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Process Puzzler: placate capricious controller
This Month's Puzzle
We use a heat exchanger, carbon steel tube condenser coil in our spray tower. During normal operation of 100 psig at 150 ° F. The treated water-cooled 45 ° F running on the side of the tube. The shell side handles metal chlorides, for example, FeCl2, and TiCl4 VCl4. These chlorides condensed to form liquid and evaporate to form gases. A strong chlorine corrosion and erosion has been the reason why Spiral heat exchanger was chosen over a shell and tube. Chlorine is generally dry, but sometimes caused the points of the upstream water exchangers corrosion. One engineer pushes idea of cladding type 304L stainless steel with an alloy of nickel. Share this promotional test to improve service life. A concern is how to bend the tube affect the layer. How can we ensure that our operations manager nervous that this coating work? Does any other ideas? Keep in mind to replace the heat exchangers in a different style, it requires a major change in the pipeline around the units.
CHANGE EXCHANGER
Try searching in a hybrid heat exchanger that integrates the strengths of both plates and frame and shell and tube exchangers without its weaknesses. It is a good compromise between cost and performance. My experience is that as a happy customer exchanger built in France. Its design aims to provide the best cost cycle of life for our situation.
LOOK AT LINING TANTALUM
I do not consider all available options. Coating is a dangerous option. May change duplex steel tube would be a better option. Another is try to find a consultant. It is a manufacturer in Germany, which is "tantalined" equipment the manufacture of heat exchangers spiral carbon steel pipe line. This last point might be your best option.
EXPANSION WATCH THERMAL
We used copper-nickel tubes for applications such as heat transfer. The veneer can be applied after the hose is bent, but must have careful with the amount of expansion to reach the temperature variation.
Extensive testing
A few years ago, an engineer at the plant in Grimsby, United Kingdom, looked to our chlorinators tantalum coating. The reactors are large brick-lined. Inside, the chlorine comes in contact with carbon monoxide carbon from the combustion of coke, chlorine reacts with the mineral for chlorine, the production of titanium tetrachloride, TiCl4. Drawing water and hydrogen chloride (HCl) of the chlorine is recycled, a constant problem. Unfortunately, the brick and steel hull carbon chlorination is quickly attacked the area of moisture penetration – where water to condense and HCl. These chlorinators are water cooled by the falling film heat transfer, it is difficult to detect progression of the shell. This development is a significant risk to the environment.
Tantalum Engineer thought, the only material is not susceptible to chloride attack wet work. He was looking for chlorination test coupons in the recovery comes. These coupons include welds and other features.
With the heat exchanger, the combination of the welds and it becomes a challenge to offer coupons. I suggest you install a coupon that includes a plate welds in crisis not unlike the process of forming an elbow. Test In a large bowl, if possible, do not affect the chlorination process. If the coupon survives, his idea of coating can be successful. The next test is to verify the process manufacturing. A very good test for the identification of cracks in metal tubes is a test of dye penetration. It is a destructive test that shows gaps in the interstitial areas between the crystals in metals nickel alloys and other similar means of sonography are not identified. Use this method to validate the manufacturing process.
It would be very easy to grow timid about this request. When you look at our heating coil coating, which operated about 1000 ° C, it was decided. We felt it was too risky and decided to go to coils of high nickel alloy in place.
In March Puzzle
The administration wants to increase our production process by changing the batch mode of polymers. Now some of the monomers acrylics will in most solvents and other ingredients. Then, the monomer is added slowly until the reactor is elevated about 55%. Instead, the administration wants to increase the maximum level in about 65% and increase the final concentration of polymer of about 2%. Reaction is highly exothermic chilled water cooling ensures double envelope. At the top of the reactor coolant horizontal shell and tube using a water cooling tower evaporates the solvent capture. The agitation consists of a single axial rotor and tank baffles to reflect reduced viscosity above 5000 cP. To achieve the production target, it was suggested that we add all the monomers at a time, laboratory tests have shown that it can work, but our current approach seems more secure. Likes management plan and want to put them into practice immediately. Our production engineer is a bit nervous – Should we worry? How to address this problem? Are there changes in the process necessary? What do you think?
And, of course, if you have a process problem you'd like to ask our readers, send it and we are happy to consider publication.
