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Article(id=1320423087481410090, tenantId=1146029695717560320, journalId=1319355204128309394, issueId=1320423027695792874, articleNumber=null, orderNo=null, doi=10.3969/j.issn.1001-4837.2026.02.007, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1754841600000, receivedDateStr=2025-08-11, revisedDate=1761840000000, revisedDateStr=2025-10-31, acceptedDate=null, acceptedDateStr=null, onlineDate=1792742996330, onlineDateStr=2026-10-23, pubDate=1772208000000, pubDateStr=2026-02-28, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1792742996330, onlineIssueDateStr=2026-10-23, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1792742996330, creator=13701087609, updateTime=1792742996330, updator=13701087609, issue=Issue{id=1320423027695792874, tenantId=1146029695717560320, journalId=1319355204128309394, year='2026', volume='43', issue='2', pageStart='1', pageEnd='86', issueExtLink='null', onlineDate='null', pubDate='1772208000000', pubDateStr='2026-02-28', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1792742982076, creator='13701087609', updateTime=1792745307038, updator='13701087609', preIssue=null, nextIssue=null, articleTotal=null, ext={EN=IssueExt(id=1320432779335156588, tenantId=1146029695717560320, journalId=1319355204128309394, issueId=1320423027695792874, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1320432779335156589, tenantId=1146029695717560320, journalId=1319355204128309394, issueId=1320423027695792874, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null, downloadFileDto=null}, startPage=71, endPage=78, ext={EN=ArticleExt(id=1320423087720485419, articleId=1320423087481410090, tenantId=1146029695717560320, journalId=1319355204128309394, language=EN, title=Failure causes analysis of U‑shaped section of reboiler heat exchange tubes, columnId=1320423010939548239, journalTitle=Pressure Vessel Technology, columnName=Safety Analysis, runingTitle=null, highlight=null, articleAbstract=

A 2507 duplex steel （S25073） U‑shaped tube reboiler in a chemical plant experienced a leakage during operation.After disassembly，it was discovered that the U‑shaped bend exhibited severe corrosion and perforation，resulting in the failure of the reboiler.To address the above issues，various methods such as macroscopic inspection，microscopic morphology analysis，chemical composition analysis，metallographic analysis，mechanical property analysis，residual stress analysis，and heat exchange vibration analysis were employed to investigate the causes of failure.The results show that inadequate circulation of the liquid phase material at the U‑shaped bend causes the corrosive medium to evaporate and concentrate，thereby increasing the risk of corrosion.Meanwhile，residual stress in the U‑shaped bend region reaches up to 231 MPa.Under the combined effect of these two factors，the heat exchange tube corrodes and failes at the U‑shaped bend.The straight pipe section do not experience significant corrosion because the concentration effect of the liquid phase material is not obvious and the residual stress is low，ensuring that the corrosion resistance still met the requirements.Based on the analysis of the failure causes，suggestions for improving the selection of the reboiler under this operating condition are proposed.After the actual operation under the working conditions，it has been verified that the reboiler with the improved selection performes well under the same conditions.This case shows that in the design of heat exchange with corrosion tendency，apart from the conventional calculation of heat transfer，vibration analysis and strength calculation，the corrosion problem caused by local concentration should be paid more attention.

, authors=Zhiming WANG, Cong WANG, authorsList=Zhiming WANG, Cong WANG, authorCompany=null, correspAuthors=Cong WANG, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1320423091361141316, articleId=1320423087481410090, tenantId=1146029695717560320, journalId=1319355204128309394, language=CN, title=再沸器换热管U形段失效原因分析, columnId=1320423011124097617, journalTitle=压力容器, columnName=安全分析, runingTitle=null, highlight=null, articleAbstract=

某化工企业的一台2507双相钢（S25073）材质U形管再沸器在运行过程中发生泄漏，拆解后发现换热管的U形弯处存在严重腐蚀穿孔，进而导致再沸器失效。针对上述问题，采用宏观检查、微观形貌分析、化学成分分析、金相分析、力学性能分析、残余应力分析和换热器振动分析等探究失效原因。结果表明，U形弯处液相物料循环不畅，导致腐蚀性介质在弯管局部发生蒸发提浓，增加了腐蚀风险；同时U形管加工后弯管区局部残余应力最高达到231 MPa，在二者综合作用下，换热管从U形弯处发生腐蚀失效。直管段由于液相物料提浓效应不明显、残余应力低，耐腐蚀性能依然满足要求，故未发生明显腐蚀。基于失效原因分析，对该工况下再沸器的选型提出改进建议，经过实际工况运行验证，改进选型后的再沸器在同样工况下运行良好。该案例说明在有腐蚀倾向的换热器设计中，除常规传热计算、振动分析、强度计算以外，还应重点关注是否存在局部提浓导致的腐蚀问题。

, authors=王志明, 王聪, authorsList=王志明, 王聪, authorCompany=null, correspAuthors=王聪, authorNote=

王志明（1986）男，高级工程师，主要从事新工艺开发等工作，通信地址：300400天津市北辰区中国天辰工程有限公司，E-mail：。

, correspAuthorsNote=
王聪（1979）男，教授级高工，主要从事化工新工艺、新技术开发工作，通信地址：300400天津市北辰区中国天辰工程有限公司，E-mail：。
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王志明（1986）男，高级工程师，主要从事新工艺开发等工作，通信地址：300400天津市北辰区中国天辰工程有限公司，E-mail：。

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王志明（1986）男，高级工程师，主要从事新工艺开发等工作，通信地址：300400天津市北辰区中国天辰工程有限公司，E-mail：。

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Reference(id=1320423100479558287, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2020, volume=46, issue=7, pageStart=148, pageEnd=null, url=null, language=null, rfNumber=7, rfOrder=13, authorNames=ZHU R Y, journalName=Chemical Engineering Design Communications, refType=null, unstructuredReference=ZHU R Y.Study on the effect of metallographic structure on the corrosion resistance of dual-phase steel pump housing［J］.Chemical Engineering Design Communications，2020，46（7）：148., articleTitle=Study on the effect of metallographic structure on the corrosion resistance of dual-phase steel pump housing, refAbstract=null), Reference(id=1320423100567638672, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2023, volume=40, issue=11, pageStart=67, pageEnd=74, url=null, language=null, rfNumber=8, rfOrder=14, authorNames=梁春雷, 艾志斌, 赵阁, journalName=压力容器, refType=null, unstructuredReference=梁春雷，艾志斌，赵阁，等.乙二醇装置奥氏体不锈钢设备应力腐蚀开裂探讨［J］.压力容器，2023，40（11）：67-74., articleTitle=乙二醇装置奥氏体不锈钢设备应力腐蚀开裂探讨, refAbstract=null), Reference(id=1320423100630553233, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2023, volume=40, issue=11, pageStart=67, pageEnd=74, url=null, language=null, rfNumber=8, rfOrder=15, authorNames=LIANG C L, AI Z B, ZHAO G, journalName=Pressure Vessel Technology, refType=null, unstructuredReference=LIANG C L，AI Z B，ZHAO G，et al.Discussion on stress corrosion cracking of austenitic stainless steel equipment in ethylene glycol unit［J］.Pressure Vessel Technology，2023，40（11）：67-74., articleTitle=Discussion on stress corrosion cracking of austenitic stainless steel equipment in ethylene glycol unit, refAbstract=null), Reference(id=1320423100701856402, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2019, volume=44, issue=12, pageStart=165, pageEnd=169, url=null, language=null, rfNumber=9, rfOrder=16, authorNames=蔺晓亮, 陈兴润, 王宝君, journalName=金属热处理, refType=null, unstructuredReference=蔺晓亮，陈兴润，王宝君，等.固溶温度对S32750双相不锈钢组织和力学性能的影响［J］.金属热处理，2019，44（12）：165-169., articleTitle=固溶温度对S32750双相不锈钢组织和力学性能的影响, refAbstract=null), Reference(id=1320423100785742483, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2019, volume=44, issue=12, pageStart=165, pageEnd=169, url=null, language=null, rfNumber=9, rfOrder=17, authorNames=LIN X L, CHEN X R, WANG B J, journalName=Heat Treatment of Metals, refType=null, unstructuredReference=LIN X L，CHEN X R，WANG B J，et al.Effect of solution temperature on microstructure and mechanical properties of S32750 duplex stainless steel［J］.Heat Treatment of Metals，2019，44（12）：165-169., articleTitle=Effect of solution temperature on microstructure and mechanical properties of S32750 duplex stainless steel, refAbstract=null), Reference(id=1320423100873822868, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2024, volume=21, issue=11, pageStart=130, pageEnd=137, url=null, language=null, rfNumber=10, rfOrder=18, authorNames=施斌卿, 胡涌玉, 刘小钪, journalName=装备环境工程, refType=null, unstructuredReference=施斌卿，胡涌玉，刘小钪，等.固溶处理对S32001双相不锈钢力学性能和点蚀敏感性的影响［J］.装备环境工程，2024，21（11）：130-137., articleTitle=固溶处理对S32001双相不锈钢力学性能和点蚀敏感性的影响, refAbstract=null), Reference(id=1320423100978680469, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2024, volume=21, issue=11, pageStart=130, pageEnd=137, url=null, language=null, rfNumber=10, rfOrder=19, authorNames=SHI B Q, HU Y Y, LIU X T, journalName=Equipment Environmental Engineering, refType=null, unstructuredReference=SHI B Q，HU Y Y，LIU X T，et al.Effect of solid solution treatment on mechanical properties and pitting susceptibility of S32001 duplex stainless steel［J］.Equipment Environmental Engineering，2024，21（11）：130-137., articleTitle=Effect of solid solution treatment on mechanical properties and pitting susceptibility of S32001 duplex stainless steel, refAbstract=null), Reference(id=1320423101079343766, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2021, volume=50, issue=3, pageStart=101, pageEnd=115, url=null, language=null, rfNumber=11, rfOrder=20, authorNames=李嘉栋, 陈超, 张世贵, journalName=表面技术, refType=null, unstructuredReference=李嘉栋，陈超，张世贵，等.不同应力条件下不锈钢局部腐蚀行为的研究进展［J］.表面技术，2021，50（3）：101-115., articleTitle=不同应力条件下不锈钢局部腐蚀行为的研究进展, refAbstract=null), Reference(id=1320423101154841239, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2021, volume=50, issue=3, pageStart=101, pageEnd=115, url=null, language=null, rfNumber=11, rfOrder=21, authorNames=LI J D, CHEN C, ZHANG S G, journalName=Surface Technology, refType=null, unstructuredReference=LI J D，CHEN C，ZHANG S G，et al.Research progress on localized corrosion behavior of stainless steel under different stress conditions［J］.Surface Technology，2021，50（3）：101-115., articleTitle=Research progress on localized corrosion behavior of stainless steel under different stress conditions, refAbstract=null), Reference(id=1320423101238727320, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2025, volume=null, issue=1, pageStart=40, pageEnd=42, url=null, language=null, rfNumber=12, rfOrder=22, authorNames=宁涛, journalName=锅炉制造, refType=null, unstructuredReference=宁涛.电站锅炉高温过热器管开裂失效分析［J］.锅炉制造，2025（1）：40-42., articleTitle=电站锅炉高温过热器管开裂失效分析, refAbstract=null), Reference(id=1320423101331002009, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, doi=null, pmid=null, pmcid=null, year=2025, volume=null, issue=1, pageStart=40, pageEnd=42, url=null, language=null, rfNumber=12, rfOrder=23, authorNames=NING T, journalName=Boiler Manufacturing, refType=null, unstructuredReference=NING T.Analysis of cracking failure of high‑temperature superheater tube in power plant boiler［J］.Boiler Manufacturing，2025（1）：40-42., articleTitle=Analysis of cracking failure of high‑temperature superheater tube in power plant boiler, refAbstract=null)], funds=null, companyList=[AuthorCompany(id=1320423091629576773, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, xref=null, ext=[AuthorCompanyExt(id=1320423091642159686, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, companyId=1320423091629576773, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, 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tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Fig.2, caption=Leakage situation of heat exchange tubes, figureFileSmall=I8MEUzkN64hKOOYWvab26w==, figureFileBig=APtY0IQ7I1eeNazSWeeeCw==, tableContent=null), ArticleFig(id=1320423093328269919, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图2, caption=换热管泄漏情况, figureFileSmall=I8MEUzkN64hKOOYWvab26w==, figureFileBig=APtY0IQ7I1eeNazSWeeeCw==, tableContent=null), ArticleFig(id=1320423093382795872, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Fig.3, caption=The morphology of exchanger tube after leakage, figureFileSmall=xWptlnKwWeTf4SA8Sv6NHw==, figureFileBig=fzDQnPR1HAbVzlIZRru5Zg==, tableContent=null), ArticleFig(id=1320423093445710433, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图3, caption=泄漏后换热管形貌, figureFileSmall=xWptlnKwWeTf4SA8Sv6NHw==, figureFileBig=fzDQnPR1HAbVzlIZRru5Zg==, tableContent=null), ArticleFig(id=1320423093546373730, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Fig.4, caption=The morphology of failed heat exchanger tube, figureFileSmall=bWVl+ZqLEUmmeLmgYdqiVA==, figureFileBig=JHv7dU3vIJUVEdX0ldkM7g==, tableContent=null), ArticleFig(id=1320423093613482595, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图4, caption=失效换热管形貌, figureFileSmall=bWVl+ZqLEUmmeLmgYdqiVA==, figureFileBig=JHv7dU3vIJUVEdX0ldkM7g==, tableContent=null), ArticleFig(id=1320423095282815588, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Fig.5, caption=The morphology of local uniform corrosion, figureFileSmall=E8cOlaKTzU00Hng50nLpIA==, figureFileBig=jNY8RpDFD/5LXSd922CHXg==, tableContent=null), ArticleFig(id=1320423095358313061, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图5, caption=局部均匀腐蚀形貌, figureFileSmall=E8cOlaKTzU00Hng50nLpIA==, figureFileBig=jNY8RpDFD/5LXSd922CHXg==, tableContent=null), ArticleFig(id=1320423095429616230, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Fig.6, caption=The morphology of cross sectional of corrosion pit, figureFileSmall=/EdxRfmJ1E/3uAPm19ioYQ==, figureFileBig=qc5Mdchk7CF+u9xnUQIrmQ==, tableContent=null), ArticleFig(id=1320423095500919399, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图6, caption=腐蚀坑局部横截面形貌, figureFileSmall=/EdxRfmJ1E/3uAPm19ioYQ==, figureFileBig=qc5Mdchk7CF+u9xnUQIrmQ==, tableContent=null), ArticleFig(id=1320423095576416872, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Fig.7, caption=The corrosion morphology of heat exchange tube, figureFileSmall=tZsF3zPka7HRQlflpDhCgg==, figureFileBig=uFJZQVd2WJOidUcv1VcWiA==, tableContent=null), ArticleFig(id=1320423095643525737, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图7, caption=换热管腐蚀形貌, figureFileSmall=tZsF3zPka7HRQlflpDhCgg==, figureFileBig=uFJZQVd2WJOidUcv1VcWiA==, tableContent=null), ArticleFig(id=1320423095744189034, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Fig.8, caption=Amplified image of pitting corrosion, figureFileSmall=ReBKWrM+1sPgXwKlRdDi6A==, figureFileBig=lmj0FLBLShTGLzLE2/P1bQ==, tableContent=null), ArticleFig(id=1320423095823880811, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图8, caption=点蚀坑处放大图, figureFileSmall=ReBKWrM+1sPgXwKlRdDi6A==, 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journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图10, caption=金相显微组织（200×）, figureFileSmall=YlFlLNAGo4bvVzrCGcpXdQ==, figureFileBig=J87cgin/QaA+rTvqO+PmUg==, tableContent=null), ArticleFig(id=1320423096260088432, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Fig.11, caption=Residual stress test sample, figureFileSmall=srEsdjfRD6M2QWRCcpys9Q==, figureFileBig=YXlw/Sifz5kTC9gnb8h0ow==, tableContent=null), ArticleFig(id=1320423096419471985, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图11, caption=残余应力测试样品, figureFileSmall=srEsdjfRD6M2QWRCcpys9Q==, figureFileBig=YXlw/Sifz5kTC9gnb8h0ow==, tableContent=null), ArticleFig(id=1320423096553689714, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Fig.12, caption=Tail support of the reboiler, figureFileSmall=f62wq0ory4KvF2xIzJMADg==, figureFileBig=0j7VRbQ0hTfFOwwAqL8uNg==, tableContent=null), ArticleFig(id=1320423096641770099, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=图12, caption=再沸器尾部支撑, figureFileSmall=f62wq0ory4KvF2xIzJMADg==, figureFileBig=0j7VRbQ0hTfFOwwAqL8uNg==, tableContent=null), ArticleFig(id=1320423096725656180, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Tab.1, caption=

Composition analysis result

, figureFileSmall=null, figureFileBig=null, tableContent=
元素CSiMnPSNiCrMoNCu
分析结果0.020.530.760.0250.0056.1725.503.540.290.08
标准要求≤0.03≤0.80≤1.20≤0.035≤0.0156.00~8.0012.00~26.003.00~5.000.24~0.32≤0.50
), ArticleFig(id=1320423096792765045, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=表1, caption=

成分分析结果

, figureFileSmall=null, figureFileBig=null, tableContent=
元素CSiMnPSNiCrMoNCu
分析结果0.020.530.760.0250.0056.1725.503.540.290.08
标准要求≤0.03≤0.80≤1.20≤0.035≤0.0156.00~8.0012.00~26.003.00~5.000.24~0.32≤0.50
), ArticleFig(id=1320423096868262518, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Tab.2, caption=

Statistics of ferrite content in uncorroded areas

, figureFileSmall=null, figureFileBig=null, tableContent=
编号PiPtPp（i）/% Pp¯/%S/%95%Cl/%Vv/%%RA
113255247.25.94.247.2±4.28.9
213.52554
3142556
4112544
511.52546
6102540
7112544
812.52550
99.52538
10122548
), ArticleFig(id=1320423096960537207, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=表2, caption=

未腐蚀区域铁素体含量统计

, figureFileSmall=null, figureFileBig=null, tableContent=
编号PiPtPp（i）/% Pp¯/%S/%95%Cl/%Vv/%%RA
113255247.25.94.247.2±4.28.9
213.52554
3142556
4112544
511.52546
6102540
7112544
812.52550
99.52538
10122548
), ArticleFig(id=1320423097036034680, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Tab.3, caption=

Statistics of ferrite content in corroded area

, figureFileSmall=null, figureFileBig=null, tableContent=
编号PiPtPp（i）/% Pp¯/%S/%95%Cl/%Vv/%%RA
18.5253445.67.55.445.6±5.411.8
29.52538
3132552
410.52542
5102540
611.52546
7132552
8142556
910.52542
1013.52554
), ArticleFig(id=1320423097107337849, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=表3, caption=

腐蚀区铁素体含量统计

, figureFileSmall=null, figureFileBig=null, tableContent=
编号PiPtPp（i）/% Pp¯/%S/%95%Cl/%Vv/%%RA
18.5253445.67.55.445.6±5.411.8
29.52538
3132552
410.52542
5102540
611.52546
7132552
8142556
910.52542
1013.52554
), ArticleFig(id=1320423097187029626, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=EN, label=Tab.4, caption=

Tensile mechanical properties test results

, figureFileSmall=null, figureFileBig=null, tableContent=
指标Rm/MPaRp0.2/MPaA/%
测试值83063538.0
标准值≥800≥550≥15
), ArticleFig(id=1320423097262527099, tenantId=1146029695717560320, journalId=1319355204128309394, articleId=1320423087481410090, language=CN, label=表4, caption=

拉伸力学性能测试结果

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指标Rm/MPaRp0.2/MPaA/%
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再沸器换热管U形段失效原因分析
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王志明 , 王聪
压力容器 | 安全分析 2026,43(2): 71-78
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压力容器 |安全分析 2026 , 43 (2) : 71 -78
再沸器换热管U形段失效原因分析
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王志明 , 王聪
作者信息
  • 中国天辰工程有限公司，天津 300400
通讯作者:
王聪（1979）男，教授级高工，主要从事化工新工艺、新技术开发工作，通信地址：300400天津市北辰区中国天辰工程有限公司，E-mail：。
作者简介:

王志明（1986）男，高级工程师，主要从事新工艺开发等工作，通信地址：300400天津市北辰区中国天辰工程有限公司，E-mail：。

Failure causes analysis of U‑shaped section of reboiler heat exchange tubes
Zhiming WANG , Cong WANG
Affiliations
  • China Tianchen Engineering Corporation Ltd.，Tianjin 300400，China
出版时间: 2026-02-28 doi: 10.3969/j.issn.1001-4837.2026.02.007
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摘要
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某化工企业的一台2507双相钢（S25073）材质U形管再沸器在运行过程中发生泄漏，拆解后发现换热管的U形弯处存在严重腐蚀穿孔，进而导致再沸器失效。针对上述问题，采用宏观检查、微观形貌分析、化学成分分析、金相分析、力学性能分析、残余应力分析和换热器振动分析等探究失效原因。结果表明，U形弯处液相物料循环不畅，导致腐蚀性介质在弯管局部发生蒸发提浓，增加了腐蚀风险；同时U形管加工后弯管区局部残余应力最高达到231 MPa，在二者综合作用下，换热管从U形弯处发生腐蚀失效。直管段由于液相物料提浓效应不明显、残余应力低，耐腐蚀性能依然满足要求，故未发生明显腐蚀。基于失效原因分析，对该工况下再沸器的选型提出改进建议，经过实际工况运行验证，改进选型后的再沸器在同样工况下运行良好。该案例说明在有腐蚀倾向的换热器设计中，除常规传热计算、振动分析、强度计算以外，还应重点关注是否存在局部提浓导致的腐蚀问题。

再沸器  /  换热管  /  双相钢  /  残余应力  /  腐蚀

A 2507 duplex steel （S25073） U‑shaped tube reboiler in a chemical plant experienced a leakage during operation.After disassembly，it was discovered that the U‑shaped bend exhibited severe corrosion and perforation，resulting in the failure of the reboiler.To address the above issues，various methods such as macroscopic inspection，microscopic morphology analysis，chemical composition analysis，metallographic analysis，mechanical property analysis，residual stress analysis，and heat exchange vibration analysis were employed to investigate the causes of failure.The results show that inadequate circulation of the liquid phase material at the U‑shaped bend causes the corrosive medium to evaporate and concentrate，thereby increasing the risk of corrosion.Meanwhile，residual stress in the U‑shaped bend region reaches up to 231 MPa.Under the combined effect of these two factors，the heat exchange tube corrodes and failes at the U‑shaped bend.The straight pipe section do not experience significant corrosion because the concentration effect of the liquid phase material is not obvious and the residual stress is low，ensuring that the corrosion resistance still met the requirements.Based on the analysis of the failure causes，suggestions for improving the selection of the reboiler under this operating condition are proposed.After the actual operation under the working conditions，it has been verified that the reboiler with the improved selection performes well under the same conditions.This case shows that in the design of heat exchange with corrosion tendency，apart from the conventional calculation of heat transfer，vibration analysis and strength calculation，the corrosion problem caused by local concentration should be paid more attention.

reboiler  /  heat exchange tube  /  duplex stainless steel  /  residual stress  /  corrosion
王志明, 王聪. 再沸器换热管U形段失效原因分析. 压力容器, 2026 , 43 (2) : 71 -78 . DOI: 10.3969/j.issn.1001-4837.2026.02.007
Zhiming WANG, Cong WANG. Failure causes analysis of U‑shaped section of reboiler heat exchange tubes[J]. Pressure Vessel Technology, 2026 , 43 (2) : 71 -78 . DOI: 10.3969/j.issn.1001-4837.2026.02.007
正文
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0　引言
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换热器是实现冷热流体热量传递的重要设备，管壳式换热器在化工企业中应用非常广泛，其性能和使用寿命直接影响大型装置长周期运行的稳定性和安全性。针对在役换热器失效问题，由于换热器的材质及服役工况各不相同，失效原因也各不相同，遍及材料、应力、温度、介质、管束振动等［1-5］。
某化工厂的双相钢U形管再沸器在运行过程中发生换热管泄漏，经拆检发现U形弯区域存在较为严重的腐蚀，导致换热管穿孔泄漏，但直管区域未见明显变化。为查明该再沸器换热管的失效原因，改进设备设计和操作方法，避免装置后续运行过程中同类事件的再次发生，对该再沸器进行失效原因分析。
1　概况
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该再沸器为BXU型管壳式换热器，结构示意见图1，其主要设计参数如下。
用途：卧式壳程再沸器，直径1 700 mm，换热管直管段长度5 000 mm，支撑板间距800 mm。
管内介质：1.8 MPa饱和水蒸气（饱和温度210 ℃）。
管外介质：pH值为3~4的含微量硫酸的水溶液（约96%水，4%丙二醇和丙二醇甲醚，少量硫酸），操作温度185~190 ℃。壳程设置双进口双出口，并预留足够的不布管区域，经HTRI软件计算，满足进出料沿换热管长度方向的均布要求。
换热管：规格为∅19×2 mm，材质为2507双相钢（S25073），出厂要求对弯管区域及靠近弯管区域200 mm的直管段进行固溶处理。
酸洗钝化：设备出厂前进行酸洗钝化处理，使用蓝点法进行检测，并使用氯离子合格的脱盐水进行冲洗置换。
该再沸器投用6个月之后，工艺操作发现精馏塔塔釜出料量显著上升，初步判断再沸器发生泄漏，水蒸气从换热管内泄漏至壳程，使精馏塔水量增加。随即使用单位紧急停用该再沸器，氮气置换合格后拆下再沸器，壳程通入水，拆卸管箱，从管板处面向再沸器观察泄漏情况，发现靠近分程隔板的内侧换热管（即U形弯半径小的换热管）泄漏明显，如图2所示。
抽出整个换热管束进行检查，发现U形管区域存在较为明显的腐蚀，但直管段腐蚀并不明显。管束上部直管及弯管区域腐蚀情况见图3。
为进一步分析泄漏原因，截取管束外侧部分弯管段和直管段进行宏观检查、微观形貌分析、化学成分分析、金相分析、力学性能分析、残余应力分析和再沸器振动分析。充水测试发现管束内侧小弯管半径的换热管泄漏量大，初步判断小弯管半径换热管腐蚀更加明显，并未整体拆解管束，对内侧换热管进行取样分析。
2　试验及分析
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2.1　宏观检查
对发生腐蚀的换热管进行切割取样，分别取直管段和弯管段见图4。
由图5可以看出，腐蚀为均匀腐蚀+点腐蚀，发生在弯管段，并且主要在弯管段的弯曲面上。
对截面区域放大十倍发现呈犬牙状点蚀特征，点蚀深度0.7~1.1 mm不等，如图6所示。
2.2　微观形貌分析
为观察失效换热管腐蚀区域的微观形貌，对换热管外壁切割取样后，进行扫描电子显微镜（SEM）分析，见图7和图8。由图可知，微观形貌上存在明显的块状腐蚀产物，同时点蚀主要优先发生在铁素体相上。
使用EDS能谱对换热管表面及点蚀坑底部的腐蚀产物进行分析，如图9所示，其主要成分为C，Cr，Ni，P，Fe等元素，并含有S，Cl等腐蚀性元素，与工艺介质中含有低浓度硫酸相符。
2.3　化学成分分析
为验证换热管材质是否符合标准，根据GB/T 11170—2008《不锈钢 多元素含量的测定 火花放电原子发射光谱法（常规法）》及GB/T 20124—2006《钢铁 氮含量的测定 惰性气体熔融热导法（常规方法）》进行化学成分分析，结果如表1所示。
由表1可知，该失效换热管的化学成分虽然Ni含量和Mo含量偏低，接近标准下限，但仍符合GB/T 21833.1—2020《奥氏体-铁素体型双相不锈钢无缝钢管 第1部分：热交换器用管》对2507材质的要求。因此，换热管腐蚀失效并不是因为化学成分不合格。
2.4　金相分析
金相分析是检查材料冶炼、加工和热处理后材料组织结构和缺陷情况的一种有效方法。对于双相钢材质，其能够有效反应材料内奥氏体+铁素体2种不同组织结构的分布的均匀性、晶粒大小和形态等，为耐腐蚀性能判断提供一定的依据［6-8］。
在换热管腐蚀及未腐蚀区域选取金相试样，进行镶嵌研磨抛光，腐蚀后进行显微观察。结果表明，腐蚀及未腐蚀区域的显微组织均为奥氏体+铁素体双相组织，如图10所示。
通过在腐蚀及未腐蚀区域各任选10个视场，按照ASTM E562-2019e1 Standard Test Method for Determining Volume Fraction by Systematic Manual Point Count对铁素体相的比例进行评定，结果如表2和表3所示。腐蚀区域和未腐蚀区域的双相比例平均值接近1∶1，但腐蚀区域内存在不均匀现象，铁素体含量略低，这与宏观检查发现的铁素体腐蚀较多结果相符。
2.5　力学性能分析
取换热管直管段样品，按照GB/T 228.1—2021《金属材料 拉伸试验 第1部分：室温试验方法》进行拉伸力学性能测试，测试结果如表4所示，可知该换热管力学性能指标满足GB/T 21833.1—2020对于2507材质的要求。
按照GB/T 203.1—2018《金属材料 洛氏硬度试验 第1部分：试验方法》，对样品进行洛氏硬度测试，结果如表5所示，可以看出换热管洛氏硬度测试结果未见异常。
2.6　残余应力分析
U形管相较于直管，最大的性能区别在于冷弯过程中会引入很大的内应力，虽然后续有固溶处理恢复综合性能，但残余应力和综合性能与固溶处理的效果相关［9-10］，而残余应力也是导致腐蚀加剧的常规因素之一。因此，在换热管上取弯管段样品，如图11所示。按照GB/T 7704—2017《无损检测 X射线应力测定方法》进行残余应力测试，结果如表6所示（负号表示残余应力方向与设定方向相反）。
取换热管远离U形弯的直管段样品，按照同样的分析方法进行残余应力测试，结果见表7。
由表6和表7可知，虽然U形管在弯制后进行了固溶处理，但实际残余应力依然很大，并没有被有效消除。GB/T 21833.1—2020《奥氏体-铁素体型双相不锈钢无缝钢管 第1部分：热交换器用管》中规定：冷拔成型的换热管在交付时必须经过热处理且酸洗。因此，直管段虽然在弯制成型后未固溶处理，但弯制前已经经过热处理，残余应力水平较低。
2.7　换热器振动分析
振动是换热管服役过程中泄漏失效的原因之一。为确认振动对该再沸器的影响，使用HTRI软件对再沸器进行振动分析，并将分析结果与GB/T 151—2014《热交换器》中换热器振动分析要求进行复核，相关分析结果如下。
（1）该再沸器换热管无支撑间距为TEMA最大无支撑间距的0.639倍，小于0.8倍，满足无支撑间距要求。
（2）卡门漩涡频率与换热管最低固有频率的比值最大为0.148，小于标准要求值0.5。
（3）湍流抖振主频率与换热管最低固有频率的比值最大为0.194，在壳程出口处，小于标准要求值0.5。
（4）换热管的最大振幅为0.022 mm，满足标准要求。
（5）横流流速是临界横流流速的0.194 5倍，满足标准要求。
由上述分析可知，该再沸器出现振动损坏的可能性较低。且操作人员在巡检过程中并未发现任何异常的振动、声响等，进一步说明振动不是再沸器失效的诱因。
3　失效原因分析
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根据前文分析测试结果可知，该再沸器换热管的化学成分、金相组织、力学性能均合格，满足相关标准要求；振动分析说明再沸器振动也不是其失效的诱因。同时，从再沸器的总体状态和换热管的宏观检查可以看出，腐蚀发生在换热管的U形弯处，说明存在其他因素导致U形弯处的物料腐蚀能力加强或U形弯处材料耐腐蚀性能减弱。
经仔细查阅该再沸器制造图发现，该设备在U形弯处设置有全支撑，并且全支撑板下端仅开有很小放净口（再沸器上有N7放净口和N8放空口，但该管口仅为检修置换使用，正常生产过程中为盲死状态），如图12所示。这种设置导致液相向弯管区的流动严重受限（即N4口的壳程进料只能通过换热管与支撑板的间隙，以及支撑板最下端的放净口等受限通道进入），但弯管区汽化的气相向外流动并无阻挡。
正常工作下，该再沸器壳程介质与精馏塔进行循环，汽化后气液两相并流返回精馏塔（按设计参数，汽化率约10wt%）。但对于设置有尾部支撑板的U形弯而言，液相介质因为支撑板的阻挡无法顺利进入弯管部位，但弯管仍在不断对介质进行加热汽化（弯管区换热面积为120 m2，是整个再沸器换热面积的10%），导致U形弯发生非挥发性腐蚀介质硫酸的富集，硫酸浓度显著高于非U形弯区域，pH值显著低于非U形弯区域，使U形弯处所接触介质的腐蚀性大幅加强。
此外，充水试验时再沸器靠近分程隔板的换热管泄漏较多，证明小弯管直径U形管的腐蚀更加严重，且弯管区域残余应力较高，可以推测在U形管冷弯及固溶处理过程中，残余应力并未有效消除，而弯管半径越小残余应力越高。文献［11-12］指出，较高的残余应力将显著降低材质的耐腐蚀性。
综合上述分析，结构设计不合理导致U形弯介质滞流，局部硫酸浓缩，腐蚀性增加，同时加工过程中的残余应力过高，导致材料耐腐蚀性下降，诱使U形弯发生腐蚀，是导致该再沸器泄漏失效主要原因。
4　结论与建议
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通过对某U形管再沸器的换热管进行分析，找到腐蚀失效的原因，为后续解决该使用工况下的腐蚀问题提供思路。
（1）针对该再沸器，使用直管，而不使用U型管，避免弯制过程中残余应力的影响。
（2）避免壳程截至的流动死区，防止腐蚀性物质积聚。
基于上述分析，对该再沸器进行更换，新设计的设备替换成直管BXM型壳程再沸器（再沸器基本结构如材质、换热管尺寸、换热面积、设计温度、设计压力未发生较大变化，仅再沸器形式由BXU型替换为BXM型）。经过一年多的服役，未发现泄漏问题，检修时通过壳程管口对换热管外壁进行宏观检查，以及通过两侧管板对换热管两端壁厚进行检测，未发现明显异常。这也证明前文原因分析的正确性。
该再沸器意外失效事故也为后续工程设计敲响了警钟。
（1）在再沸器的设计过程中，除需要重视常规的传热效果计算、振动可能性分析、设备强度计算以外，在有腐蚀可能性的工况下，需要注意实际物理结构对设备内部物料流场的影响，是否会出现腐蚀性截至富集提浓等。
（2）U形管在弯制过程中，残余应力的处理十分重要，尤其对于特殊耐腐蚀的材质。这些工况下的换热管应在交付前做好残余应力检测。

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2026年第43卷第2期
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doi: 10.3969/j.issn.1001-4837.2026.02.007
  • 接收时间：2025-08-11
  • 首发时间：2026-10-23
  • 出版时间：2026-02-28
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  • 收稿日期：2025-08-11
  • 修回日期：2025-10-31
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    中国天辰工程有限公司，天津 300400

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王聪（1979）男，教授级高工，主要从事化工新工艺、新技术开发工作，通信地址：300400天津市北辰区中国天辰工程有限公司，E-mail：。
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2种不同金属材料的力学参数
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Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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