HEAT EXCHANGER FOR COOLING CRACKED GAS

Abstract

A cracked gas cooling heat exchanger includes a tube connection between an uncooled tube (1) and a cooled tube (2), having a cooled inner tube (3) enclosed by a jacket tube (4), with a tube intermediate space (5) for flowing cooling medium. A gas inlet header (11) has a GI tube inner part (12) and a GI tube outer part (13) and a cooling space (14) with an insulating layer (15). The GI tube outer part connects via a water chamber (6) to the jacket tube. The GI tube inner part faces the inner tube and is connected on a face (8) of the water chamber. A weld backing ring (16), between an end face (9) of the cooling space and a bottom face (8) of the water chamber, is in the insulating layer of the cooling space, arranged in a turn-out/groove (17) in the insulating layer.

Claims

1. A heat exchanger for cooling cracked gas, the heat exchanger comprising: a cooled tube configured as a double tube comprising a cooled inner tube and a jacket tube, the inner tube being enclosed by the jacket tube at a radial distance to form a tube intermediate space, through which a cooling medium flows; an uncooled tube; a tube connection between the uncooled tube and the cooled tube, the tube connection comprising: a water chamber having a water chamber end face and a water chamber bottom end face; a gas inlet header connected to the uncooled tube, the gas inlet header having a forked cross section and comprising a tube inner part and a tube outer part, defining a cooling intermediate space therebetween, and an insulating layer of a heat-insulating material in the cooling intermediate space, wherein the tube outer part is connected via the water chamber to the jacket tube, with the tube outer part connected to the water chamber end face and the tube inner part facing the water chamber bottom end face at an axial distance therefrom; and a ring configured as a weld pool backing ring arranged between an end face of the cooling intermediate space and the water chamber bottom end face and inserted into the insulating layer of the cooling intermediate space in a mounted turn-out or groove in the insulating layer on the end face of the cooling intermediate space, wherein the weld pool backing ring is in contact with a tubular inner surface of the tube outer part, wherein the insulating layer with the weld pool backing ring provide an overhang of 0.3 mm to 1.3 mm over a welded edge of the gas inlet header.

2. A heat exchanger in accordance with claim 1, wherein the weld pool backing ring is embedded with a force in the insulating layer on the end face of the cooling intermediate space and is pressed onto the tube inner surface of the tube outer part.

3. A heat exchanger in accordance with claim 1, wherein: the weld pool backing ring is provided with a concave recess opposite the tube inner surface on the end face of the cooling intermediate space; the tube outer part has a discharging end with a ring-shaped end piece forming a gas inlet header welding lip formed on or adjacent to the end face of the cooling intermediate space; the water chamber has an opposite welding lip at the bottom end face of the water chamber; and the gas inlet header welding lip and the opposite welding lip have a web width of 0.5 mm to 1.5 mm.

4. A heat exchanger in accordance with claim 3, wherein: the weld pool backing ring is formed on the end face of the cooling intermediate space towards the tube inner surface with a concave recess with a radius of 0.5 mm; and the tube outer part on or adjacent to the end face of the cooling intermediate space and the bottom end face of the water chamber have, located opposite one another, the gas inlet header welding lip and the opposite welding lip with a web width of 1.0 mm.

5. A heat exchanger in accordance with claim 3, wherein the weld pool backing ring and the tube outer part and the water chamber bottom end face with the gas inlet header welding lip and the opposite welding lip are welded together with a fully welded-through weld seam in full connection without a remaining gap.

6. A heat exchanger in accordance with claim 1, wherein the weld pool backing ring is formed of a ceramic or metallic material and is configured as a sealing ring and as an insulating ring.

7. A process for connecting an uncooled tube and a cooled tube of a heat exchanger for cooling cracked gas with a tube connection between the uncooled tube, the process comprising the steps of: clamping a weld pool backing ring, embedded in an insulating layer inserted in a cooling intermediate space of a gas inlet header, in contact with a tube inner surface of a tube outer part of the gas inlet header, in a device for preparing a weld seam connection from the gas inlet header to a water chamber; attaching the gas inlet header to the water chamber without air gap with contact of a gas inlet welding lip of the gas inlet header, at a ring-shaped end piece of the tube outer part of the gas inlet header, on an end face of the cooling intermediate space with a water chamber sealing lip, formed at a water chamber bottom end face of the water chamber located opposite the gas inlet welding lip; preparing a first welding layer with an MAG welding torch and with an MAG welding wire with a welding filler material for a root protection; mechanically removing weld slag formed on a top side of the first welding layer; and welding or filling a remaining weld seam with a welding material over the first welding layer in one pass in 2n welding layers or welding beads.

8. A process in accordance with claim 7, wherein: the weld pool backing ring is inserted into a provided turn-out or groove in the insulating layer of heat-insulating material on the end face; and the insulating layer and the weld pool backing ring are arranged with an overhang of 0.3 mm to 1.3 mm over a welded edge of the gas inlet header.

9. A process in accordance with claim 8, wherein the weld pool backing ring and the insulating layer are inserted with the overhang of 0.5 mm over the welded edge of the gas inlet header.

10. A process in accordance with claim 9, wherein: the gas inlet header is attached to the water chamber by means of a device; the gas inlet header is positioned at the welding position; and the gas inlet header is pressed onto the water chamber with the protruding insulating layer and the protruding weld pool backing ring without a remaining air gap and tack-welded at three to four points of the weld seam to be formed.

11. A process in accordance with claim 10, wherein: the prepared tube connection is fed to an automatic welding machine and clamped with a three jaw or four jaw chuck on a gas inlet inner side of the gas inlet header; and a first welding torch of the automatic welding machine is guided into the weld joint of the weld seam.

12. A process in accordance with claim 11, wherein the first welding layer is executed with a metal welding process with active gases and with a welding filler material with a slag formation; the weld slag is formed between a melt pool formed and the weld pool backing ring; and the melt formed is protected by the weld slag being formed against atmospheric oxygen.

13. A process in accordance with claim 12, wherein: deposited weld slag on a top side of the welding layer is entirely mechanically removed after welding of the first welding layer; the remaining weld seam is welded and filled with a second welding torch of the automatic welding machine and with a usual welding material in a pass with 2n welding layers or weld beads.

14. A process in accordance with claim 13, wherein the remaining weld seam is closed and filled with a solid wire in a pass with 2n welding layers or weld beads, wherein n is 1 to 12.

15. A process in accordance with claim 14, wherein a remaining weld seam is closed and filled with a solid wire in a pass with 2n welding layers or weld beads, wherein n is 3 to 8.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In the drawings:

[0030] FIG. 1 is a longitudinal sectional view through the bottom part of a heat exchanger with a tube connection according to the present invention on a reduced scale; and

[0031] FIG. 2 is a detail Z according to FIG. 1, shown on an enlarged scale before welding.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0032] Referring to the drawings, FIG. 1 shows a longitudinal section through the bottom part of a heat exchanger, not shown, with a tube connection between an uncooled tube 1 and a cooled tube 2. The cooled tube 2 is configured as a double tube and consists of a cooled inner tube 3 and a jacket tube 4. The inner tube 3 is enclosed by the jacket tube 4 at a radial distance, forming a tube intermediate space 5, through which a cooling medium flows.

[0033] The cooled tube 2 is in connection with the uncooled tube 1 via a water chamber 6 (abbreviated as WC) and a gas inlet header 11 (abbreviated as GI), which is connected to the uncooled tube and is forked in cross section. The gas inlet header is aligned flush with its gas inlet inner side 20 on the uncooled tube 1 and has a GI tube inner part 12 and a GI tube outer part 13. A cooling intermediate space 14, into which an insulating layer 15 consisting of a heat-insulating material is inserted, is formed between the GI tube inner part 12 and the GI tube outer part 13.

[0034] The GI tube outer part 13 of the gas inlet header 11 is connected via the water chamber 6 to the jacket tube 4 of the cooled tube 2 on a WC end face 7. The GI tube inner part 12 of the gas inlet header 11 faces the cooled inner tube 3 at an axial distance of about 0.3 mm to 1.3 mm on a WC bottom end face 8 of the water chamber 6.

[0035] As is shown in FIG. 2, a weld pool backing ring 16, which is in contact with a tube inner surface 10 of the GI tube outer part 13, is arranged on an end face 9 of the cooling intermediate space 14 in the inserted insulating layer 15 consisting of heat-insulating material.

[0036] The weld pool backing ring 16 is arranged in a mounted turn-out or groove 17 in the insulating layer 15 consisting of heat-insulating material on the end face 9 of the cooling intermediate space 14 and is in contact with a tube inner surface 10 of the GI tube outer part 13. The insulating layer 15 consisting of heat-insulating material and the weld pool backing ring 16 have a short overhang (axial extension) of 0.3 mm to 1.3 mm over (beyond) the welded edge of the gas inlet header 11 on the end face 9 of the cooling intermediate space 14. An overhang of 0.5 mm is preferred.

[0037] The weld pool backing ring 16 is embedded firmly (embedded with a pressing force) in the insulating layer 15 consisting of heat-insulating material on the end face 9 of the cooling intermediate space 14 and is pressed onto the tube inner surface 10 of the GI tube outer part 13.

[0038] The weld pool backing ring 16 is provided with a concave recess 21 on the end face 9 of the cooling intermediate space 14 in contact with the tube inner surface 10 of the tube outer part 13. On the end face 9 of the cooling intermediate space 14 of the gas inlet header 11, a circumferential GI welding lip 18 in the form of a web is provided at the discharging end piece 22 of the GI tube outer part 13. A circumferential WC welding lip 19 is likewise formed on the WC bottom end face 8 of the water chamber 6. The respective GI/WC welding lips 18, 19 are arranged opposite one another and are each formed with a web width of 0.5 mm to 1.5 mm. A web width of 1.0 mm is preferred.

[0039] Furthermore, the weld pool backing ring 16 and the GI tube outer part 13 of the gas inlet header 11 and the WC bottom end face 8 of the water chamber with the respective mounted, circumferential GI/WC welding lip 18, 19 are connected to the water chamber 6 in full connection without a remaining gap with fully welded-through weld seam by welding with an MAG welding torch using a slag-carrying welding filler material for the first welding layer or root layer and the complete removal of the weld slag on the first welding layer and filling of the remaining weld seam with 2n welding layers or weld beads of a welding torch with a usual welding material without a welding filler, wherein n=1-12 and preferably n=3-8.

[0040] The weld pool backing ring 16, which consists of a ceramic or metallic material, is configured as a sealing ring and as an insulating ring.

[0041] In a process for connecting a tube connection between an uncooled tube 1 and a cooled tube 2 of a heat exchanger, not shown, a gas inlet header 11 is attached to a conventional device (conventional jig), not shown, in a first step, wherein a cooling intermediate space 14, in which an insulating layer 15 consisting of heat-insulating material is inserted, is formed between a GI tube inner part 12 and a GI tube outer part 13.

[0042] In a second step, a weld pool backing ring 16 is embedded into a mounted turn-out or groove 17 in the insulating layer 15 consisting of heat-insulating material on an end face 9 of the cooling intermediate space 14, wherein the insulating layer 15 consisting of heat-insulating material and the weld pool backing ring 16 have a small overhang of about 0.3 mm to 1.3 mm over the welded edge of the gas inlet header 11, and an overhang of 0.5 mm is preferably provided.

[0043] In a third step, the gas inlet header 11 is attached to the water chamber 6 without air gap by means of a conventional device, not shown. A mounted GI welding lip 18 at the discharging end piece 22 of the GI tube outer part 13 of the gas inlet header 11 is aligned with a WC welding lip 19 formed on an opposite water chamber bottom end side 8 of the water chamber 6 and is positioned at a welding layer and is tack-welded at three to four points in the circumferential area of a round weld seam of the welding layer. The insulating layer 15 mounted with a small overhang of about 0.5 mm and the weld pool backing ring 16 provided with a small overhang of 0.5 mm are pressed onto the water chamber 6 without a remaining air gap by means of a device, not shown.

[0044] Such an attachment of the gas inlet header 11 to the water chamber is prevented in case of a prior-art Wolfram Inert Gas welding process, because no forming gas can be guided to the root area for the necessary root protection of the root weld seam.

[0045] After attaching the gas inlet header 11 to the water chamber 6 and after tack welding at three to four points in the circumferential area of the welding layer, the component is fed to a conventional automatic welding machine, not shown, and clamped with a three-jaw/four-jaw chuck on a gas inlet inner side 20 of the gas inlet header.

[0046] The automatic welding machine, not shown, guides by scanning a Metal Active Gas welding torch, not shown, or MAG welding torch into the prepared weld joint of the weld seam. The weld seam is prepared by the GI welding lip 18 with a web width of 1.0 mm, which is formed on the discharging end piece 22 of the tube outer part 13 of the gas inlet header 11, and the counterpiece of the WC welding lip 19, likewise with a web width of 1.0 mm, which is formed on a WC bottom end face 8 of the water chamber, being aligned with one another.

[0047] The first welding layer is carried out (prepared) with the MAG welding torch and an MAG welding wire with a welding filler material for a strong slag formation or as slag-carrying, wherein the weld slag being formed is formed between the weld pool being formed and the weld pool backing ring 16. As a result of the weld slag being formed, the melt being formed is protected against atmospheric oxygen, so that a reaction with atmospheric oxygen is prevented. The first welding layer is welded exclusively with an MAG welding wire with welding filler material.

[0048] In another step, the weld slag formed on the top side of the first welding layer is entirely removed mechanically after the welding of the first welding layer.

[0049] The welding torch is again positioned in the welding layer by the welding robot with a usual welding material, and the remaining weld seam above the first welding layer is welded and filled in a pass with 2n welding layers or weld beads with the usual welding material, and preferably a solid wire, wherein n=1-12, preferably n=3-8.

[0050] It is achieved and ensured with the process that the gas inlet header 11 is fully welded through to the water chamber 6 of a heat exchanger at the critical point of the tube connection of an uncooled tube 1 with a cooled tube 2, without a remaining area of a weld seam, which is not fully welded through, remaining.

[0051] It is further guaranteed with the process that a constantly defined weld shrinkage can be maintained in the welded connection of a GI tube outer part of a gas inlet header to a water chamber. Such a defined weld shrinkage is ensured by a gas inlet header being aligned with a GI welding lip which is mounted at the discharging end piece of a GI tube outer part on a WC welding lip arranged opposite a WC bottom end face with a respective web width of 0.5 mm to 1.5 mm, preferably 1.0 mm, and being attached and welded onto a water chamber without air gap.

[0052] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.

LIST OF REFERENCE NUMBERS

[0053] 1 Uncooled tube [0054] 2 Cooled tube [0055] 3 Cooled inner tube [0056] 4 Jacket tube [0057] 5 Tube intermediate space [0058] 6 Water chamber [0059] 7 WC end face [0060] 8 WC bottom end face [0061] 9 End face [0062] 10 Tube inner surface [0063] 11 Gas inlet header [0064] 12 GI tube inner part [0065] 13 GI tube outer part [0066] 14 Cooling intermediate space [0067] 15 Insulating layer consisting of heat-insulating material [0068] 16 Weld pool backing ring [0069] 17 Turn-out or groove [0070] 18 GI welding lip [0071] 19 WC welding lip [0072] 20 GI inner side [0073] 21 Concave recess [0074] 22 End piece of GI tube outer part