Fatigue Life Analysis of Cyclone Separator Group Structure in a Reactor Device

In the chlorination industry, the reactor is a crucial equipment in which the chlorination reaction takes place. However, when the reactor is subjected to complex conditions such as high temperatures (e.g., >200 °C) and high pressures (e.g., >10 MPa), its structural integrity is significantly compromised, leading to severe safety issues. In this study, the fatigue life of a reactor is analyzed, with particular focus on the fatigue behavior of the cyclone separator under varying working conditions, such as changes in the temperature, pressure, and chemical environment. Using finite element simulations under steady-state conditions and the S-N curve from fatigue testing, the fatigue life and potential weak points of the reactor under different amplitudes and vibration frequencies are analyzed and predicted. This analysis is conducted using a combined simulation approach with ABAQUS and Fe-Safe software, v 6.14. This work also considers the periodic vibrations at the base of the cyclone separator within the reactor. Fatigue simulations under different vibration conditions are performed to further assess the fatigue life of the reactor, providing a theoretical basis for the optimization of design and ensuring operational safety. In addition, the influence of welding zones on the fatigue life is discussed. The results indicate that the welding defects and stress concentration may cause the welded joint to become a critical weak point for fatigue failure. Therefore, the fatigue performance of the welding zone should be carefully considered during the design phase.