Structural Integrity Analysis of Two Over-Temperature Methanation Furnaces
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TECHNICAL ARTICLE—PEER-REVIEWED
Structural Integrity Analysis of Two Over-Temperature Methanation Furnaces Ming Zhang . Weiqiang Wang . Pengfei Wang
Submitted: 13 March 2018 / in revised form: 7 December 2018 / Published online: 24 January 2019 Ó ASM International 2019
Abstract Two methanation furnaces each had two overtemperature faults. The shell deformation degree, hydrogen cracking, and the microstructure and property of the shell material were analyzed through on-site inspection and simulation experiments. Considering the effects of pearlite spheroidization, the deterioration limit of the shell material was estimated. Strength checks of the two over-temperature methanation furnaces were conducted. The analyses revealed that the methanation furnaces basically met the requirements of subsequent safe operation, and relevant opening reinforcements were suggested. Keywords Methanation furnace Over-temperature Material deterioration Strength check Opening reinforcement
Introduction The methanation furnace is the key component of large synthetic ammonia equipment, and its role is to transform the CO and CO2 remaining in the medium gas into methane M. Zhang (&) School of Mechanical and Automotive Engineering, Qilu University of Technology (Shandong Academy of Sciences), 3501 Daxue Road, Jinan 250353, China e-mail: [email protected] W. Wang P. Wang School of Mechanical Engineering, Shandong University, 17923 Jingshi Road, Jinan 250061, China W. Wang P. Wang Engineering and Technology Research Center for Special Equipment Safety of Shandong Province, 17923 Jingshi Road, Jinan 250061, China
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to prevent the catalyst in the ammonia converter from being poisoned, and thus not working. The reactions of CO and CO2 in a methanation furnace are strong exothermic reactions, which result in a significant temperature rise. The content of CO and CO2 in the medium gas directly affects the temperature of the catalyst bed in methanation furnaces [1, 2]. The main parameters of two identical methanation furnaces designated R08-22 and R1401 are as follows: The design pressure is 2.2 MPa, the maximum working pressure is 2.0 MPa, the design temperature is 400 °C, the medium gas contains H2, N2, CO, CO2, O2, and CH4, the inner diameter is 1200 mm, the wall thickness is 20 mm, the total height is 8145 mm, and the shell material is 15CrMoR. Each methanation furnace had two overtemperature faults in service. R08-22’s over-temperature fault occurred on June 28, 2012. The maximum temperature was 440 °C, and the duration above 300 °C was about 40 min. R08-22 had a second over-temperature fault on July 26, 2012. The maximum temperature was 600 °C, and the duration above 300 °C was about 80 min. R1401 also had two over-temperature faults. R1401 first had an overtemperature fault on April 22, 2012. The maximum temperature was 530 °C, and the duration above 300 °C was about 50 min. R1401 had a second over-temperature fault on April 30, 2012. The maximum temperature was 871 °C, and the duration above 300 °C was about 3 h. Over-te
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