CN1212427C - 浓硫酸输送管道的恒压阳极保护方法 - Google Patents

浓硫酸输送管道的恒压阳极保护方法 Download PDF

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CN1212427C
CN1212427C CN 02154414 CN02154414A CN1212427C CN 1212427 C CN1212427 C CN 1212427C CN 02154414 CN02154414 CN 02154414 CN 02154414 A CN02154414 A CN 02154414A CN 1212427 C CN1212427 C CN 1212427C
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郑建国
周斌
史立军
王振华
徐暾家
陶永顺
肖世猛
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Tianhua Institute of Chemical Machinery and Automation Co Ltd
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Abstract

一种浓硫酸输送管道的恒压阳极保护方法,将浓硫酸输送管道(1)作为阳极,与管道保护控制仪(3)的正极相连;辅助阴极(2)起导通电流的作用,与管道保护控制仪(3)的负极相连,阴极(2)制成棒状形式,沿管道径向插入浓硫酸管道中;管道保护控制仪(3)选择能够输出稳定直流电流、电压可调的整流器、稳压电源或恒槽压仪。该方法参比电极不参与控制,克服了参比电极不稳定对保护效果的影响;克服了参比电极故障导致的系统失控,即使在管道内未充满酸的情况下阳极保护系统也能正常工作;阴极材料处于阴极保护状态,延长了使用寿命,降低了更换费用;阳极保护电源简便、可靠、稳定、操作简单且成本大大降低;浓硫酸输送管道处于恒压阳极保护状态时,年腐蚀率在0.05mm以下,可达到理想的保护效果。

Description

浓硫酸输送管道的恒压阳极保护方法
技术领域    本发明属于电化学防腐蚀阳极保护技术领域,特别是一种浓硫酸输送管道的防腐蚀恒压阳极保护方法。
背景技术    目前,绝大多数硫酸生产厂家采用铸铁管道、不锈钢管道输送浓硫酸,这些管道在低温浓硫酸中耐蚀性较强,但在高温浓硫酸中(70~120℃,93~98%H2SO4)耐蚀性较差,不锈钢管道年腐蚀率在1mm以上,铸铁管道腐蚀更严重,管道的使用寿命很短,经常造成停产,无法满足制酸生产的正常运行,并且生产的硫酸质量达不到标准。也有关于不锈钢浓硫酸输送管道采用恒电位法阳极保护的应用,但此种使用恒电位仪控制管道电位的方法,不仅阳极保护系统组成复杂,而且恒电位仪的成本高。尤其当工艺出现故障,如管道内部未充满酸、参比电极悬空,将导致阳极保护系统失控。
发明内容    为了克服恒电位法保护的以上缺点,本发明提供一种简便、安全、可靠、成本低的输送浓硫酸管道的恒压阳极保护方法。
本发明提供的浓硫酸管道恒压阳极保护方法的依据是:测定不锈钢在浓硫酸中的阳极极化曲线可知,不锈钢在浓硫酸中有很宽的钝化区。如:304L不锈钢在25℃、98%H2SO4中,钝化电位区间为-400~+1,000mV(本文电位值均相对于Hg-Hg2SO4参比电极),维钝电流密度为0.03A/m2;在80℃、98%H2SO4中,钝化电位区间为-200~+700mV,维钝电流密度为0.13A/m2。可以看出,钝化电位区范围近1,000mV,为实施恒压法阳极保护提供了足够空间。若304L不锈钢管道控制在此钝化电位区间,年腐蚀率可控制在0.05mm以下,从而达到理想的保护效果。
                 表1  304L和316L不锈钢在浓H2SO4中的电化学参数
材质 浓度(%) 温度(℃)   致钝电流密度(A/m2)   维钝电流密度(A/m2)    钝化区间(mV)       腐蚀率(mm/a)
 自然  保护
304L     93     25     0.45     0.030 -   -   -
    50     5.66     0.046 -   -   -
    80     9.72     0.124 -   2.00   <0.10
    98     25     2.30     0.033 -400~+1000   -   -
    50     2.51     0.049 -200~+900   -   -
    80     4.92     0.133 -200~+700   0.60   <0.05
316L     93     25     1.00     0.032 -   -   -
    50     1.30     0.041 -   -   -
    80     5.45     0.160 -   1.20   <0.10
    98     25     自钝化     0.014 -200~+1000   -   -
    50     0.16     0.019 -200~+800   -   -
    80     0.23     0.064 -200~+600   0.30   <0.02
    100     0.20     0.365 -   -   -
    120     6.80     1.14 -   -   -
鉴于以上方法依据,为实现上述目的,本发明采取的技术方案为:浓硫酸输送管道的恒压阳极保护方法,是将浓硫酸输送管道作为阳极,与管道保护控制仪的正极相连;辅助阴极起导通电流的作用,与管道保护控制仪的负极相连,阴极制成棒状形式,沿管道径向插入浓硫酸管道中,阴极面积和阴极间距随着管道直径、长度和形状的变化而变化;管道保护控制仪可选择能够输出稳定直流电流、电压可调的整流器、稳压电源、恒槽压仪等。
恒压法阳极保护系统以电解槽阴阳极之间的电压E槽压作为控制指标,经过理论分析与现场试验,根据不锈钢管道在不同浓度的浓硫酸中的保护电位,列出如表2所示的控制指标。
表2  304L/316L不锈钢浓硫酸输送管道的恒压法阳极保护控制指标
材质   浓度  保护电位范围(mV) 控制指标E槽压(mV)
304L316L   93%     -200~600     200~1100
  98%     -300~700     100~1200
理想的阴极材料应电位稳定、耐腐蚀、成本低,并且具有一定的强度,如18-8型不锈钢、25-20型不锈钢、哈氏合金、Inconel合金等。阴极材料在93~98%H2SO4中应表现出如图2所示的阴极极化特性,也就是说,阳极保护系统正常工作时,阴极电位处于φ2值,相对应的阴极电流密度为i2。若浓硫酸生产中工艺条件变化,如浓硫酸温度、浓度变化,则管道的维钝电流密度变化,导致阴极电流密度变为i1或i3,相对应的阴极电位为φ1和φ3。i2与i1和i3相比变化较大,但φ2与φ1和φ3较接近。即当阴极电流密度变化的幅度较大时,阴极电位的变化很小。
对于电化学系统因为有:i=(S×i)÷S
式中:i—辅助阴极的电流密度,A/m2
      S—管道(阳极)的保护面积,m2
      S—阴极面积,m2
      i—管道(阳极)处在钝态时的维钝电流密度,A/m2
在方法实施中,管道面积S确定,维钝电流密度i确定,即S×i确定,因此,阴极面积的大小直接影响i的大小,一般情况下S∶S为300~700∶1。
阴极间距与管道的管径和浓硫酸的浓度有关,其有关数据列于表3中。在保证阴极面积恒定和强度许可的情况下,增加阴极的长度有利于电流的分散,使管道的阳极保护电位更趋一致,以达到理想的保护状态。
                    表3  阴极布置间距
     管径(mm)     ≤300  300~500     ≥500
间距(m)  93%H2SO4     2~3   2~4     3~5
 98%H2SO4     2~4   2~4     3~5
本发明提供的浓硫酸输送管道的恒压阳极保护方法,充分挖掘、利用了该体系阳极保护的潜力,无论在阴极选择,还是在电源方面与恒电位阳极保护方法相比具有以下突出的优点:
(1)该方法参比电极不参与控制,克服了参比电极不稳定对保护效果的影响。
(2)克服了参比电极故障导致的系统失控,即使在管道内未充满酸的情况下阳极保护系统也能正常工作。
(3)阴极材料在阳极保护系统正常工作时处于阴极保护状态。试验证明,在阳极保护系统正常工作时,阴极的保护度在75~90%,阴极材料得到很好的保护,延长了使用寿命,降低了阴极的更换费用。
(4)阳极保护电源简便、可靠、稳定、操作简单且成本大大降低。
(5)浓硫酸输送管道处于恒压阳极保护状态时,年腐蚀率可控制在0.05mm以下,可达到理想的保护效果。
附图说明    图1为浓硫酸输送管道的恒压法阳极保护的系统布置图;
            图2为阴极材料的阴极极化曲线图。
具体实施方式
实施例一:
对一条30米长、φ=200mm的输送浓硫酸管道进行阳极保护,浓硫酸浓度为98%,温度为85~90℃。阳极保护系统接线如图1布置,将浓硫酸输送管道1作为阳极,与管道保护控制仪3的正极相连;棒状形式阴极2与管道保护控制仪3的负极相连,沿管道径向插入浓硫酸管道中,阴极间距为2m,共布置阴极16支,沿管道1轴向一字排列,以并联方式接管道保护控制仪3,S∶S=500∶1。阳极保护系统开始工作时,调节阳极保护控制仪,使其输出1.7V的电压,在5~10分钟后,测得管道(阳极)电位为200~250mV,此时,降低阳极保护控制仪的输出电压,使其输出0.8V的稳定电压,管道(阳极)电位逐渐下降,最终稳定在150~250mV区间内,处于良好的保护状态。阴极电位最终稳定在-400~-500mV区间内,处于阴极保护状态。
实施例二:
对某制酸厂家的三条输酸管道进行阳极保护。输酸管道管径φ=400mm,每条管线长度L≈35m,浓硫酸浓度为93%和98%,浓硫酸温度为70~90℃。阳极保护系统接线如图1布置,将浓硫酸输送管道1作为阳极,与管道保护控制仪3的正极相连;棒状形式阴极2与管道保护控制仪3的负极相连,沿管道径向插入浓硫酸管道中,输送93%和98%浓硫酸的管道由不同的控制仪控制。阴极间距为2.5m,共布置阴极45支,沿管道1轴向一字排列,以并联方式接管道保护控制仪3,S∶S=550∶1。阳极保护系统开始工作时,调节阳极保护控制仪,使其输出1.7V的电压,在5~10分钟后,测得管道(阳极)电位为200~250mV,此时,降低阳极保护控制仪的输出电压,输送93%浓硫酸的管道控制仪输出700mV的电压,管道(阳极)电位逐渐下降,最终稳定在50~150mV区间内,处于良好的保护状态。输送98%浓硫酸的管道控制仪输出800mV的电压,管道(阳极)电位逐渐下降,最终稳定在150~250mV区间内,处于良好的保护状态。所有阴极电位最终为-400~-500mV区间内,处于阴极保护状态。
上述方法实施例中,阳极保护电位与管道直径、材料、浓硫酸的浓度、温度等有关,阴极的材料、设置的阴极个数与间距,也与浓硫酸的浓度、温度、管道直径及长度有关,具体数据可以在本发明技术方案及具体实施例的引导下,通过对具体的工艺条件做具体的试验得到,没有一个可以包容上述变量的函数式。

Claims (6)

1、一种浓硫酸输送管道的恒压阳极保护方法,其特征在于将浓硫酸输送管道(1)作为阳极,与管道保护控制仪(3)的正极相连;辅助阴极(2)起导通电流的作用,与管道保护控制仪(3)的负极相连,阴极(2)制成棒状形式,沿管道径向插入浓硫酸管道中;管道保护控制仪选择能够输出稳定直流电流、电压可调的整流器、稳压电源或恒槽压仪。
2、根据权利要求1所述的浓硫酸输送管道的恒压阳极保护方法,其特征在于上述阳极保护系统以电解槽阴阳极之间的电压E槽压作为控制指标,对于304L、316L不锈钢浓硫酸输送管道,浓硫酸浓度为93%,保护电位范围为-200~600mV,控制指标E槽压为200~1100mV;对于304L、316L不锈钢浓硫酸输送管道,浓硫酸浓度为98%,保护电位范围为-300~700mV,控制指标E槽压为100~1200mV。
3、根据权利要求1所述的浓硫酸输送管道的恒压阳极保护方法,其特征在于上述阴极的材料符合电位稳定、耐腐蚀、成本低,并且具有一定的强度的特点,在93~98%H2SO4中表现出的阴极极化特性为:阴极电流密度变化的幅度较大时,阴极电位的变化却很小。
4、根据权利要求1或3所述的浓硫酸输送管道的恒压阳极保护方法,其特征在于上述阴极的材料选择18-8型不锈钢、25-20型不锈钢、哈氏合金或Inconel合金。
5、根据权利要求1或3所述的浓硫酸输送管道的恒压阳极保护方法,其特征在于上述阴极的间距与管道管径和浓硫酸浓度有关,间距为2~5米,沿管道轴向一字排列,以并联方式接管道保护控制仪(3)。
6、根据权利要求1或3所述的浓硫酸输送管道的恒压阳极保护方法,其特征在于上述阳极的保护面积S与阴极面积S的比例为300~700∶1。
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