RESUMO
Herein, we apply a computational diffusion model based on Fick's law to study the manner in which a cable production line and its operating conditions can be enhanced to effectively reduce the CH4 concentration in cables insulated with cross-linked polyethylene (XLPE). Thus, we quantitatively analyze the effect of the conductor temperature, curing tube temperature distribution, transition zone length, and online relaxation on CH4 generation and transport during the production of 132 kV cables with an insulation thickness of 16.3 mm. Results show that the conductor temperature, which is initially controlled by a preheater, and the curing tube temperature distribution considerably affect the CH4 concentration in the cable because of their direct impact on the insulation temperature. The simulation results show 2.7% less CH4 remaining in the cable when the preheater is set at 160 °C compared with that when no preheater is used. To study the curing tube temperature distribution, we consider three distribution patterns across the curing tube: constant temperature and linear incremental and decremental temperature. The amount of CH4 remaining in the cable when the temperature was linearly increased from 300 to 400 °C was 1.6% and 3.7% lower than in the cases with a constant temperature at 350 °C and a linear temperature decrease from 400 to 300 °C, respectively. In addition, simulations demonstrate that the amount of CH4 removal from the cable can be increased up to 9.7% by applying an elongated and insulated transition zone, which extends the residence time for CH4 removal and decelerates the decrease in cable temperature. Finally, simulations show that the addition of the online relaxation section can reduce the CH4 concentration in the cable because the high cable temperature in this section facilitates CH4 removal up to 2.2%, and this effect becomes greater at low production speeds.
RESUMO
In this work, we apply a computational diffusion model based on Fick's laws to study the generation and transport of methane (CH 4 ) during the production of a cross-linked polyethylene (XLPE) insulated cable. The model takes into account the heating process in a curing tube where most of the cross-linking reaction occurs and the subsequent two-stage cooling process, with water and air as the cooling media. For the calculation of CH 4 generation, the model considers the effect of temperature on the cross-linking reaction selectivity. The cross-linking reaction selectivity is a measure of the preference of cumyloxy to proceed either with a hydrogen abstraction reaction, which produces cumyl alcohol, or with a ß -scission reaction, which produces acetophenone and CH 4 . The simulation results show that, during cable production, a significant amount of CH 4 is generated in the XLPE layer, which diffuses out of the cable and into the conductor part of the cable. Therefore, the diffusion pattern becomes a non-uniform radial distribution of CH 4 at the cable take-up point, which corresponds well with existing experimental data. Using the model, we perform a series of parametric studies to determine the effect of the cable production conditions, such as the curing temperature, line speed, and cooling water flow rate, on CH 4 generation and transport during cable production. The results show that the curing temperature has the largest impact on the amount of CH 4 generated and its distribution within the cable. We found that under similar curing and cooling conditions, varying the line speed induces a notable effect on the CH 4 transport within the cable, while the cooling water flow rate had no significant impact.
