Reformation Dust

Reformer catalyst dust is a critical issue in the operation of continuous reforming units; its hazards are evident in aspects such as equipment performance, catalyst efficiency, and safe production, and it requires systematic measures for prevention and control. I. Main hazards of dust: Equipment blockage and wear. Dust accumulates in reactors, regenerators, and pipelines, which can lead to the blockage of Johnson Screens. This results in uneven gas distribution and increased pressure drops; in severe cases, it may cause the equipment to overheat or sinter. At the same time, dust particles cause abrasion on components such as lift pipes and valves, reducing the equipment’s lifespan. The catalyst’s performance declines as dust covers the active sites on its surface, reducing its reaction efficiency ； Heavy metals contained in the dust (such as iron and nickel) may migrate to the catalyst surface, exacerbating side reactions (such as cracking reactions) and leading to a decrease in selectivity. Fluctuations in system operation, along with dust accumulation, lead to uneven fluidization of the catalyst, causing blockages in the lift pipe or interruptions in circulation, and resulting in frequent shutdowns of the plant. For example, the Sudan Refinery was forced to perform manual cleaning every 5 days due to a sharp increase in the pressure difference across the dust filters, resulting in an operational capacity of 96.7%. Safety risk: The accumulation of dust in the sealed hopper can cause the solenoid valve to get stuck, leading to procedural failures ； Finer dust can also clog instrument pipelines, causing distorted monitoring and increasing operational risks. Furthermore, dust accumulation on the compressor impeller may disrupt dynamic balance, leading to unit shutdown. II. Prevention and Optimization Measures: Source control – improving catalyst quality and loading standards. Use catalysts with high mechanical strength (such as Axens CR-401), regularly test their strength parameters, and replace aged catalysts in a timely manner ； The loading process must be strictly regulated to prevent mechanical damage during transportation and loading; new catalysts need to be sieved to remove any broken particles. Equipment optimization: Improve the filtering and conveying systems; upgrade the material of dust filter elements (such as metal sintered tubes) to ensure sealing, and replace the elements regularly ； Optimize the riser design: reduce the number of elbows, standardize the pipe diameter, lower the gas-solid flow velocity, and minimize wear. Precise control of operating parameters to increase gas flow: While ensuring the required circulation rate, the lowest effective gas flow rate is used to reduce catalyst wear ； Optimization of leaching gas volume: The optimal leaching gas volume is determined using response surface methodology (such as the Box-Behnken model) to improve dust separation efficiency. Enhanced operation and maintenance: Regularly clean the Johnson net and hoppers of accumulated dust to prevent blockages ； Strengthen the maintenance of the balance valve in the closed hopper to prevent pressure buildup caused by dust buildup. III. Additional Recommendations: Application of online monitoring technology – Introduce a real-time dust concentration monitoring system, combined with a differential pressure warning model, to intervene in advance when abnormal operating conditions occur. Occupational health protection: For positions with dust exposure, personal protective equipment such as dust masks and air-supplied helmets is provided, and regular screening for pneumoconiosis is carried out. Through the above measures, dust generation can be significantly reduced (for example, the dust amount at the Sudan refinery decreased by 304 kilograms after maintenance), ensuring the long-term stable operation of the equipment.