双纹管换热器化学清洗技术应用.doc

双纹管换热器化学清洗技术的应用双纹管换热器因具有体积小, 安装和操作方便, 换热效果好等优点被广泛应用于焦化厂生产的换热系统。济南钢铁集团总公司焦化厂(简称济钢焦化厂) 现有各种规格的双纹管换热器25 台, 在焦化的生产换热中发挥了重要作用。但双纹管换热器也存在一定的缺点, 即结垢、腐蚀、穿孔内漏时, 无法处理, 大多是一次性使用。一台160m 2 的双纹管换热器重9.7t, 价值为8 9 万元, 所以换热器因结垢堵塞而更换造成的浪费十分巨大。1995 年7 月, 济钢焦化厂回收车间洗涤系统2 台SS- 16 型双纹管换热器发生严重堵塞, 换热效果明显下降, 对生产造成很大威胁。因这两台换热器担负着从蒸氨系统送来的温度35 40的蒸氨废水, 在此与18的低温水进行热交换, 使蒸氨废水的温度必须降到25左右才能保持洗氨塔内正常的喷淋洗氨。如果蒸氨废水的温度高于28的煤气温度, 洗涤效果差, 煤气中的NH3、HCN、H2S、CO 2等杂质就清洗不下来, 那么煤气净化效果就不好, 而市民使用不合格的煤气易发生安全问题,甚至造成供煤气管道、设备的腐蚀, 发生煤气泄漏, 危及市民的生命安全。另外, 从生产角度来讲, 这道工序不合格, 将对下道洗涤煤气中的苯生产带来麻烦, 整个洗涤生产流程将发生严重的不稳定。由于2 台换热器的严重堵塞, 循环水量由65m 3/h 降为36m 3/h; 阻力由0.050.1M Pa 增加到0.5 0.6M Pa, 蒸氨废水出口温度由原来的25升至32以上, 造成洗氨生产的紊乱。为了确保生产, 决定更换2 台新双纹管换热器。原2 台双纹管换热器安装设置在洗涤泵房屋顶上, 堵塞的换热器内有大量垢物杂质, 重量比新换热器重量增加很多, 且泵房前有许多管道支架等障碍物, 吊车无法靠近, 因而吊装十分困难。后将靠边的一台换下, 但由于2 台换热器是串联使用, 堵塞问题仍没得到根本解决。对报废的换热器进行观察分析, 发现出入口处有厚5 10mm 的黑色焦油物挂结在通道壁上, 使宽20mm 的通道空间余量很小了, 为了尽快稳定生产, 经过充分的论证, 济钢焦化厂决定采用化学清洗新技术。主要清洗双纹管换热器通道内的水垢及煤焦油、软沥青等积物。2清洗程序(1) 根据堵塞情况及垢物性质, 按比例配制一定浓度的化学清洗溶液, 并不断调整各组份的添加量。(2) 配制清洗剂。选定由碳酸钠、苛性钠、渗透剂、表面活性剂、乳化剂等十几种化学品组成并配制成浓度为10% 的清洗液。(3) 清洗液入口温度为55, 出口温度为30, 可根据垢物介质的构成情况调整入口清洗液的温度。(4) 采用浸泡与循环相结合的清洗方法。一般情况需浸泡15 20h, 然后进行强制性循环6h。(5) 清洗的排除物为粘稠的黑色液体并伴有絮状焦油物, 流到地面上则结为膏状, 重量约为50 80kg。(6) 清洗到一定程度后, 打开双纹管换热器的出、入口观察焦油物清洗程度, 然后加入“洗油王”并适当调节配方, 用泵打入换热器废氨水通道内, 同时在循环水通道入口处通入蒸气进行加热, 促使焦油物最大限度的溶于“洗油王”溶液内而排出, 依次循环多遍。(7) 清洗完毕后, 进行酸洗以清除水垢。酸洗液入口温度为50, 由6% 的盐酸溶液加入适量的缓蚀剂等, 酸洗过程中有气体排出及泡沫产生, 酸洗终止时酸溶液浓度为3.5% , 并排出黑色液体。(8) 酸洗后进行碱洗中和, 加入苛性钠、碳酸钠、磷酸三钠组成的混合液体浸泡及循环6h, 直至黑色液体排尽终止。(9) 最后用清水冲洗, 直到pH 值为7, 冲洗结束。3清洗效果(1) 清洗后的双纹管换热器投入使用后, 蒸氨废水出口温度由32降至28以下, 满足了洗氨塔工艺生产的要求。(2) 循环水量由清洗前的36m 3/h 增加到46m 3/h 以上, 提高了28%。(3) 设备阻力由清洗前的0.50 0.60M Pa 降至0.25 0.30M Pa, 降低了50%。(4) 洗后的循环水量与设计指标相比, 清洗率达70.8% 以上, 基本上保证了正常生产。由于清洗效果比较明显, 我们又在济钢焦化厂蒸氨废水余热采暖站使用的SS100- 16 型双纹管换热器上应用, 使采暖循环水温度达72。应用化学清洗技术进行富氨水管道的除垢, 效果更好。该管道直径为 133mm , 后变径为 159mm 的管道, 管道全长400m , 结垢平均厚度为15 20mm , 清洗液采用盐酸溶液中添加1% 左右的硝酸溶液, 同时加入缓蚀剂、渗透剂、乳化剂等溶液进行清洗, 管道壁上清洗率为100%。表中列出SS100- 16 型双纹管换热器清洗前后的情况对比。从表内对比数字可以看出, 经过配方的不断调整和清洗经验的积累, 清洗效果越来越好。4结束语清洗后的双纹管换热器及管道立即投入生产, 节约资金30 万元以上。因为清洗1台换热器只需资金3000 7500 元, 我们共修2 台价值11000 元, 加上400m 管道清洗费共计2.5 万元, 所以采用化学清洗技术的经济效益是巨大的。另外, 设备清洗在现场就地施工, 不需吊车机械费、人工费, 两项可节约8000 余元。应用化学清洗技术施工简单方便, 时间短, 一般需2 3d, 结垢介质复杂时, 可适当延长清洗时间。济钢焦化厂采用化学清洗技术处理双纹管换热器的结垢堵塞问题直接和间接效益可达50 万元以上, 达到了降成本、反浪费、增效益的目的。一、双纹管换热器1.产品简介双纹管换热器是一种新型强化传热高效节能换热设备，它适用于生产、生活及采暖空调等多种换热场合，分为汽-水、水-水两种换热形式、又分立式、卧式两种结构形式，型号齐全，选用方便，亦可根据具体情况进行特殊设计，研制成功后受到广大客户的一致好评。2.特点（1）强化传热双纹管是用高导热系数的紫铜管经过特殊加工形成内外螺纹，内外流体经过螺纹时产生强烈扰动，因而传热系数明显提高。（2）不易结垢由于换热管采用紫铜，而且易形成湍流，对换热管壁有较强的冲刷作用，加上螺纹管本身有热补偿能力，通过热胀冷缩有自洁作用，因而不易结垢。（3）体积小，占地面积少由于传热系数明显提高，因而系统换热面积的情况下，外形尺寸减少，占地面积减少，从换热器的寿命和运行费用等综合考虑，总的结果投资省。3.热力计算W = KFTW 传热量（W/h）K 传热系数（W/m2K）F 传热面积（m2）T 对数平均温差（）汽 水换热时K=1791+768V1水 水换热时K=768+640（V1+V2）V1 管内水流速（m/s）V2 管外水流速（m/s）4.设计说明（1）双纹管汽-水换热器为固定管板式，管壳程均为单程；双纹管水换热器为全逆流固定管板式，管壳程均为双程，可进行串联、并联和混联使用。（2）本系列换热器设计压力为0.6Mpa、1.0Mpa和1.6Mpa，汽-水换热器最大操作压力和温度可按下表选用，水-水换热气最大操作压力分别为0.57Mpa、1.95Mpa和1.52Mpa，最大操作温度为180。设计压力Mpa管程蒸汽在下列温度时的最大操作压力最大操作压力Mpa最高操作温度200250300350600为耳式支座。公称直径200的无支座，换热管长1米的卧式换热器无支座。（3）设计压力伪.6Mpa和1.0Mpa的换热器接管法兰采用HGJ45-91，压力等级为1.0Mpa。设计压力为1.6Mpa的换热器接管法兰采用HGJ46-91，压力等级为1.6Mpa。5.使用说明（1）本换热器应按设计部门提供的管路系统图进行安装，运行前应首先检查各部件安装是否正确、安全可靠。（2）介质为水时，均应采用软化水，并在进水管路上设除污器。运行时，首先打开被加热介质的进出水阀，采暖空调系统开启循环水泵，确认系统充满水后，方可打开加热介质的出口阀，然后打开进口阀。6.型号说明SW Q(S) L(W) *./.* SW-双纹管换热器 Q(S)-Q 汽水 S 水水 L(W)-L 立式 W 卧式 *-公称直径(mm) /-管程/壳程设计压力Mpa *-换热面积()双纹管换热器汽-水 SWQL 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