Pipe and device for thermally cleaving hydrocarbons

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is the national stage application under 35 U.S.C. § 371 of International Application No. PCT/EP2018/058615 filed on Apr. 4 2018, and claims the benefit of DE 102017003409.5 filed on Apr. 7, 2017 and EP 17000601.9 filed on Apr. 7, 2017, the entire disclosures of which are incorporated herein by reference in their entireties.

The invention relates to a pipe for thermal cracking of hydrocarbons in the presence of steam, in which the feed mixture is guided through externally heated pipes. The invention further relates to an apparatus for thermal cracking of hydrocarbons.

For the high-temperature pyrolysis of hydrocarbons (mineral oil derivatives), pipe furnaces have been found to be useful, in which a hydrocarbon/steam mixture at temperatures exceeding 750° C. is guided through rows of individual pipes or pipes in a meandering arrangement (cracking pipe coils) made of heat-resistant nickel-chromium-iron alloy with high oxidation resistance/scaling resistance and high carburization resistance. The pipe coils consist of straight pipe sections that run vertically or horizontally and are joined to one another via U-shaped pipe curves or are arranged parallel to one another. They are typically heated with the aid of sidewall burners and/or else with the aid of base burners and therefore have a “light side” facing the burners and a “dark side” offset by 90°, i.e. running in the direction of the rows of pipes. The average pipe wall temperatures (TMT) here in some cases exceed 1000° C.

The lifetime of the cracking pipes depends very significantly on the creep resistance and carburization resistance and on the carbonization rate of the pipe material. Crucial factors for the carbonization rate, i.e. for the growth of a layer of carbon deposits (pyrolysis coke) on the inner pipe wall, are not only the type of hydrocarbons used but also the cracking gas temperature in the inner wall region and what is called the cracking severity, which comprehends the effect of the system pressure and the dwell time in the pipe system on the ethylene yield. The cracking severity is adjusted using the average exit temperature of the cracking gases (e.g. 850° C.). The higher the gas temperature in the vicinity of the inner pipe wall is above this temperature, the more significant will be the growth of the layer of pyrolysis coke, the insulating effect of which causes the pipe wall temperature to rise further. Although the nickel-chromium-iron alloy with 0.4% carbon, more than 25% chromium and more than 20% nickel, for example 35% chromium, 45% nickel and optionally 1% niobium, which is used as pipe material has high carburization resistance, the carbon at defects in the oxide layer diffuses into the pipe wall, where it leads to considerable carburization that can extend as far as carbon contents of 1% to 3% at wall depths of 0.5 mm to 3 mm. This is associated with considerable embrittlement of the pipe material with the risk of cracking under thermal cycling stress, especially in the startup and shutdown of the furnace.

In order to degrade the carbon deposits (coking) at the inner pipe wall, it is necessary to stop cracking operation from time to time and burn the pyrolysis coke with the aid of a steam/air mixture. This entails an interruption of operation for up to 36 hours and therefore considerably impairs the economic viability of the process.

British patent specification 969 796 and European patent specification 1 136 541 A1 also disclose the use of cracking pipes with internal fins. Although such internal fins result in a greater inner surface area by many percent, for example 10% greater, and accordingly better heat transfer, they are also associated with the disadvantage of a considerable increase in pressure drop compared to a smooth pipe owing to friction on the increased internal pipe surface area. The higher pressure drop entails a higher system pressure, and hence inevitably alters the dwell time and worsens the yield. An additional factor is that the known pipe materials having high carbon and chromium contents can no longer be profiled by cold forming, for example cold drawing. They have the disadvantage that their formability decreases significantly with increasing heat resistance. The effect of this has been that the high pipe wall temperatures of up to 1050° C., for example, that are desired with regard to the ethylene yield require the use of centrifugally cast pipes. However, since centrifugally cast pipes can be manufactured only with a cylindrical wall, special shaping methods are required, for example an electrolytically material-removing processing operation or a shape-imparting welding method, in order to produce internal pipes.

Finally, U.S. Pat. No. 5,950,718 also discloses an entire spectrum of angles of inclination and also distances between the internal fins, but without considering the characteristics of the fins.

EP 1 525 289 B9 discloses a finned pipe for thermal cracking of hydrocarbons which has helical internal fins that are inclined relative to the pipe axis.

WO 2010/043375 A1 discloses a nickel-chromium-iron alloy having a high oxidation resistance and carburization resistance, rupture resistance and creep resistance, composed of 0.4% to 0.6% carbon, 28% to 33% chromium, 15% to 25% iron, 2% to 6% aluminum, up to 2% silicon, up to 2% manganese, up to 1.5% niobium, up to 1.5% tantalum, up to 1.0% tungsten, up to 1.0% titanium, up to 1.0% zirconium, up to 0.5% yttrium, up to 0.5% cerium, up to 0.5% molybdenum, up to 0.1% nitrogen, balance: nickel including melting-related impurities.

Against this background, it is an object of the invention to improve the economic viability of the thermal cracking of hydrocarbons in pipe furnaces with externally heated pipes.

It has been recognized that, in a pipe having the features of the preamble of claim 1, there is a relationship between the features that characterize the pipe, namely

- the number N_Tof grooves that have been introduced into the inner surface of the pipe and extend in a helix around the longitudinal axis along the inner surface,
- the diameter of the inner surface area into which the grooves have been introduced, in a cross section at right angles to the longitudinal axis,
- the radius r₂of the groove base of the grooves that each have the form of a circular arc in their groove base and are at right angles in cross section to the longitudinal axis, and
- the groove depth TT of the grooves which, in the cross section at right angles to the longitudinal axis, corresponds in each case to the smallest distance between the circle having the diameter Di on which the inner surface lies and the center of which lies on the longitudinal axis, and the furthest removed point of the groove base of the groove from the longitudinal axis,

which can be taken into account to improve the economic viability of the thermal cracking of hydrocarbons in pipe furnaces with externally heated pipes.

To wit, it has been recognized that it is possible to establish a characteristic value based on heat transfer considerations that can be calculated in two different ways, each of which, however, depends solely on the above-described features that characterize the pipe.

According to a first heat transfer consideration, this characteristic value can be expressed as

P1*|D_eqv|²+P2*|D_eqv|+P3

with the constants P1, P2 and P3 and numerical value |D_eqv| of the equivalent diameter D_eqvwhich is dependent on the internal diameter Di measured in mm.

Good results are achieved when the constant P1 chosen is a number from the claimed range from −0.2 to −0.3. In a preferred embodiment, the constant P1 is selected from a range from −0.25 to −0.295, especially preferably from a range from −0.287 to −0.2655. Especially preferably, the constant P1 is equal to −0.287 or −0.2655.

Good results are achieved when the constant P2 chosen is a number from the claimed range from 310 to 315. In a preferred embodiment, the constant P2 is selected from a range from 310 to 312, especially preferably from a range from 310.42 to 311.31. Especially preferably, the constant P2 is equal to 310.42 or 311.31.

Good results are achieved when the constant P3 chosen is a number from the claimed range from 200 to 1500. In a preferred embodiment, the constant P3 is selected from a range from 230 to 1400, especially preferably from a range from 261.21 to 1076. Especially preferably, the constant P3 is equal to 261.21 or 1076.

The characteristic value used according to the invention for the configuration of the pipe is expressed in the aforementioned relationship as a function of the numerical value |D_eqv| of the equivalent diameter D_eqvwhich is dependent on the internal diameter Di measured in mm. The term “numerical value” in this context and in the rest of the documents is understood to mean the dimensionless number of a value of a physical parameter which is composed of the numerical value and the measurement unit. A physical parameter is a quantitative determinable property of a physical object, process or state. Its value (size) is reported as the product of a numerical value (the measured value) and a measurement unit. Since the relationships used according to the invention for the configuration of the pipe are dimensionless, the numerical value of the physical parameters is employed. In order to clarify this, the numerical value of a parameter is represented in the description and the claims by the nomenclature otherwise frequently used for the representation of a quantity, for example as |D_eqv|. The representation of a variable between two horizontal lines, for example |D_eqv|, is understood in the context of this description and the claims to be a representation of the numerical value of the value (size) of a physical parameter expressed by the variable. The numerical value |Di| of a diameter Di expressed in mm of 70 mm is, for example, the number 70.

The characteristic value used for the configuration of the pipe according to the invention is expressed in the above relationship as a function of the numerical value |D_eqv| of the equivalent diameter D_eqvwhich is dependent on the internal diameter Di measured in mm. The equivalent diameter is the diameter of the inner surface area that would be possessed by a smooth, non-grooved pipe of passage area corresponding to the passage area of the pipe of the invention. Passage area is understood to mean the free area within the pipe in a cross section at right angles to the longitudinal axis. It has been found that heat transfer-based considerations can frequently be made more easily in a smooth pipe. It has also been found that users of the pipe of the invention, in their apparatuses for thermal cracking of hydrocarbons in the presence of steam, in which the feed mixture is guided through externally heated tubes, have in the past frequently worked with smooth pipes. For the changeover to the pipes of the invention, it is therefore easier if a comparison with the smooth pipe of corresponding passage area can be made.

The equivalent diameter D_eqvis found via the relationship D_eqv=2 r_eqvfrom the radius of the inner surface area that would have been possessed by a smooth, non-grooved pipe having a passage area corresponding to the passage area of the pipe of the invention. If the passage area A_eqvof the smooth pipe (A_eqv=π(r_eqv)²) is equated to the passage area of the pipe of the invention, it is possible to express the passage area A_eqvof the smooth pipe as follows in the features that characterize the pipe (the symbols used relate to a nomenclature as also elucidated by way of example in FIG. 5):

$\langle r_{eqv} \rangle = \langle \sqrt{\frac{\langle A_{eqv} \rangle}{π}} \rangle$

$A_{eqv} = A_{1} + N_{T} \cdot A_{T}$

$A_{1} = π \cdot {\langle r_{1} \rangle}^{2}$

$A_{T} = [\langle r_{2} \rangle \cdot \frac{b_{2}}{2} - \frac{s \cdot (\langle r_{2} \rangle - (\langle TT \rangle + h))}{2}] - [\langle r_{1} \rangle \cdot \frac{b_{1}}{2} - \frac{s \cdot (\langle r_{1} \rangle - h)}{2}]$

$b_{1} = 2 \cdot \langle r_{1} \rangle \cdot \arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{1} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}})}^{2}} \rangle}{\langle r_{1} \rangle})$

$b_{2} = 2 \cdot \langle r_{2} \rangle \cdot \arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{1} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}})}^{2}} \rangle}{\langle r_{2} \rangle})$

$s = 2 \cdot \langle \sqrt{2 \cdot \langle r_{1} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}})}^{2}} \rangle$

$h = \frac{2 \cdot \langle r_{2} \rangle \cdot \langle TT \rangle - {\langle TT \rangle}^{2}}{2 \cdot (\langle r_{1} \rangle - \langle r_{2} \rangle + \langle TT \rangle)}$

The passage area of the pipe of the invention that has been equated to the passage area A_eqvof the smooth pipe is composed of the passage area A₁bounded by the inner surface area into which the grooves have been introduced, which can be determined easily from the radius of the inner surface by A₁=π r₁², and the additional areas that are provided by the number of N_Tgrooves with their respective passage areas A_T.

After solving the above relationship, the passage area of the pipe of the invention that has been equated to the passage area A_eqvof the smooth pipe can thus be expressed as follows exclusively with the features that characterize the pipe (also referred to hereinafter as formula (1)):

$A_{eqv} = π \cdot {\langle r_{1} \rangle}^{2} + N_{T} \cdot [[{\langle r_{2} \rangle}^{2} \cdot \arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{1} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}})}^{2}} \rangle}{\langle r_{2} \rangle}) - \langle \sqrt{2 \cdot \langle r_{1} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}})}^{2}} \rangle \cdot (\langle r_{2} \rangle - (\langle TT \rangle + \frac{2 \cdot \langle r_{2} \rangle \cdot \langle TT \rangle - {\langle TT \rangle}^{2}}{2 \cdot (\langle r_{1} \rangle - \langle r_{2} \rangle + \langle TT \rangle)}))] - [{\langle r_{1} \rangle}^{2} \cdot \arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{1} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}})}^{2}} \rangle}{\langle r_{1} \rangle}) - \langle \sqrt{2 \cdot \langle r_{1} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ \langle TT \rangle - {\langle TT \rangle}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{1} \rangle - \\ \langle r_{2} \rangle + \langle TT \rangle) \end{matrix}})}^{2}} \rangle \cdot (\langle r_{1} \rangle - \frac{2 \cdot \langle r_{2} \rangle \cdot \langle TT \rangle - {\langle TT \rangle}^{2}}{2 \cdot (\langle r_{1} \rangle - \langle r_{2} \rangle + \langle TT \rangle)})]]$

According to a second heat transfer consideration, this characteristic value can be described as

C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv|−C8)*C9

or, taking account of further cross-linkages, as

C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv|−C8)*C9+(VD−C6)*(|D_eqv|−C8)*C10+(|D_eqv|−C8)*(|D_eqv|−C8)*C11

as a function of the numerical value |D_eqv| of the equivalent diameter D_eqvdependent on the internal diameter Di measured in mm, the number N_Tof grooves and the numerical value |TT| of the groove depth TT measured in mm and the groove density VD which describes the ratio of the grooves N_Tin the pipe in relation to the reference number N_refof the maximum number of grooves having a groove depth TT=1.3 mm that can be introduced in the inner surface area of a pipe having the same equivalent diameter D_eqv. The constants here are fixed as follows:

- C1=1946.066
- C2=302.378
- C3=−2.178
- C4=266.002
- C5=1.954
- C6=50.495
- C7=−2.004
- C8=79.732
- C9=−1.041
- C10=0.04631
- C11=−0.26550

It has been recognized that, if these two calculation methods for the characteristic value are equated, the relationship

P1*|D_eqv|²+P2*|D_eqv+P3=C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv|−C8)*C9

or, taking account of further cross-linkages, the relationship

P1*|D_eqv|²+P2*|D_eqv|+P3=C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv−C8)*C9+(VD−C6)*(|D_eqv|−C8)*C10+(|D_eqv|−C8)*(|D_eqv|−C8)*C11

is obtained as a description of the relationship of the pipe-characterizing features with one another, which characterize a pipe that improves the economic viability of the thermal cracking of hydrocarbons in pipe furnaces with externally heated pipes. The pipe-characterizing features to be used specifically for the pipe, namely

- the number N_Tof grooves that have been introduced into the inner surface of the pipe and extend in a helix around the longitudinal axis along the inner surface,
- the diameter of the inner surface area into which the grooves have been introduced, in a cross section at right angles to the longitudinal axis,
- the radius r₂of the groove base of the grooves that each have the form of a circular arc in their groove base and are at right angles in cross section to the longitudinal axis, and
- the groove depth TT of the grooves which, in the cross section at right angles to the longitudinal axis, corresponds in each case to the smallest distance between the circle having the diameter Di on which the inner surface lies and the center of which lies on the longitudinal axis, and the furthest removed point of the groove base of the groove from the longitudinal axis,

can be ascertained by simple iterations on the basis of this relationship. Every pair of these four pipe-characterizing features that satisfies this relationship constitutes a pipe that improves the economic viability of the thermal cracking of hydrocarbons in pipe furnaces with externally heated pipes.

In practice, it is found that the work associated with the iteration can in practice be reduced even further. For instance, findings for individual features among the four that characterize the pipe arise from stiffness or manufacturing restrictions or else from the need to manufacture the pipe with a particular passage area.

A maximum possible weight of the individual pipe that results from the plant in which the pipe is to be used may result in a restriction in respect of the maximum wall thickness of the pipe, which in turn results in a restriction in respect of the maximum producible groove depth TT from stiffness aspects. Restrictions in respect of wall thickness (and hence in respect of maximum producible groove depth) may also arise from other aspects, for example from the heat transfer to be achieved.

Stiffness considerations may also result in an upper limit in respect of the number N_Tof grooves that have been introduced into the inner surface of the pipe and extend in a helix around the longitudinal axis along the inner surface in combination with the groove depth TT. If an excessive number of excessively deep grooves is introduced, the stiffness of the pipe may be weakened excessively.

It is also possible that limits with regard to the radius r₂of the circular arc of the groove base in combination with the groove depth TT will result from the tendency of the pipe to coking in the thermal cracking of hydrocarbons in the presence of steam, in which the feed mixture is guided through the externally heated pipes.

Moreover, restrictions arise from manufacturing aspects, for example with regard to the radius r₂of the circular arc of the groove base in combination with the groove depth TT. The grooves may be produced, for example, by a deep-hole drilling method, for example in the manner described in the German patent application with application number 10 2016 012 907.7, which has been filed by the applicant but is yet to be published. This is done using indexable inserts for production of the grooves. These indexable inserts are available in fixed sizes. If—as is recommended for reasons of economic viability—the already obtainable indexable inserts are employed, dispensing with the likewise conceivable option of specifically manufacturing indexable inserts for the production of the specific pipe, this also results in settings for the radius r₂of the circular arc of the groove base in combination with the groove depth TT. It may also be found to be the case that a pipe having a first number of grooves can be manufactured more quickly and at much lower cost than a pipe having a second, greater number of grooves compared to the first number, and so this too can result in a restriction in respect of the number of grooves to be introduced.

Restrictions can also arise from the fact that a certain throughput of feed mixture is required for the pipe and, therefore, a minimum passage area of the pipe.

The result is that, prior to the performance of the iteration, there are already ranges within which individual features among the four that characterize the pipe cannot lie and hence these can be ruled out in the iteration.

The above-described relationship

C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv|−C8)*C9

or the relationship that includes further cross-linkages

C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv|−C8)*C9+(VD−C6)*(|D_eqv|−C8)*C10+(|D_eqv|−C8)*(|D_eqv|−C8)*C11

refer to the groove density VD. The groove density VD is the ratio of the grooves N_Tin the pipe in relation to the reference number N_refof the maximum number of grooves having a groove depth TT=1.3 mm that can be introduced in the inner surface area of a pipe having the same equivalent diameter D_eqvin percent.

The finding of the invention can be applied to pipes having a broad spectrum of diameters Di of the inner surface into which the grooves are introduced. It is obviously possible to introduce more grooves having a fixed radius r₂of the circular arc in the groove base of the groove and a fixed groove depth TT into a pipe having greater diameter Di than into a pipe having small diameter Di. In order nevertheless to be able to state a relationship for all diameters, a normalization has been developed, in which what is introduced into the relationship is no longer the actual number of grooves N_Tbut the groove density VD.

The groove density VD—since it is expressed in percent—is found from the relationship

VD=N_T/N_ref*100

where the reference number N_refis the greatest natural number at which the relationship

$N_{ref} \leq \frac{π}{\arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{eqv} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{eqv} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{eqv} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}})}^{2} \rangle}}{\langle r_{eqv} \rangle})}$

is satisfied, where A_eqvis the equivalent diameter calculated from the formula (1) and where

$\langle r_{eqv} \rangle = \langle \sqrt{\frac{\langle A_{eqv} \rangle}{π}} \rangle$

and in the case of which it is simultaneously possible to find an r_Nrefto be determined by iteration which, with reference to the equivalent diameter A_eqvcalculated by formula (1), satisfies the following relationships (also referred to hereinafter as formula (2)):

$A_{eqv} = π \cdot {\langle r_{N_{ref}} \rangle}^{2} + N_{ref} \cdot [[{\langle r_{2} \rangle}^{2} \cdot \arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{N_{ref}} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}})}^{2}} \rangle}{\langle r_{2} \rangle}) - \langle \sqrt{2 \cdot \langle r_{N_{ref}} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}})}^{2}} \rangle \cdot (\langle r_{2} \rangle - (1.3 + \frac{2 \cdot \langle r_{2} \rangle \cdot 1.3 - {1.3}^{2}}{2 \cdot (\langle r_{N_{ref}} \rangle - \langle r_{2} \rangle + 1.3)}))] - [{\langle r_{N_{ref}} \rangle}^{2} \cdot \arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{N_{ref}} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}})}^{2}} \rangle}{\langle r_{1} \rangle}) - \langle \sqrt{2 \cdot \langle r_{N_{ref}} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}})}^{2}} \rangle \cdot (\langle r_{N_{ref}} \rangle - \frac{2 \cdot \langle r_{2} \rangle \cdot 1.3 - {1.3}^{2}}{2 \cdot (\langle r_{N_{ref}} \rangle - \langle r_{2} \rangle + 1.3)})]]$

with the secondary conditions

$π \geq N_{ref} \cdot \arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{N_{ref}} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}})}^{2} \rangle}}{\langle r_{N_{ref}} \rangle}), r_{N_{ref}} < r_{eqv}$

N_refcan be determined easily by the following sequence of steps:

In a first step, the right-hand side of the relationship

is worked out using the values of the pipe which is to be examined for achievement of the advantages of the invention. Since N_refmust be a natural number, the natural number corresponding to the calculated value is assumed when the calculated value is a natural number, or the smaller natural number closest to the calculated value. A pipe is taken as an example here with Di=60 mm, TT=2.05 mm, r₂=8 mm and N_T=8. This gives N_ref≤19.4967769. Thus, N_refis assumed to be 19 in the first step.

A second step checks whether it is possible with the N_reffound in the first step to calculate an r_Nrefwith which, referring to the equivalent diameter A_eqvcalculated by the formula (1), the formula (2) can be satisfied without infringing the secondary condition

A_eqvis worked out with the values of the pipe which is to be examined for achievement of the advantages of the invention, calculated by the formula (1). Given the aforementioned example values (Di=60 mm, TT=2.05 mm, r₂=8 mm and N_T=8), an A_eqvof 2963.77397 mm²is found for the example values given. Therefore, the second step of the search for N_refexamines whether it is possible with the N_reffound in the first step to find an r_Nrefwhich, with the A_eqvthus calculated, satisfies the formula (2) and, at the same time, the secondary conditions mentioned are met.

This iteration can easily be performed with a spreadsheet program, for example Microsoft® Excel and the “Goal Seek” function provided in such spreadsheet programs. An initially empty first cell is taken, which is then taken as the “variable cell” in the Goal Seek function. This cell is filled with any numerical value, for example |r₁|. Then the aforementioned equation for A_eqv, which expresses A_eqvin terms of r_Nref, is input into a second cell, referring in respect of r_Nrefto the first cell filled with any numerical value, for example |r₁|, and taking the value of r₂from the characteristic data of the pipe which is to be examined for achievement of the advantages of the invention.

In a third cell, the equation “=A_eqv−value from the second cell” is input, calculating the A_eqvhere by the formula (1).

The following equation is input in a fourth cell:

$= π - N_{ref} \cdot \arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{N_{ref}} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}})}^{2}} \rangle}{\langle r_{N_{ref}} \rangle})$

where r_Nrefrefers to the first cell filled with any numerical value, for example |r₁|, and the value of r₂is taken from the characteristic data of the pipe which is to be examined for achievement of the advantages of the invention. An IF-THEN test is then added in a fifth cell, which gives the output word “FALSE” if the value in the fourth cell is less than zero and otherwise gives the output word “TRUE”.

With the spreadsheet thus prepared, it is then possible to start the Goal Seek function envisaged in the spreadsheet program. The Goal Seek function asks which is the target cell. The third cell is given as the input. The Goal Seek function also asks for the target value. This is input as 0 (zero). The Goal Seek function also asks for the variable cell. The first cell is given as the input. The Goal Seek function will lead to a value in the first cell. If the fifth cell contains “TRUE” for this value, the N_reffound in the first step is the N_refto be used. If the value in the fifth cell is “FALSE”, the N_reffound in the first step is reduced by the number 1 and hence a new N_refis formed, with which the second step is conducted again. In general, even at the end of the Goal Seek function, this results in a value in the first cell for which the word “TRUE” is also present in the fifth cell, and so the new N_refthus obtained is the N_refto be used. Otherwise, the new N_refis once again reduced by the number 1 and the second step is conducted once again. It has been found that, even when such a Goal Seek function in a spreadsheet program is not perfect in terms of the later post-decimal places, this does not have any noticeable effect on the interpretation anyway owing to the remaining tolerances.

With the N_refthus found, for the pipe to be examined for achievement of the advantages of the invention, it is possible to determine the groove density VD from VD=100*N_T/N_ref. If it is confirmed with the values thus obtained that

P1*|D_eqv|²+P2*|D_eqv|+P3=C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv|−C8)*C9

or, taking account of further cross-linkages, that

P1*|D_eqv|²+P2*|D_eqv|+P3=C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv|−C8)*C11,

it is confirmed that the pipe with these four features characterizing the pipe (N_T, Di, r₂, TT), on which the calculation is based, improves the economic viability of the thermal cracking of hydrocarbons in pipe furnaces having externally heated pipes.

With the abovementioned example values (Di=60 mm, TT=2.05 mm, r₂=8 mm and N_T=8), an N_refof 19 is found in the first step. In the second step, the Goal Seek function with N_refof 19 gives an r_Nrefof 29.4509992. In the fourth cell, however, the value of −0.07096658 results, and so the word “FALSE” is the output in the fifth cell. If the N_refof 19 is reduced by the number 1 to 18 and the second step is conducted again, the Goal Seek function with N_refof 18 results in an r_Nrefof 29.5192908. In the fourth cell, however, the value 0.10620948 results, and so the word “TRUE” is the output in the fifth cell. N_ref=18 would be the value to use in the later examination of the pipe for compliance with the invention for the calculation of the groove density VD.

The pipe of the invention extends along a longitudinal axis and has grooves introduced into its inner surface. The number of grooves present is expressed by the variable N_T. The grooves extend in helical form around the longitudinal axis along the inner surface of the pipe. In a preferred embodiment, the grooves are distributed homogeneously over the circumference of the pipe. This means that, in any cross section at right angles to the longitudinal axis, for all grooves, the distance in circumferential direction between two grooves in an adjacent arrangement is the same for all grooves.

The groove depth is regarded as the distance of the lowest point in the groove from the inner surface. This means, in a cross section at right angles to the longitudinal axis, the shortest distance between the furthest removed point (lowest point) in the groove, viewed from the longitudinal axis in radial direction, and an inner surface circle around the longitudinal axis on which the portions of the inner surface arranged furthest inward that remain between the grooves lie. There are envisaged embodiments of the invention in which the inner surface of the pipe is cylindrical and the grooves are introduced into this cylindrical inner surface. In that case, portions of the inner surface that form parts of a cylinder remain between the grooves. The inner surface circle on which the portions of the inner surface arranged furthest inward lie—since all remaining portions of the inner surface in this embodiment are arranged the same distance inwards—is the circle in the cross section on which the remaining portions of the cylindrical inner surface lie. But there are also envisaged embodiments in which the inner surface remaining between two grooves shrinks virtually to a line because the groove opening (the opening cross section of the groove in the inner surface area) chosen is very large. Especially when, in such an embodiment, the curvature of the surface of the groove changes from a concave curvature in the groove base (a circular arc in the groove base) to a convex curvature of the surface of the groove in the region of the groove opening, the effect of such embodiments may be as if, in circumferential direction, grooves (in that case meaning the convex-curved region of the groove) were followed by fins arranged between the grooves (in that case meaning the concave-curved region of the groove) and the wall bounding the groove (or better: the concave-curved groove base) merged into an outer surface of the fin. The inner surface circle on which the portions of the inner surface arranged furthest inward do of course lie, in such embodiments, is the circle in the cross section on which the vertices of the “fins” in this cross section lie. The groove depth is expressed by the variable TT in the relationship that characterizes the pipe that has been found in accordance with the invention.

In a preferred embodiment, the grooves in a cross section at right angles to the longitudinal axis, at least in the groove base, have a rounded cross section that can preferably be approximated by a circular arc or corresponds to a circular arc. In the region of the groove opening, the cross-sectional geometry of the groove, in a preferred embodiment, can widen out, especially as a result of a change from a concave cross-sectional geometry in the groove base to a convex cross-sectional geometry in the region of the groove opening. In an alternative embodiment, in a cross section at right angles to the longitudinal axis, the cross-sectional geometry of the entire groove can be approximated by a circular arc or corresponds to a circular arc. Likewise conceivable are embodiments in which the groove in a cross section at right angles to the longitudinal axis has the cross-sectional geometry of a portion of an ellipse. In a preferred embodiment, the shape of the cross section of a groove at right angles to the longitudinal axis remains the same for all cross sections at right angles to the longitudinal axis. In a particularly preferred embodiment, the shape and size of the cross section of a groove at right angles to the longitudinal axis remains the same for all cross sections at right angles to the longitudinal axis. In a preferred embodiment, all grooves of the pipe have the same shape, and especially preferably the same shape and size, in a cross section at right angles to the longitudinal axis, preferably in all cross sections at right angles to the longitudinal axis. If the grooves have different sizes and especially different groove depths, the groove depth TT of the deepest groove is used for the relationship of the invention that characterizes the pipe.

In a preferred embodiment, a cross section of the pipe at right angles to the longitudinal axis is rotationally symmetric about the longitudinal axis. This means that there is at least one angle between 0° and 360° by which the cross section of the pipe can be mapped on itself by rotation about the longitudinal axis.

In a preferred embodiment, a cross section of the pipe at right angles to the longitudinal axis has point symmetry about the point occupied by the longitudinal axis in that cross section.

In a preferred embodiment, a cross section of the pipe at right angles to the longitudinal axis has mirror symmetry about an axis that runs at right angles to the longitudinal axis and lies in that cross section.

In a cross section at right angles to the longitudinal axis, the pipe has an internal diameter which is expressed by the variable Di. The internal diameter is the diameter of the inner surface circle, i.e. the circle around the longitudinal axis, on which the portions of the inner surface arranged furthest inward that remain between the grooves lie.

In a preferred embodiment, the pipe cross section on the inside has a diameter Di within a range from 15 mm to 280 mm, especially preferably from 15 mm to 180 mm, especially preferably from 20 mm to 150 mm and especially preferably from 30 mm to 140 mm.

In a preferred embodiment, the groove depth TT is within a range from 0.1 mm to 10 mm, especially preferably from 1.0 mm to 7 mm and most preferably from 1.0 mm to 4 mm.

In a preferred embodiment, the number of grooves N_Tis within a range from 1 to 100, especially preferably from 2 to 50 and most preferably from 2 to 30.

In a preferred embodiment, the groove density VD is within a range from 1% to 347%, especially preferably from 2% to 113% and most preferably from 10% to 105%.

In a preferred embodiment, the grooves run at an angle of 20° to 40°, preferably of 22.5° to 32.5°, based on the longitudinal axis.

In a preferred embodiment, in a cross section at right angles to the longitudinal axis, the circular arc segment in the inner surface circle occupied by a portion of the inner surface arranged between two grooves is greater than 1% of the circular arc segment in the inner surface circle occupied by the groove opening of at least one of the grooves adjoining this portion of the inner surface area, especially greater than 2%, especially greater than 5%, especially greater than 10%, especially greater than 30%, especially greater than 50%, especially greater than 70%. In a preferred embodiment, in a cross section, the circular arc segment in the inner surface circle occupied by the portion of the inner surface arranged between two grooves is equal to or greater than the circular arc segment in the inner surface circle occupied by the groove opening of at least one of the grooves adjoining this portion of the inner surface.

An apparatus of the invention for thermal cracking of hydrocarbons in the presence of steam, in which the feed mixture is guided through externally heated pipes, has at least one pipe of the invention.

In the pipe of the invention, the heat supply in the pipe wall and in the pipe interior which is inevitably different across the pipe circumference between the light side and dark side is balanced, and the heat is rapidly removed inward toward the core zone. This is associated with a reduction in the risk of local overheating of the process gas at the pipe wall and of the formation of coke caused thereby. Moreover, the thermal stress on the pipe material is lower owing to the temperature compensation between light side and dark side, which leads to an extension of lifetime. Finally, in the case of the pipe of the invention, there is also homogenization of the temperature across the pipe cross section with the result of a better olefin yield. The reason for this is that, without the radial temperature compensation of the invention in the interior of the pipe, there would be excess cracking at the hot pipe wall and too low a reaction conversion in the middle of the pipe.

The pipe of the invention, according to the material, can be produced, for example, from a centrifugally cast pipe by twisting the ends of a pipe with axially parallel grooves in opposite directions, or by generating the internal profile by preforming a centrifugally cast pipe, for example by hot forging, hot drawing or cold forming via a profile mold, for example a floating mandrel or a mandrel rod with an external profile corresponding to the internal profile of the pipe.

Cutting machines for internal profiling of pipes are known in various variants, for example from German patent specification 195 23 280. These machines are also suitable for production of a pipe of the invention.

The inner surface of the pipe of the invention should have minimum roughness; it may therefore have been smoothed, for example mechanically polished or electrolytically leveled.

Suitable pipe materials for use in ethylene plants include nickel-chromium-iron alloys with 0.1% to 0.5% carbon, 20% to 35% chromium, 20% to 70% nickel, up to 3% silicon, up to 1% niobium, up to 5% tungsten and additions of hafnium, titanium, rare earths, or zirconium, of up to 0.5% in each case, and up to 6% aluminum.

For the pipe, it is especially preferable to use a nickel-chromium-iron alloy having high oxidation resistance and carburization resistance, rupture resistance and creep resistance, composed of

- 0.05% to 0.6% carbon
- 20% to 50% chromium
- 5% to 40% iron
- up to 6% aluminum
- up to 2% silicon
- up to 2% manganese
- up to 1.5% niobium
- up to 1.5% tantalum
- up to 6.0% tungsten
- up to 1.0% titanium
- up to 1.0% zirconium
- up to 0.5% yttrium
- up to 0.5% cerium
- up to 0.5% molybdenum
- up to 0.1% nitrogen
- balance: nickel including melting-related impurities.

The table below shows possible embodiments of the invention that conform to the proposed relationship of the invention. In one line, for a chosen internal diameter D_eqv, a pair N_TMaxand TT_minand VD_maxis specified for a good heat transfer, but a lower heat transfer in relation to a second pair of N_Tminand TT_maxand VD_min. In addition, the table shows a heat transfer estimated by a simulation program (H_min(D_eqv, TT_min, VD_Max) [watts]) for the lower heat transfer; H_Max(D_eqv, TT_max, VD_min) [watts]) for the further-improved heat transfer).

H_min(D_eqv, TT_min,

No.
D_eqv
N_Tmax
VD_max
TT_min
VD_max) [watts]

1
35
9
100
1.3
10831.95559

2
40
11
100
1.3
12288.96106

3
45
12
100
1.3
13732.69121

4
50
14
100
1.3
15163.14603

5
55
16
100
1.3
16580.32553

6
60
18
100
1.3
17984.2297

7
65
20
100
1.3
19374.85855

8
70
21
100
1.3
20752.21208

9
75
23
100
1.3
22116.29028

10
80
25
100
1.3
23467.09315

11
85
27
100
1.3
24804.62071

12
90
29
100
1.3
26128.87294

13
95
30
100
1.3
27439.84984

14
100
32
100
1.3
28737.55142

15
105
34
100
1.3
30021.97768

16
110
36
100
1.3
31293.12861

17
115
38
100
1.3
32551.00422

18
120
39
100
1.3
33795.6045

19
125
41
100
1.3
35026.92946

20
130
43
100
1.3
36244.9791

21
135
45
100
1.3
37449.75341

22
140
47
100
1.3
38641.25239

23
160
54
100
1.3
43274.4951

24
180
61
100
1.3
47695.33262

25
200
68
100
1.3
51903.76496

26
280
97
100
1.3
66613.44243

H_max(D_eqv, TT_max,

No.
D_eqv
NT_min
VD_min
TT_max
VD_min) [watts]

27
35
3
33.33333333
2.7
11564.65262

28
40
3
27.27272727
2.7
13032.35209

29
45
3
25
2.7
14463.96054

30
50
3
21.42857143
2.7
15887.80079

31
55
3
18.75
2.7
17292.40888

32
60
3
16.66666667
2.7
18679.77042

33
65
3
15
2.7
20051.07678

34
70
3
14.28571429
2.7
21404.40771

35
75
3
13.04347826
2.7
22746.18795

36
80
3
12
2.7
24073.38983

37
85
3
11.11111111
2.7
25386.30292

38
90
3
10.34482759
2.7
26685.1369

39
95
3
10
2.7
27969.09023

40
100
3
9.375
2.7
29240.37497

41
105
3
8.823529412
2.7
30497.91084

42
110
3
8.333333333
2.7
31741.77677

43
115
3
7.894736842
2.7
32972.03508

44
120
3
7.692307692
2.7
34188.38764

45
125
3
7.317073171
2.7
35391.6438

46
130
3
6.976744186
2.7
36581.40387

47
135
3
6.666666667
2.7
37757.6973

48
140
3
6.382978723
2.7
38920.54851

49
160
3
5.555555556
2.7
43437.89962

50
180
3
4.918032787
2.7
47741.49693

51
200
3
4.411764706
2.7
51831.75693

52
280
3
3.092783505
2.7
66063.32146

It has been recognized that the expected heat transfer, both for the good but slightly lower value in relation to the further-optimized value (H_min(D_eqv, TT_min, VD_Max) [watts]) and for the further-optimized value H_max(D_eqv, TT_max, VD_min) [watts]), can be plotted in direct proportion to the internal diameter, as shown in FIG. 4. The table below shows the values of the different variables of the relationships used in accordance with the invention for the individual pipes. The circular arc in the groove base had a radius r₂of 8 mm.

No.
A_eqv
A₁
A_T
r₁
b₁
b₂
s
h

1
962.113
870.691
10.158
16.648
11.365
12.331
11.146
0.961

2
1256.637
1149.789
9.713
19.131
10.883
11.77
10.737
0.769

3
1590.431
1477.643
9.399
21.688
10.543
11.374
10.44
0.638

4
1963.495
1835.026
9.176
24.168
10.303
11.093
10.226
0.547

5
2375.829
2231.74
9.006
26.653
10.12
10.878
10.059
0.479

6
2827.433
2667.765
8.87
29.141
9.975
10.708
9.927
0.426

7
3318.307
3143.09
8.761
31.63
9.858
10.57
9.818
0.383

8
3848.451
3666.405
8.669
34.162
9.76
10.455
9.727
0.348

9
4417.865
4220.229
8.593
36.652
9.679
10.359
9.65
0.319

10
5026.548
4813.348
8.528
39.143
9.609
10.278
9.585
0.295

11
5674.502
5445.756
8.472
41.635
9.55
10.207
9.529
0.274

12
6361.725
6117.451
8.423
44.128
9.498
10.146
9.48
0.255

13
7088.218
6836.823
8.38
46.65
9.452
10.092
9.436
0.239

14
7853.982
7587.043
8.342
49.143
9.411
10.044
9.397
0.225

15
8659.015
8376.545
8.308
51.637
9.375
10.001
9.362
0.213

16
9503.318
9205.329
8.277
54.131
9.343
9.963
9.331
0.201

17
10386.891
10073.393
8.25
56.626
9.314
9.928
9.303
0.191

18
11309.734
10988.968
8.225
59.143
9.287
9.897
9.278
0.182

19
12271.846
11935.564
8.202
61.638
9.263
9.868
9.254
0.174

20
13273.229
12921.438
8.181
64.133
9.241
9.842
9.233
0.166

21
14313.882
13946.589
8.162
66.628
9.221
9.818
9.213
0.159

22
15393.804
15011.017
8.144
69.124
9.202
9.796
9.195
0.153

23
20106.193
19669.568
8.086
79.127
9.14
9.722
9.135
0.132

24
25446.9
24956.406
8.041
89.128
9.092
9.666
9.088
0.116

25
31415.927
30871.542
8.006
99.13
9.055
9.621
9.052
0.103

26
61575.216
60807.235
7.917
139.124
8.962
9.511
8.96
0.072

27
962.113
877.692
28.14
16.715
14.619
17.379
14.158
1.573

28
1256.637
1175.212
27.142
19.341
14.145
16.706
13.832
1.279

29
1590.431
1511.08
26.45
21.932
13.82
16.241
13.592
1.08

30
1963.495
1885.673
25.941
24.5
13.582
15.899
13.409
0.935

31
2375.829
2299.186
25.548
27.053
13.4
15.636
13.263
0.825

32
2827.433
2751.727
25.236
29.596
13.255
15.426
13.145
0.739

33
3318.307
3243.365
24.981
32.131
13.138
15.256
13.047
0.669

34
3848.451
3774.144
24.769
34.66
13.041
15.114
12.964
0.612

35
4417.865
4344.095
24.59
37.186
12.959
14.994
12.894
0.563

36
5026.548
4953.239
24.437
39.707
12.889
14.891
12.833
0.522

37
5674.502
5601.591
24.304
42.226
12.829
14.802
12.779
0.486

38
6361.725
6289.163
24.187
44.743
12.776
14.724
12.732
0.455

39
7088.218
7015.965
24.085
47.257
12.729
14.656
12.691
0.428

40
7853.982
7782.002
23.993
49.77
12.688
14.595
12.653
0.404

41
8659.015
8587.28
23.912
52.282
12.651
14.54
12.62
0.382

42
9503.318
9431.804
23.838
54.793
12.617
14.491
12.589
0.363

43
10386.891
10315.577
23.771
57.302
12.587
14.446
12.562
0.345

44
11309.734
11238.601
23.711
59.811
12.56
14.406
12.537
0.329

45
12271.846
12200.88
23.656
62.319
12.535
14.369
12.514
0.315

46
13273.229
13202.415
23.605
64.826
12.512
14.335
12.493
0.302

47
14313.882
14243.208
23.558
67.333
12.491
14.304
12.473
0.289

48
15393.804
15323.26
23.515
69.839
12.472
14.275
12.455
0.278

49
20106.193
20036.081
23.371
79.86
12.407
14.178
12.394
0.241

50
25446.9
25377.119
23.26
89.877
12.357
14.105
12.347
0.212

51
31415.927
31346.407
23.173
99.889
12.318
14.046
12.31
0.19

52
61575.216
61506.358
22.953
139.922
12.22
13.899
12.216
0.133

In the CFD analysis (computational fluid dynamics analysis) used for the estimation of the values (H_min(D_eqv, TT_min, VD_Max) [watts]) and H_max(D_eqv, TT_max, VD_min) [watts]), the following simulation conditions were used:

Boundary conditions for simulation of the heat transfer:

Temperature of the space for external heating of the pipes: 1300° C.

Emissivity E of the pipes: 0.85

Inclusion of light/dark sides (light side: 80% radiation 20% convection; dark side: 20% radiation 80% convection) and of the physical material properties of density, specific heat capacity and thermal conductivity as a function of temperature

Simulation length: 2 m

TABLE 1

State of the feed mixture at the pipe inlet

Parameter
Value

Temperature, ° C.
621

Pressure, bar
2

Area-specific mass flow rate, g/(s · m²)
52912.8

TABLE 2

Physical properties of the feed mixture

Specific heat
Dynamic
Thermal

Temperature
Density
capacity
viscosity
conductivity

° C.
kg/m³
kJ/kgK
kg/ms
W/mK

620
0.87467615
2.81553015
2.941481E−05
0.08947538

630
0.86669998
2.82698110
2.974235E−05
0.09122076

640
0.85872380
2.83843205
3.006989E−05
0.09296613

650
0.85074763
2.84988300
3.039743E−05
0.09471151

660
0.84277145
2.86133395
3.072497E−05
0.09645688

670
0.83479528
2.87278490
3.105251E−05
0.09820226

680
0.82681910
2.88423585
3.138005E−05
0.09994763

690
0.81884293
2.89568680
3.170759E−05
0.10169301

700
0.81086675
2.90713775
3.203513E−05
0.10343838

710
0.80289058
2.91858870
3.236268E−05
0.10518376

720
0.79491440
2.93003965
3.269022E−05
0.10692913

730
0.78693823
2.94149060
3.301776E−05
0.10867451

740
0.77896205
2.95294155
3.334530E−05
0.11041988

750
0.77098588
2.96439250
3.367284E−05
0.11216526

760
0.76300970
2.97584345
3.400038E−05
0.11391063

770
0.75503353
2.98729440
3.432792E−05
0.11565601

780
0.74705735
2.99874535
3.465546E−05
0.11740138

790
0.73908118
3.01019630
3.498300E−05
0.11914676

800
0.73110500
3.02164725
3.531055E−05
0.12089213

810
0.72312883
3.03309820
3.563809E−05
0.12263751

820
0.71515265
3.04454915
3.596563E−05
0.12438288

830
0.70717648
3.05600010
3.629317E−05
0.12612826

840
0.69920030
3.06745105
3.662071E−05
0.12787363

850
0.69122413
3.07890200
3.694825E−05
0.12961901

The pipe of the invention is preferably used for thermal cracking of hydrocarbons in the presence of steam, in which the feed mixture is guided through externally heated pipes.

The invention is elucidated in detail by a drawing that shows merely embodiments of the invention. The figures show:

FIG. 1 a perspective view of a pipe of the invention,

FIG. 2 a first possible cross section of a pipe of the invention in a section plane at right angles to the longitudinal axis of the pipe,

FIG. 3 a second possible cross section of a pipe of the invention in a section plane at right angles to the longitudinal axis of the pipe,

FIG. 4 a diagram that shows, for a pair of numbers N_Tof grooves and groove depths TT that leads to good results and for a pair of numbers N_Tof grooves and groove depths TT that leads to further-improved results, the dependence of the heat transfer achieved with this pair on the internal diameter and

FIG. 5 a cross section through a pipe of the invention with a groove.

The inventive pipe 1 shown in FIG. 1 extends along a longitudinal axis A and has a number of 3 grooves 2 introduced into the inner surface that extend in a helix around the longitudinal axis A along the inner surface.

In the cross section of the inventive pipe 1 shown in FIG. 2, it is apparent that, in a preferred embodiment, the grooves 2 are introduced into the otherwise cylindrical inner surface of the pipe 1. Between the grooves 2, there thus remain portions of the cylindrical inner surface of the pipe 1.

Included in FIG. 2 is the groove depth TT and the diameter Di and the inner surface circle 3.

It is likewise shown in FIG. 2 that the cross section of the grooves 2 can be represented by a circular arc.

In the cross section of the inventive pipe 1 shown in FIG. 3, it is apparent that, in an alternative embodiment, the concave grooves in the groove base 4 can merge into a convex shape in the direction of the groove opening 5, and that the portion of the inner surface that remains between two grooves 2 shrinks virtually down to a line. Included in FIG. 3 is the groove depth TT and the diameter Di and the inner surface circle 3.

FIG. 4 shows the values of (H_min(D_eqv, TT_min, VD_max) [watts]) and H_Max(D_eqv, TT_max, VD_min) [watts]) that are reported in the table as a function of the equivalent diameter D_eqv. It is apparent that these values can be represented by a line in each case.

FIG. 5 and the detail Y shown in FIG. 5 show, by way of example, in an inventive pipe with a groove, the nomenclature of the abbreviations A₁, r₁, TT, h, b₂, b₁, A_T, r₂and s used in the claims and this description.

The way in which the four values N_T, Di, r₂and TT that characterize the pipe may be found can be shown by the examples that follow.

In one example, there is the external requirement that the passage area is to correspond to that of a smooth pipe of diameter 60 mm. In addition, from a manufacturing point of view, the tools usable for the manufacture of the pipe result in the restriction that a groove depth TT of 1.3 mm and a radius r₂of the circular arc of the groove base of 8 mm is to be chosen in the case of grooves having a cross section in the shape of a circular arc. The question is what diameter Di and what number of grooves can improve the economic viability of the thermal cracking of hydrocarbons in pipe furnaces with externally heated pipes.

The starting point is thus:

D_eqv=60 mm

A_eqv=π(60/2)=2827.43 mm²

TT=1.3 mm

r₂=8 mm

A_eqvdirectly gives r_eqv=Di_eqv/2=30 mm

r₂and r_eqvgive, for the determination of the N_refin the first step by the formula

$π \geq N_{ref} \cdot \arcsin (\frac{\langle \sqrt{2 \cdot \langle r_{N_{ref}} \rangle \cdot \frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}} - {(\frac{\begin{matrix} 2 \cdot \langle r_{2} \rangle \cdot \\ 1.3 - {1.3}^{2} \end{matrix}}{2 \cdot \begin{matrix} (\langle r_{N_{ref}} \rangle - \\ \langle r_{2} \rangle + 1.3) \end{matrix}})}^{2}} \rangle}{\langle r_{N_{ref}} \rangle}), r_{N_{ref}} < r_{eqv}$

is simultaneously fulfilled. The number 18 should thus be used as N_ref.

N_ref=18 gives VD=N_T/18*100.

Inserting the minimum values of P1, P2 and P3, for the left-hand term of the equation

P1*|D_eqv|²+P2*|D_eqv|+P3=C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv|−C8)*C9+(VD−C6)*(|D_eqv|−C8)*C10+(|D_eqv|−C8)*(|D_eqv|−C8)*C11

with the constants

- C1=1946.066
- C2=302.378
- C3=−2.178
- C4=266.002
- C5=1.954
- C6=50.495
- C7=−2.004
- C8=79.732
- C9=−1.041
- C10=0.04631
- C11=−0.26550
- −0.2≥P1≥−0.3
- 310≤P2≤315
- 200≤P3≤1500

gives the value

P1*|D_eqv|²+P2*|D_eqv|+P3=−0.3*(60)²+310*60+200=17720

and inserting the maximum values of P1, P2 and P3 gives, for the left-hand term of the equation,

P1*|D_eqv|²+P2*|D_eqv|+P3=−0.2*(60)²+315*60+1500=19680

For the right-hand term of the equation

C1+C2*|TT|+C3*VD+C4*|D_eqv|+(|TT|−C5)*(VD−C6)*C7+(|TT|−C5)*(|D_eqv|−C8)*C9+(VD−C6)*(|D_eqv|−C8)*C10+(|D_eqv|−C8)*(|D_eqv|−C8)*C11

inserting |TT|=1.3 and |D_eqv|=60 gives

1946.066+302.378*1.3+−2.178*VD+266.002*60+(1.3−1.954)*(VD−50.495)*−2.004+(1.3−1.954)*(60−79.732)*−1.041+(VD−50.495)*(60−79.732)*0.04631+(60−79.732)*(60−79.732)*−0.26550
and so:
18162.4329−1.7812VD

and with VD=N_T/N_ref*100=N_T/18*100=5.5556 N_Tthe result is

18162.4329−9.8954N_T

In order to ensure that the pipe achieves the advantages of the invention, N_Tshould be chosen such that the relationship

19680≥18162.4329−9.8954N_T

- and the relationship
  
  18162.4329−9.8954N_T≥17720
  
  are fulfilled. Both relationships would be fulfilled with 1≤N_T≤44.71.

Since the N_Tthus found is greater than the previously calculated parameter N_ref, even in the case of introduction of the maximum possible number of grooves (N_ref=18), the advantages of the invention can still be achieved at this valley depth. The user is thus at liberty in this working example to endow the pipe with up to the maximum possible number of grooves without losing the advantages of the invention.

The N_Tthus found can be used to iteratively determine the radius r₁of the pipe and hence the internal diameter Di (=2 r₁) of the pipe using the formula (1), since A_eqv=2827.43 mm².

Therefore, it is possible to determine all the parameters needed for the manufacture of the pipe that implements the benefits of the invention.

Number	Date	Country	Kind
102017003409.5	Apr 2017	DE	national
17000601	Apr 2017	EP	regional

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Pipe and device for thermally cleaving hydrocarbons

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