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文章编号：1672-6987（2026）04-0029-10；DOI：10. 16351/j. 1672-6987. 2026. 04. 004
程千里 1 ，李炳青 2 ，王 宁 3* ，宁延利 3 （1. 中国石化青岛炼油化工有限责任公司，山东 青岛 266599；2. 青岛市黄岛区市场监督管理综合保障中心，山东 青岛 266520；3. 青岛科技大学 化工学院，山东 青岛 266042）
摘 要：炼化企业稳定塔顶空冷器和常顶空冷器是炼油化工装置中的关键设备，由于其特殊 的工作环境（高温、含硫腐蚀性介质、复杂应力等），存在腐蚀、开裂、结垢与堵塞等安全风险。 针对国内某炼化企业稳定塔顶空冷器板束开裂与常顶空冷器入口结垢问题，通过多尺度失效 分析发现：稳定塔顶空冷器板束开裂属湿硫化氢环境应力腐蚀开裂（SSCC），根本原因为焊缝 铁素体含量异常偏高及 σ 相析出，导致硬度超标，在 H2S 分压 0. 016 MPa、残余应力与微量 Cl− 浓缩协同作用下诱发裂纹。常顶空冷器入口结垢主因是 FeS 腐蚀产物与有机胺盐结晶耦合沉 积，叠加注水 pH 失控及流体动力学缺陷，在空冷入口滞留区形成硬垢。两设备失效机制存在 深度关联，本质是由腐蚀产物跨设备迁移形成恶性循环。稳定塔顶空冷器采用焊接工艺优化 及材质升级可有效预防开裂；常顶空冷器结垢则需通过注水策略优化及胺剂替代协同解决。
关键词：空冷器板束；开裂失效；空冷器入口；结垢
中图分类号：TE 986 文献标志码：A
引用格式：程千里，李炳青，王宁，等 . 炼化空冷器开裂与结垢失效机制研究［J］. 青岛科技 大学学报（自然科学版），2026，47（4）：29-38.
CHENG Qianli， LI Bingqing， WANG Ning， et al. Research on failure mechanisms of crack⁃ ing and fouling in petrochemical air coolers［J］. Journal of Qingdao University of Science and Technology（Natural Science Edition），2026，47（4）：29-38.
Research on Failure Mechanisms of Cracking and Fouling in Petrochemical Air Coolers
CHENG Qianli1 ，LI Bingqing2 ，WANG Ning3 ，NING Yanli3 （1. Sinopec Qingdao Refining and Chemical Company Limited， Qingdao 266599， China；2. Qingdao Huangdao District Market Supervision and Administration Comprehensive Guarantee Center， Qingdao 266520， China；3. College of Chemical Engineering， Qingdao University of Science and Technology， Qingdao 266042， China）
Abstract：Stabilizer overhead air coolers and atmospheric overhead air coolers in petrochemical enterprises are critical equipment within oil refining and chemical processing units. Due to their severe operating environments （high temperatures， sulfur-containing corrosive media， complex stresses， etc. ）， they face safety risks including corrosion， cracking， scaling， and blockage. Through multiscale failure analysis of bundle cracking in a stabilizer overhead air cooler and inlet scaling in an atmospheric overhead air cooler at a domestic refinery， the following mecha⁃ nisms were identified：Stabilizer overhead air cooler bundle cracking is attributed to sulfide stress corrosion cracking （SSCC） in a wet H2S environment. The root cause involves abnor⁃ mally high ferrite content in the weld zone and σ -phase precipitation， resulting in excessive hardness （beyond acceptable limits）. Under the combined effects of H2S partial pressure （0. 016 MPa）， residual stresses， and localized Cl−concentration， cracks initiated and propa⁃ gated. Atmospheric overhead air cooler inlet scaling primarily results from coupled deposition of FeS corrosion products and organic amine salt crystals. This process is exacerbated by uncontrolled injection water pH and hydrodynamic deficiencies， leading to hard scale formation in stagnant zones at the air cooler inlet. The failure mechanisms of the two equipment units are intrinsically linked， fundamentally driven by a self-perpetuating cycle formed through crossequipment migration of corrosion products. Mitigation strategies demonstrate that：Optimized welding procedures combined with material upgrades can effectively prevent cracking in stabi⁃ lizer overhead air coolers. Scaling in atmospheric overhead air coolers requires a synergistic solution through refined water injection strategies and amine agent substitution.
Key words：air cooler plate bundle； cracking failure； the inlet of the air cooler； scaling
收稿日期：2025-06-27
作者简介：程千里（1982—），男，高级工程师 . * 通信联系人 .
