EP4134614A1 - Transferleitungswärmetauscher mit thermischer sprühbeschichtung - Google Patents
Transferleitungswärmetauscher mit thermischer sprühbeschichtung Download PDFInfo
- Publication number
- EP4134614A1 EP4134614A1 EP21190831.4A EP21190831A EP4134614A1 EP 4134614 A1 EP4134614 A1 EP 4134614A1 EP 21190831 A EP21190831 A EP 21190831A EP 4134614 A1 EP4134614 A1 EP 4134614A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- transfer line
- thermal spray
- spray coating
- line exchanger
- cooling
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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- 238000005507 spraying Methods 0.000 title claims abstract description 84
- 238000012546 transfer Methods 0.000 title claims abstract description 80
- 238000001816 cooling Methods 0.000 claims abstract description 80
- 238000000034 method Methods 0.000 claims abstract description 59
- 239000000463 material Substances 0.000 claims abstract description 33
- 239000007921 spray Substances 0.000 claims abstract description 18
- 229910003470 tongbaite Inorganic materials 0.000 claims abstract description 18
- 238000012423 maintenance Methods 0.000 claims abstract description 16
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 14
- 239000000956 alloy Substances 0.000 claims abstract description 14
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910001120 nichrome Inorganic materials 0.000 claims abstract description 13
- 230000008569 process Effects 0.000 claims description 40
- 238000000576 coating method Methods 0.000 claims description 22
- 239000011248 coating agent Substances 0.000 claims description 18
- 238000005336 cracking Methods 0.000 claims description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 15
- 238000004519 manufacturing process Methods 0.000 claims description 12
- 150000001336 alkenes Chemical class 0.000 claims description 9
- 229930195733 hydrocarbon Natural products 0.000 claims description 8
- 150000002430 hydrocarbons Chemical class 0.000 claims description 8
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 7
- 239000005977 Ethylene Substances 0.000 claims description 7
- 238000012544 monitoring process Methods 0.000 claims description 7
- 238000002485 combustion reaction Methods 0.000 claims description 5
- 238000010891 electric arc Methods 0.000 claims description 5
- 238000010285 flame spraying Methods 0.000 claims description 5
- 239000000446 fuel Substances 0.000 claims description 5
- 238000007750 plasma spraying Methods 0.000 claims description 5
- 238000010290 vacuum plasma spraying Methods 0.000 claims description 5
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 4
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 claims description 4
- 230000001066 destructive effect Effects 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 238000002604 ultrasonography Methods 0.000 claims description 3
- 239000010410 layer Substances 0.000 description 19
- 230000003628 erosive effect Effects 0.000 description 15
- 230000008439 repair process Effects 0.000 description 9
- 239000000571 coke Substances 0.000 description 8
- 239000002245 particle Substances 0.000 description 6
- 239000000919 ceramic Substances 0.000 description 5
- 230000007547 defect Effects 0.000 description 5
- 239000011241 protective layer Substances 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 3
- 239000002826 coolant Substances 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 238000005235 decoking Methods 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- 238000001514 detection method Methods 0.000 description 3
- 230000000670 limiting effect Effects 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 230000002829 reductive effect Effects 0.000 description 3
- 238000004227 thermal cracking Methods 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- 229910000975 Carbon steel Inorganic materials 0.000 description 2
- 239000012790 adhesive layer Substances 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000010962 carbon steel Substances 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 229910052750 molybdenum Inorganic materials 0.000 description 2
- 239000011733 molybdenum Substances 0.000 description 2
- 210000003739 neck Anatomy 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- OTMSDBZUPAUEDD-UHFFFAOYSA-N Ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000002480 mineral oil Substances 0.000 description 1
- 235000010446 mineral oil Nutrition 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 230000036961 partial effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 238000010517 secondary reaction Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F19/00—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers
- F28F19/02—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers by using coatings, e.g. vitreous or enamel coatings
- F28F19/06—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers by using coatings, e.g. vitreous or enamel coatings of metal
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
- C10G9/34—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts
- C10G9/36—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts with heated gases or vapours
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/131—Wire arc spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F19/00—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers
- F28F19/02—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers by using coatings, e.g. vitreous or enamel coatings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F27/00—Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/20—C2-C4 olefins
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0022—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for chemical reactors
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0059—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for petrochemical plants
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0075—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for syngas or cracked gas cooling systems
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2265/00—Safety or protection arrangements; Arrangements for preventing malfunction
- F28F2265/16—Safety or protection arrangements; Arrangements for preventing malfunction for preventing leakage
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- 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
- 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
- F28F9/18—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
Definitions
- the present disclosure refers to transfer line exchangers with improved cooling capacity, equipped with a thermal spray coating and a method for the maintenance of transfer line exchangers with the help of a thermal spray coating.
- Ethylene is the basic feedstock in the production of plastics.
- Ethylene and other olefins such as propylene are produced by thermal cracking of hydrocarbons in pyrolysis furnaces in the presence of steam, with ethane, naphtha and other mineral oil fractions serving as the main feedstocks.
- the gas generated in the furnace usually has a temperature of around 850 to 1000 °C and is be rapidly cooled after leaving the reaction zone of the furnace to prevent secondary reactions and to stabilize the gas composition.
- this rapid cooling of the cracked gas is achieved by transfer line exchangers (TLE).
- TLE transfer line exchangers
- the high-temperature gas is cooled down by passing the gas through cooling pipes which are surrounded by a cooling medium, thus employing the principle of heat transfer.
- Transfer line exchangers operate under very harsh conditions. Apart from the extreme temperatures, the gas entering the transfer line exchangers may contains coke particles which cause two major problems in traditional heat exchangers: erosion and fouling. A third potential problem is corrosion on the water side of the exchanger. In light of these problems, careful monitoring of the equipment, in particular the cooling tubes of the transfer line exchanger, is mandatory as faulty tubes bear the risk of furnace failure. The state of the transfer line exchanger may be controlled by regularly measuring the wall thickness of the tubes. Affected tube sections are replaced by de-assembling of the heat exchanger, replacing the affected tube and re-assembling the exchanger, a process which is not only time consuming but due to the size of the equipment also a safety hazard. Further, any repairs also require extended downtimes of the cracking furnace which in turn can affect the production performance of the entire cracker.
- EP 1 331 465 relates to transfer line exchangers used for cooling gaseous output from furnaces of ethylene production where high pressure water vapor is produced outside of tubes, with a shell under pressure, and with an inlet tube plate separating the inside of the shell from an inlet manifold of the fluid to be cooled, with the tube plate having, on the manifold side, an anti-erosion layer and the tube plate having passages in it for communication with the interior of the tubes of the tube nest and around each passage, on the opposite side of the tube plate relative to the manifold, there being a projecting neck on which is welded a corresponding tube of the nest, the tube plate being made of steel lightly alloyed with molybdenum or chromo-molybdenum and the anti-erosion layer being made of a weld deposit of Nickel-Chrome Alloy 625, harder than the tube plate, and the tubes being welded on an "internal bore welding" at a distance from the plate surface which is approximately equal to at least the thickness of the
- US 7,237,601 describes a heat exchanger for cooling hot gas that contains solid particles, comprising a casing; respective tube plates disposed at ends of the casing, heat exchanger tubes through which said hot gas flows, wherein said heat exchanger tubes are surrounded by said casing, and wherein ends of said heat exchanger tubes are welded into bores of said tube plates via weld seams; and a protective layer that coats an end face of that one of said tube plates disposed on a gas inlet side, an inner wall of said bores, said weld seams, and an inlet region of said heat exchanger tubes, and wherein said protective layer comprises a metallic adhesive layer, a high temperature and erosion resistant ceramic layer, and a high temperature and erosion resistant metal layer disposed between said adhesive layer and said ceramic layer.
- the ceramic top layer does not allow repair by welding so that extensive replacement of the coated parts is required.
- WO 2007/006446 refers to a shell-and-tube heat exchanger equipped with a tube plate lining which is resistant to wear for use in thermal cracking equipment comprising cooling tubes through which the gas to be cooled is circulated, each tube being secured by a tube plate at both ends of the tube and enclosed in a casing through which a coolant material is circulated; the surface of the tube plate on the gas inlet side which is impacted by gas as it enters the shell-and-tube heat exchanger is faced, at least partially, by a protective layer; the protective layer comprising sleeves with faces; the sleeve faces being aligned side-to-side and end-to-end at the outer edges; the sleeves being at least partially inserted into the cooling tube ends; and the sleeves being made from a heat resistant metallic material.
- the proposed solution increases rather than shortens the time required for repairs as the sleeves have to be removed before any affected tube sections can be replaced.
- the present disclosure provides a transfer line exchanger with cooling tubes through which the gas to be cooled is processed, wherein the inner surface of each cooling tube is at least partially equipped with a thermal spray coating.
- the thermal spray coating is obtained from a spray material formed of Cr 3 C 2 and a NiCr alloy.
- the spray coating material comprises at least 60 wt.-%, preferably at least 70 wt.-% of Cr 3 C 2 , based on the total weight of the spray material.
- the gas inlet side of each cooling tube which is impacted by gas as it enters the cooling tube is equipped with the thermal spray coating.
- the thermal spray coating extends at least 100 mm, preferably at least 150 mm, more preferably at least 200 mm, especially at least 500 mm into the cooling tube from the gas inlet side.
- the thermal spray coating covers at least 0,5% of the inner surface of the cooling tube from the gas inlet side, preferably at least 2%, more preferably at least 5%, based on the complete inner surface of the cooling tube.
- the thermal spray coating has a thickness of 0.1 to 0.5 mm, more preferably 0.15 to 0.3 mm.
- the thermal spray coating is directly applied on-site to the surface of the cooling tube.
- the thermal spray coating is weldable coating, preferably a single layer coating.
- the thermal spray coating does not contain any layers formed of a different material than the thermal spray material, preferably no different material than Cr3C2/NiCr alloy.
- the thermal spray coating is applied by HVOF (High Velocity Oxy-Fuel Spraying), Combustion Flame Spraying, Plasma Spraying, Vacuum Plasma Spraying or Two-Wire Electric Arc Spraying, preferably HVOF.
- HVOF High Velocity Oxy-Fuel Spraying
- Combustion Flame Spraying Plasma Spraying
- Vacuum Plasma Spraying Vacuum Plasma Spraying
- Two-Wire Electric Arc Spraying preferably HVOF.
- the cooling tube is made of heat-resistant carbon steel.
- the cooling tubes are secured by a tube plate at both ends of the tubes and the tube plate at the gas inlet side is equipped with a thermal spray coating, preferably a thermal spray coating obtained from a thermal spray material formed of Cr 3 C 2 and a NiCr alloy.
- a further object of the present disclosure is an apparatus for the production of olefins, in particular ethylene and propylene, comprising the transfer line exchanger of the present disclosure.
- a still further object of the present disclosure is a process for the cracking of hydrocarbons, in particular for the production of olefins, comprising: (i) feeding a feedstock of hydrocarbons into a cracking coil located inside a thermal reactor; (ii) heating the feedstock to obtain a cracking gas; and (iii) introducing the cracking gas into a transfer line exchanger for cooling, wherein the transfer line exchanger is a transfer line exchanger of the present disclosure.
- the present disclosure refers to a process for the maintenance of a transfer line exchanger comprising the steps of: (i) detecting faults on the inner surface of the cooling tubes; and (ii) applying a thermal spray coating to the faults.
- detection of faults is conducted by measuring the wall thickness of the cooling tube on the process side, preferably via non-destructive methods, in particular via ultrasound.
- the thermal spray coating is applied by HVOF (High Velocity Oxy-Fuel Spraying), Combustion Flame Spraying, Plasma Spraying, Vacuum Plasma Spraying or Two-Wire Electric Arc Spraying, preferably by HVOF.
- HVOF High Velocity Oxy-Fuel Spraying
- Combustion Flame Spraying Plasma Spraying
- Vacuum Plasma Spraying Vacuum Plasma Spraying
- Two-Wire Electric Arc Spraying preferably by HVOF.
- the thermal spray coating is obtained from a spray material formed of Cr 3 C 2 and a NiCr alloy.
- the spray coating material comprises at least 60 wt.-%, preferably at least 70 wt.-% of Cr 3 C 2 , based on the total weight of the spray material.
- Another object of the present disclosure is a method for monitoring the water side surface of cooling tubes of transfer line exchangers by measuring the wall thickness of the cooling tubes from the process side of the tubes.
- a transfer line exchanger for application in thermal cracking equipment which addresses wear protection of the cooling tubes while at the same providing a solution that does not interfere with established safety measures or negatively impacts the cooling capacity of the transfer line exchanger.
- thermal spray coating of the transfer line exchanger of the present disclosure is compatible with certified measurement procedures for determining the wall thickness of the cooling tubes, while at the same time limiting coke deposition in the tubes, thus reducing the risk of fouling and the need for decoking of the equipment.
- thermal spray coating also resulted in an improved cooling efficiency, resulting in a lower temperature increase of the cracking gas passing through the transfer line exchanger during olefin production.
- the thermal spray coating is in particular chosen with regard to its wear protection properties. Accordingly, preference is given to materials with a high wear resistance, in particular Nickel-Chromcarbides.
- the thermal spray coating is obtained from a spray material formed of Cr 3 C 2 and a NiCr alloy.
- the spray coating material comprises at least 60 wt.-%, preferably at least 70 wt.-% of Cr 3 C 2 , based on the total weight of the spray material.
- the thermal spray coating is in particular intended to protect the gas inlet site of the cooling tubes against erosion caused by coke particles present in the gas stream. Therefore, an embodiment is preferred, wherein the gas inlet side of each cooling tube, which is impacted by gas as it enters the cooling tube, is equipped with the thermal spray coating.
- the thermal spray coating extends at least 100 mm, preferably at least 150 mm, more preferably at least 200 mm, especially at least 500 mm into the cooling tube from the gas inlet side.
- the entire inner surface of the cooling tube is covered with a thermal spray coating.
- the thermal spray coating covers at least 0,5% of the inner surface of the cooling tube from the gas inlet side, preferably at least 2%, more preferably at least 5%, based on the complete inner surface of the cooling tube.
- the thermal spray coating should provide sufficient protection against erosion without affecting the cooling of the gas stream.
- a thickness of the thermal spray coating of no more than 0.7 mm and no less than 0.05 mm was found to be advantageous.
- the thermal spray coating thus has a thickness of 0.1 to 0.5 mm, more preferably 0.15 to 0.3 mm.
- thermal spray coating can be directly applied to the surface of the cooling tube. Therefore, in a preferred embodiment, the thermal spray coating is directly applied to the surface of the cooling tube, preferably on-site. In a further preferred embodiment, the thermal spray coating is a weldable coating, preferably a single layer coating. In a particular preferred embodiment, the thermal spray coating does not contain any layers formed of a different material than the thermal spray material, preferably no different material than Cr 3 C 2 /NiCr alloy.
- thermal spray coating is applied by HVOF (High Velocity Oxy-Fuel Spraying), Combustion Flame Spraying, Plasma Spraying, Vacuum Plasma Spraying or Two-Wire Electric Arc Spraying, preferably HVOF, a technique which does not require stationary equipment and can also be easily used in tight spaces.
- HVOF High Velocity Oxy-Fuel Spraying
- the transfer line exchanger of the present disclosure is particularly designed for use in cracker applications where rapid cooling of the cracked gas is necessary. Accordingly, the material of the cooling tubes is preferably selected for its efficient heat transfer while at the same being able to withstand the harsh process conditions. Therefore, in a preferred embodiment, the cooling tube is made of heat-resistant carbon steel.
- each cooling tube of the transfer line exchanger is secured by a tube plate at both ends of the tube.
- the plate at the gas inlet side is thus also in contact with the hot gas entering the cooling tubes and also prone to erosion and fouling.
- each cooling tube is secured by a tube plate at both ends of the tube and the tube plate at the gas inlet side is equipped with a thermal spray coating, preferably a thermal spray coating obtained from a thermal spray material formed of Cr 3 C 2 and a NiCr alloy.
- the transfer line exchanger of the present disclosure is in particular designed for application in the production of olefins by cracking. Therefore, a further object of the present disclosure is an apparatus for the production of olefins, in particular ethylene and propylene, comprising the transfer line exchanger of the present disclosure.
- a further object of the present disclosure is a process for the cracking of hydrocarbons, in particular for the production of olefins, comprising: (i) feeding a feedstock of hydrocarbons into a cracking coil located inside a thermal reactor; (ii) heating the feedstock to obtain a cracking gas; and (iii) introducing the cracking gas into a transfer line exchanger for cooling, wherein the transfer line exchanger is a transfer line exchanger of the present disclosure.
- the gas entering the transfer line exchanger has a temperature of 750 to 1000 °C, preferably 800 to 950 °C.
- a further object of the present disclosure is therefore the use of a thermal spray coating in the erosion protection of transfer line exchangers, in particular the use of a thermal spray coating obtained from a coating material formed of Cr 3 C 2 and NiCr alloy, especially applied to the gas inlet area of the cooling tubes.
- a further object of the present disclosure is a process for the maintenance of a transfer line exchanger comprising the steps of: (i) detecting faults on the inner surface of the cooling tubes; and (ii) applying a thermal spray coating to the faults.
- Detection of the faults is preferably conducted by measuring the wall thickness of the cooling tube, preferably via non-destructive methods, in particular via ultrasound.
- the process of the present disclosure can in particular be applied for repairing any faults due to erosion on the inside of the cooling tubes. It was surprisingly found that the process of maintenance of the present disclosure could be applied to transfer line exchangers which are already equipped with a thermal spray coating as well as to common transfer line exchangers without any wear protection. Further, the process was found to offer a fast and cost-effective way of ensuring safe operation of the transfer line exchanger. In contrast to measures suggested by others, the coating did not interfere with the detection of any faults on the water side of the tubes, which under normal circumstances are not accessible and are thus monitored by way of measuring the wall thickness of the cooling tubes in the process side. Rather, the faults could still be detected even after the coating was put in place inside the tube. Also, tedious disassembly of the transfer line exchanger and partial or complete exchange of tubes could be reduced.
- the maintenance process of the present disclosure is in particular intended for on-site operation.
- suitable means had to be found to also apply the thermal spray coating directly on-site, as needed.
- the coating is preferably applied by HVOF (High Velocity Oxy-Fuel Spraying), Combustion Flame Spraying, Plasma Spraying, Vacuum Plasma Spraying or Two-Wire Electric Arc Spraying.
- HVOF was found to be the most suitable technique which could also be adapted to the limited space inside the cooling tube. Therefore, in a preferred embodiment, the thermal spray coating is applied by HVOF.
- the thermal spray coating is obtained from a spray material formed of Cr 3 C 2 and a NiCr alloy.
- the spray coating material comprises at least 60 wt.-%, preferably at least 70 wt.-% of Cr 3 C 2 , based on the total weight of the spray material. It was surprisingly found that the material not only provided sufficient protection against erosion but also limits the deposition of coke. Further, the material was found to be easily reparable by either welding or applying a new coat of the thermal spray material.
- a further object of the present disclosure is a method for monitoring the water side surface of cooling tubes of transfer line exchangers by measuring the wall thickness from the cooling tubes on the process side of the tubes.
- the process side depicts the inside of the tubes which comes into contact with the cracked gas while the water side refers to the outside of the tubes which in contact with the cooling medium, usually water.
- any deviation of the wall thickness, especially a decrease, compared to a pre-set reference value is defined as a fault or defect within the course of the present disclosure. Any defects on the water side of the cooling tube will impact the wall thickness of the cooling tubes and thus be easily detected by the method of the present disclosure.
- the method of the present disclosure for monitoring the water side of transfer line exchangers is combined with the process of the present disclosure for the maintenance of a transfer line exchanger
- the process of the present disclosure provides the means to monitor any impact of corrosion which is made impossible by some of the wear protection means usually taken such as multilayer coatings or the use of protection sleeves.
- the present disclosure allows for convenient maintenance of cooling tubes which suffer due to erosion on the inside of the tubes, any defects on the outside of the tubes, namely the water side, may need to be repaired by replacing the affected section of the tube.
- the concept of the present disclosure to apply a thermal spray coating to the inner surface of the tubes does not interfere with the replacement process. Even if the tube is supplied with a thermal spray coating, the tube may still be cut and the replacement section welded to the remaining tube which was found to be impossible, e.g. if multilayer coatings were used as wear protection, in particular those comprising ceramic layers.
- the process and the transfer line exchanger of the present disclosure may therefore be conveniently incorporated into existing crackers.
- Figure 1 shows a flow chart of a common maintenance process of transfer line exchangers in crackers.
- the inlet cone from the transfer line exchanger is removed and the wall thickness on the inside of the cooling tube is determined.
- the tubes are removed, the broken sections replaced and the transfer line exchanger re-assembled. In particular removal of the tubes is difficult due to the size and weight of the tubes and accidents regularly occur.
- Figure 2 shows a flow chart of the maintenance process of the present disclosure.
- the wall thickness of the tubes is measured. If the determined value is found to be below a pre-set minimum threshold value, a thermal spray coating is applied either to the affected area if the transfer line exchanger is already equipped with a thermal spray coating, or a larger section of the tube is equipped with the coating should no coating have been present.
- the time for repair is also considerably shortened, resulting in a more effective operation of the cracker.
- FIG. 3 schematically shows the concept of the present disclosure for monitoring and maintaining cooling tubes of transfer line exchanger.
- a measuring device (3) is placed inside a cooling tube of transfer line exchanger and the wall thickness (1) of the tube is measured.
- the measuring device is inserted from the gas inlet side (4) of the tube. If any defects, i.e. a decrease in the wall thickness, are detected on the inside of the tube, the thermal spray coating (2) can easily be renewed. At the same time, also defects on the outside of the tube can be detected this way which can then be repaired by replacing the affected section of the tube.
- Table 1 summarizes some of the advantages of the present disclosure in comparison with commonly used wear protection techniques.
- the present disclosure is compared to concepts described in other references such the use of heat sleeves as described in WO 2007/006446 and a 3-layer coating as described in US 7,237,601 .
- the time needed for repairs may be significantly shortened by the present disclosure and the risk of furnace failure reduced.
- transfer line exchangers equipped in accordance with the present disclosure showed a reduced tendency for coke deposition.
- the thermal spray coating also leads to an improvement of the cooling efficiency of the TLE.
- Table 2 Average Temperature after start-up Average Outlet Temperature during production run 20 days 30 days 40 days TLE inlet, °C TLE outlet, °C TLE outlet, °C Temp. increase, °C TLE outlet, °C Temp. increase, °C TLE outlet, °C Temp. increase, °C TLE outlet, °C Temp. increase, °C Without coating 803 330 363 33 372 42 376 46 With coating 803 330 357 27 363 33 364 34
- compositions and methods are described in broader terms of “having”, “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. Use of the term “optionally” with respect to any element of a claim means that the element is present, or alternatively, the element is not present, both alternatives being within the scope of the claim.
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- Mechanical Engineering (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Thermal Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- General Chemical & Material Sciences (AREA)
- Coating By Spraying Or Casting (AREA)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP21190831.4A EP4134614A1 (de) | 2021-08-11 | 2021-08-11 | Transferleitungswärmetauscher mit thermischer sprühbeschichtung |
EP22761559.8A EP4337907A1 (de) | 2021-08-11 | 2022-08-10 | Transferleitungstauscher mit thermischer spritzbeschichtung |
PCT/EP2022/072399 WO2023017060A1 (en) | 2021-08-11 | 2022-08-10 | Transfer line exchanger with thermal spray coating |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP21190831.4A EP4134614A1 (de) | 2021-08-11 | 2021-08-11 | Transferleitungswärmetauscher mit thermischer sprühbeschichtung |
Publications (1)
Publication Number | Publication Date |
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EP4134614A1 true EP4134614A1 (de) | 2023-02-15 |
Family
ID=77300845
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP21190831.4A Withdrawn EP4134614A1 (de) | 2021-08-11 | 2021-08-11 | Transferleitungswärmetauscher mit thermischer sprühbeschichtung |
EP22761559.8A Pending EP4337907A1 (de) | 2021-08-11 | 2022-08-10 | Transferleitungstauscher mit thermischer spritzbeschichtung |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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EP22761559.8A Pending EP4337907A1 (de) | 2021-08-11 | 2022-08-10 | Transferleitungstauscher mit thermischer spritzbeschichtung |
Country Status (2)
Country | Link |
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EP (2) | EP4134614A1 (de) |
WO (1) | WO2023017060A1 (de) |
Citations (12)
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US4075376A (en) * | 1975-04-11 | 1978-02-21 | Eutectic Corporation | Boiler tube coating and method for applying the same |
US6074713A (en) * | 1995-04-24 | 2000-06-13 | Corning Incorporated | Preventing carbon deposits on metal |
EP1331465A2 (de) | 2002-01-24 | 2003-07-30 | OLMI S.p.A. | Wärmetauscher mit dünner Endplatte |
US20060131005A1 (en) * | 2004-12-21 | 2006-06-22 | Borsig Gmbh | Heat exchanger for cooling a hot gas that contains solid particles |
WO2007006446A1 (de) | 2005-07-07 | 2007-01-18 | Ruhr Oel Gmbh | Rohrbündelwärmeübertrager mit verschleissbeständiger rohrbodenauskleidung |
US20080073063A1 (en) * | 2006-06-23 | 2008-03-27 | Exxonmobil Research And Engineering Company | Reduction of fouling in heat exchangers |
US20110277888A1 (en) * | 2005-12-21 | 2011-11-17 | Exxonmobil Research And Engineering Company | Chromiun-enriched oxide containing material and preoxidation method of making the same to mitigate corrosion and fouling associated with heat transfer components |
US20130220523A1 (en) * | 2012-02-29 | 2013-08-29 | c/o Chevron Corporation | Coating compositions, applications thereof, and methods of forming |
EP2772563A1 (de) * | 2013-02-28 | 2014-09-03 | E.G.O. Elektro-Gerätebau GmbH | Verfahren zur Herstellung einer Heizeinrichtung und Heizeinrichtung |
US20180112303A1 (en) * | 2016-10-21 | 2018-04-26 | General Electric Technology Gmbh | Method for coating article and feedstock for thermal spray process |
US20190101340A1 (en) * | 2008-07-16 | 2019-04-04 | Wisconsin Alumni Research Foundation | Metal substrates including metal oxide nanoporous thin films and methods of making the same |
IT201800004154A1 (it) * | 2018-03-30 | 2019-09-30 | Galatello Adamo Gaetano | Scambiatore di calore a fascio tubiero tle privo di setti o diaframmi forati di supporto |
-
2021
- 2021-08-11 EP EP21190831.4A patent/EP4134614A1/de not_active Withdrawn
-
2022
- 2022-08-10 WO PCT/EP2022/072399 patent/WO2023017060A1/en active Application Filing
- 2022-08-10 EP EP22761559.8A patent/EP4337907A1/de active Pending
Patent Citations (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4075376A (en) * | 1975-04-11 | 1978-02-21 | Eutectic Corporation | Boiler tube coating and method for applying the same |
US6074713A (en) * | 1995-04-24 | 2000-06-13 | Corning Incorporated | Preventing carbon deposits on metal |
EP1331465A2 (de) | 2002-01-24 | 2003-07-30 | OLMI S.p.A. | Wärmetauscher mit dünner Endplatte |
US20060131005A1 (en) * | 2004-12-21 | 2006-06-22 | Borsig Gmbh | Heat exchanger for cooling a hot gas that contains solid particles |
US7237601B2 (en) | 2004-12-21 | 2007-07-03 | Borsig Gmbh | Heat exchanger for cooling a hot gas that contains solid particles |
WO2007006446A1 (de) | 2005-07-07 | 2007-01-18 | Ruhr Oel Gmbh | Rohrbündelwärmeübertrager mit verschleissbeständiger rohrbodenauskleidung |
US20110277888A1 (en) * | 2005-12-21 | 2011-11-17 | Exxonmobil Research And Engineering Company | Chromiun-enriched oxide containing material and preoxidation method of making the same to mitigate corrosion and fouling associated with heat transfer components |
US20080073063A1 (en) * | 2006-06-23 | 2008-03-27 | Exxonmobil Research And Engineering Company | Reduction of fouling in heat exchangers |
US20190101340A1 (en) * | 2008-07-16 | 2019-04-04 | Wisconsin Alumni Research Foundation | Metal substrates including metal oxide nanoporous thin films and methods of making the same |
US20130220523A1 (en) * | 2012-02-29 | 2013-08-29 | c/o Chevron Corporation | Coating compositions, applications thereof, and methods of forming |
EP2772563A1 (de) * | 2013-02-28 | 2014-09-03 | E.G.O. Elektro-Gerätebau GmbH | Verfahren zur Herstellung einer Heizeinrichtung und Heizeinrichtung |
US20180112303A1 (en) * | 2016-10-21 | 2018-04-26 | General Electric Technology Gmbh | Method for coating article and feedstock for thermal spray process |
IT201800004154A1 (it) * | 2018-03-30 | 2019-09-30 | Galatello Adamo Gaetano | Scambiatore di calore a fascio tubiero tle privo di setti o diaframmi forati di supporto |
Also Published As
Publication number | Publication date |
---|---|
EP4337907A1 (de) | 2024-03-20 |
WO2023017060A1 (en) | 2023-02-16 |
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