为重要，因为在由氨和二氧化碳制备尿素的制备方法中，所述方法中使用的池式反应器或池式冷凝器暴露于极具腐蚀性的介质。如果在管与管板之间的任意裂隙中存在停滞的腐蚀性液体，即使具有极高耐腐蚀性的材料也容易受到裂隙腐蚀的影响。结果，因为根据本发明的管板和热交换器组件的构造，避免了裂隙腐蚀。
优选地，管板上的防护层由铬含量为26～35重量％且镍含量为3～10重量％的奥氏体-铁素体双相不锈钢级形成。可以使用同一材料来形成套管。同时，束的U形管可以由所述铬含量为26～35重量％且镍含量为3～10重量％的奥氏体-铁素体双相不锈钢级制造。
优选地，管板的厚度约为200～700mm，使得在使用时可以耐受管板的壳侧与管侧之间的普遍压力差。
为在套管与管板的两个防护层之间提供合适连接，套管可以在管板的两侧密封焊接至其上设置的防护层，以避免腐蚀性工序介质进入套管与各个碳钢管钻孔之间的裂隙。之后，各个U形管的管可以焊接至各个套管，至少焊接至其在使用时从管板朝向池式反应器或池式冷凝器的壳侧延伸的端部。U形管可以通过内孔焊接的方式焊接至套管。因此，焊接探头可以***套管和管中并经套管从管板的管侧进入到管中。
使用根据本发明的方法，可以提供管板和热交换器组件，其也能够用在包括第二热交换器的池式反应器或池式冷凝器中以发挥优势。因此，根据本发明另一方面的方法可以包括将第二热交换器连接至管板，其中第二热交换器也包括基本上U形的管束。这样的池式反应器或池式冷凝器可以例如配置成用于通过第一热交换器将热量从在池式反应器或池式冷凝器的壳部中容纳的高压工序介质交换至在池式冷凝器或池式反应器中设置的第一热交换部中容纳的含有中压尿素的溶液以至少将氨基甲酸铵分解为NH3和CO2，以及用于通过第二热交换器将热量从高压工序介质交换至在池式反应器或池式冷凝器中设置的第二热交换部中容纳的低压蒸汽冷凝物以产生低压蒸汽。在这样的池式反应器或池式冷凝器中，腐蚀性工序介质存在于管板的壳侧以及管侧。因为套管被焊接连接至管板的两个腐蚀防护层，防止腐蚀性工序介质与管板的碳钢材料级接触。
为能够将至少一个套管***管板中，包括腐蚀防护层的管板可以设置有用于容纳各个套管的钻孔，其中该方法包括将所述套管***到各个钻孔中以保护碳钢材料级钻孔表面免受腐蚀性工序介质。
根据本发明的另一方面，管板设置有泄漏检测***。优选地，泄漏检测***可操作地连接至套管与各个管钻孔之间的裂隙以及泄漏检测器例如氨检测器。使用这样的泄漏检测***，可以检测来自于壳侧或来自于管侧的意外进入套管与管板的孔之间的裂隙从而与碳钢接触的腐蚀性介质。在检测该裂隙中腐蚀性介质的存在时，可以即刻采取纠正动作以避免由工序介质腐蚀引起的碳钢管板的严重损坏。优选地，套管与管板中各个钻孔之间的所有裂隙均相互连接，并且经管连接至氨检测器。在腐蚀性工序介质(即，氨基甲酸铵)泄漏时，所述介质会进入裂隙，并分解成除其他成分之外的氨并直接由氨检测器检测。
本发明还涉及用于壳管式池式反应器或池式冷凝器的管板和热交换器组件，其配置成在反应器壳侧容纳的第一工序介质与经由管板延伸并至少部分地在反应器或冷凝器壳侧中延伸的热交换器中容纳的第二工序介质之间进行热量交换，该组件优选地通过使用上述方法制造，其中管板包括碳钢材料级，并优选地在其两侧设置有奥氏体-铁素体双相不锈钢级腐蚀防护层，其中热交换器包括至少一个奥氏体-铁素体双相不锈钢级U形管，其中至少两个套管通过管板延伸，该套管，至少其相对两端，与各个腐蚀防护层连接，并且其中U形管，至少其两端，与各个套管端部连接。
最后，本发明还涉及池式反应器或池式冷凝器，优选地为浸没式池式反应器或池式冷凝器，至少包括上述的具有第一和第二U形束的管板和热交换器组件，并且优选地通过使用上述方法制造。
根据本发明的管板和热交换器组件以及池式反应器或池式冷凝器具有与本发明方法中描述相似的优点和效果。
根据以下本发明某些实施方式的详细描述，结合附图，将更完全地理解本发明的上述和其他特征和优点，其中实施方式和附图意在说明而不限制本发明。
附图说明
图1示出根据本发明实施方式的池式反应器的示意图；并且
图2和图3示出根据本发明实施方式的管板和热交换器组件的示意图。
应该注意到，在不同附图中的相同或相应的元件表示为相同或相应的附图标记。
具体实施方式
在图1中，示出根据本发明实施方式的池式反应器1的实施例。这样的池式反应器可以用于尿素设备中以在尿素设备中由氨和二氧化碳制备尿素。池式反应器1可以是壳管式热交换器。这样的热交换器可以用作池式反应器或池式冷凝器，例如作为水平浸没式反应器或冷凝器。池式反应器1包括容器，该容器在使用时基本上水平地放置并具有第一热交换部3和第二热交换部4。在所示的实施方式中，热交换部3、4包括基本上U形的管束5、6。第一U形管束5配置成用于氨基甲酸盐的冷凝以及用于随后通过所述冷凝过程中释放的热量将氨基甲酸铵分解成NH3和CO2。
第二U形管束6配置成产生低压蒸汽。U形管束5、6均从池式冷凝器1的管板7开始至少部分地通过由池式反应器1的壳所界定的内部空间而延伸。
U形管束5、6以及管板7形成管板和热交换器组件2。管板7由碳钢材料级制造并在其两个外表面7a、7b上包括腐蚀防护层8、9(参见图2和图3)。腐蚀防护层8、9由奥氏体-铁素体双相不锈钢级制成。管板7的厚度可以约为200～700mm。在所示的实施例中，管板7包括厚度为约650mm的碳钢材料级层和各自厚度为4～35mm(例如各自约25mm)的两个腐蚀防护层8、9。钻孔10通过管板7沿其整个厚度延伸。在钻孔10中，***套管11。套管11也由奥氏体-铁素体双相不锈钢级制成并通过焊接连接12与各个腐蚀防护层连接。各个管束5、6的U形管50、60，至少其端部，与从管板7沿朝向池式反应器1的壳的方向延伸的套管11的端部连接(参见图3)。在各个U形管50、60连接至各个套管11的端部后，管50、60的腿部，即管的远离管50、60的U形部的端部与各个套管11成一线。换言之，在各个U形管50、60连接至各个套管11的端部后，U形管50、60和套管11从连接处沿相反的方向延伸。
管板和热交换器组件2通过本发明方法制造。参照图2和图3，将描述该方法。
管板7由碳钢材料级制造并在其两个表面上设置有腐蚀防护层8、9。孔10设置成穿过管板7的整个厚度。将长度为250～750mm的套管11***钻孔10中，使得套管11的两个套管端部11a、11b从各个腐蚀防护层8、9的外表面开始远离管板7而延伸。防护层8、9以及套管11由奥氏体-铁素体双相不锈钢级制造。优选地，奥氏体-铁素体双相不锈钢级中铬含量为26～35重量％且镍含量为3～10重量％，以提供所需的防腐蚀特性。将套管11密封焊接至各个腐蚀防护层的外表面，如图2和图3中清晰可见。因为套管11的相反两端部仅从管板7的外表面延伸数厘米，可以容易地设置套管11与管板7之间的密封焊接连接12。归根结底，各个束5、6的各个U形管50、60不设置为邻近管板7。
在将套管11密封焊接至管板7的各个外层8、9之后，各个管束5、6的U形管50、60，至少其端部，焊接至套管11的各个端部，例如通过内孔焊接13的方式(参见图3)。因此，U形管50、60的端部位靠于套管端部，以使各个端部相互邻接。
在制造管板和热交换器组件2的过程中，管板7可以设置有泄漏检测***。泄漏检测***可以包括至少设置在管板7管侧上设置的腐蚀防护层8下面的泄漏检测槽14(参见图2和图3)。泄漏检测槽14适当地与泄漏检测器例如氨检测器(未示出)连接。在密封焊接连接12泄漏时，检测器通过检测因工序介质的分解而形成的氨来检测腐蚀性工序介质的存在。
由于腐蚀防护层8、9和套管11，防止管板7的碳钢材料级部件与使用时存在于管板7的壳侧和管侧的腐蚀性工序介质接触(参见图1)。
尽管本发明的示例说明的实施方式在以上部分地参照附图进行了描述，应该理解的是，本发明不限于这些实施方式。根据对附图、公开内容和所附权利要求的研究，对所公开实施方式的变动可以被本领域技术人员在实施要求保护的发明时所理解并实现。
贯穿本说明书，“一个实施方式”或“实施方式”是指，结合实施方式所描述的特定特征、结构或特性包括在本发明的至少一个实施方式中。因此，贯穿说明书，短语“在一个实施方式中”或“在实施方式中”在多个地方的出现并不必然地述及同一的实施方式。此外，应该注意到，一个或更多个实施方式的特定特征、结构或特性可以以任何合适的方式进行组合，以形成新的没有明确描述的实施方式。

Claims (16)

1.一种用于壳管式热交换器的管板和热交换器组件的制造方法，所述壳管式热交换器用于由氨和二氧化碳制备尿素的装置中，例如为池式反应器或池式冷凝器，其中所述方法包括：
由碳钢材料级制造所述管板并对所述管板在其壳侧和管侧设置奥氏体-铁素体双相不锈钢级腐蚀防护层，其中所述热交换器包括至少一个奥氏体-铁素体双相不锈钢级U形管；
通过所述管板***至少两个奥氏体-铁素体双相不锈钢级套管，使得所述套管的两端沿远离所述管板的方向延伸；
将所述套管，至少其相反两端，至少连接至所述管板的防护层；
将所述至少一个U形管的两端连接至所述套管的各个端部。
2.根据权利要求1所述的方法，其中所述防护层由铬含量为26～35重量％且镍含量为3～10重量％的奥氏体-铁素体双相不锈钢级所形成。
3.根据权利要求1或2所述的方法，其中所述套管由铬含量为26～35重量％且镍含量为3～10重量％的奥氏体-铁素体双相不锈钢级所制得。
4.根据前述权利要求中任一项所述的方法，其中所述管板的厚度为约200～700mm，使得在使用时可以耐受所述管板的壳侧与管侧之间的普遍压力差。
5.根据前述权利要求中任一项所述的方法，其中所述套管在所述管板的两侧至少密封焊接至所述管板上设置的防护层，以避免腐蚀性工序介质进入所述套管与各个碳钢管钻孔之间的裂隙。
6.根据前述权利要求中任一项所述的方法，其中各个U形管束的管例如通过内孔焊接而焊接至各个所述套管。
7.根据前述权利要求中任一项所述的方法，其中所述方法包括将第二热交换器连接至所述管板，其中所述第二热交换器包括基本上U形的管束。
8.根据前述权利要求中任一项所述的方法，其中所述方法包括对含有所述腐蚀防护层的管板设置用于容纳各个所述套管的钻孔，其中所述方法包括将所述套管***到各个所述钻孔中，以保护碳钢材料级的钻孔表面免受所述腐蚀性工序介质。
9.根据前述权利要求中任一项所述的方法，其中所述管板设置有泄漏检测***。
10.根据权利要求9所述的方法，其中所述泄漏检测***可操作地连接至所述套管与各个管钻孔之间的裂隙以及泄漏检测器例如氨检测器。
11.一种用于壳管式池式反应器或池式冷凝器的管板和热交换器组件，其配置成在所述反应器或冷凝器的壳侧中容纳的第一工序介质与经由所述管板延伸并至少部分地在所述反应器或冷凝器的壳侧延伸的热交换器中容纳的第二工序介质之间进行热量交换，所述组件优选地通过使用根据前述权利要求中任一项所述的方法制造，其中所述管板包括碳钢材料级并在其两侧设置有奥氏体-铁素体双相不锈钢级腐蚀防护层，其中所述热交换器包括至少一个奥氏体-铁素体双相不锈钢级U形管，其中至少两个套管通过所述管板延伸，所述套管，至少其相反两端，连接至各个所述腐蚀防护层，并且其中所述U形管，至少其两端，连接至各个套管端部。
12.根据权利要求11所述的管板和热交换器组件，其中所述组件的热交换器包括第一和第二U形管束。
13.根据权利要求12所述的管板和热交换器组件，其中所述管板包括用于容纳各个U束的管的钻孔，其中防护套管经由各个所述钻孔延伸，以在使用时避免所述套管与所述钻孔之间的腐蚀。
14.根据权利要求11～13中任一项所述的管板和热交换器组件，其中设置在所述管板上的防护层和/或设置在所述钻孔中的套管由铬含量为26～35重量％且镍含量为3～10重量％的奥氏体-铁素体双相不锈钢级制得。
15.根据权利要求11～14中任一项所述的管板和热交换器组件，其中所述管板设置有泄漏检测***。
16.一种池式反应器或池式冷凝器，优选为水平池式反应器或池式冷凝器，至少包括根据权利要求11～15中任一项所述的具有第一和第二U束的管板和热交换器组件。
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US20150086440A1 (en) 2015-03-26
AR090886A1 (es) 2014-12-10
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PE20150141A1 (es) 2015-02-24
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