Erosion-corrosion failure of overhead air cooler in atmospheric tower

During the hydrogenation process in a petrochemical plant, the air cooler serves as a crucial heat exchanger in atmospheric towers. However, the frequent corrosion and leaks of air coolers significantly impact the safety of the process. Firstly, the Aspen software is utilized to simulate the operation of an air cooler. Then, Computational Fluid Dynamics (CFD) calculations are performed to analyze the internal flow in the air cooler. Finally, four inlet optimization strategies are proposed. It is indicated that the condensation of the oil phase results in the formation of liquid-phase oil droplets that cause erosion-corrosion. The absence of liquid-phase water condensation implies that there is minimal dew point corrosion in the tube bundle. The turbulence kinetic energy near the entrance exhibits significant variation, making erosion-corrosion more likely to occur near the entrance of the cooling tube bundle. Furthermore, vortexes form near the entrances of the first and second rows, exacerbating the corrosion in the tube bundle. By optimizing the air cooler, numerical simulations showed that the shear force of the vortex on the tube wall is reduced by nearly 50%. The internal erosion and scour effect of the improved air cooler is reduced.