Seeking help regarding the reasons for fluctuations in the pressure difference across a single stage in the butylene hydration reactor
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The hydration reactor consists of four bed sections, each with a height of 4.3 meters; the beds are filled with hydration catalyst resin. Support plates are located above and below each bed section, and these support plates are equipped with water caps in the vertical direction. The gaps in these water caps are only 0.02 mm. The function of the water caps is to ensure proper flow of the medium while simultaneously containing the catalyst resin and preventing it from leaking out. Additionally, the water caps help to distribute the material evenly； The material enters from the bottom of the reactor and exits from the top. The pressure drop that occurs as it passes through each bed layer represents the pressure difference for that bed layer. The pressure difference near the bottom of the reactor is particularly volatile. Previously, the water flow rate was 8000 kg/h, while it is now 2000 kg/h. Whenever the pressure difference of the incoming water increases, severe fluctuations occur. The reasons for this include the discharge of additives, the quality of the discharged water, and butylene issues (isobutylene and butadiene are within normal ranges). Another possible cause is problems with the monitoring instruments. Question: Could it be a catalyst issue (such as fragmentation or caking)? Is the catalyst clog caused by the water cap? Method: Currently, the water supply is completely turned off for one period, followed by a 4-hour wait before resuming water supply, but the effect is not significant; the additive supply is kept at full capacity throughout this period. What could be the reason for this? Are there any better ways to stabilize the pressure difference? The values are as follows: 117:410.137:440.223, 8:210.0918:250.149, 9:150.1019:190.165, 10:080.10610:110.193, 23:220.09423:250.213, 1410:080.09910:130.152, 154:150.1044:220.178, 16:130.12316:190.197, 23:520.10323:570.182, 1722:280.10322:380.183, 186:520.0857:040.179 – Chemical process management
Possible causes of pressure drop fluctuations in a butylene hydration reactor in a single stage include: 1. Catalyst issues: Cracked or caked catalysts can lead to blockages in the bed channels, increasing fluid resistance and causing pressure drop fluctuations. 2. Clogging of the water cap: If the tiny gaps in the water cap become blocked, it will affect the flow of material, leading to fluctuations in pressure difference. 3. Changes in operating conditions: For example, changes in the amount of water entering the system or adjustments to the inlet pressure can both cause fluctuations in the pressure difference. 4. Changes in the bed structure: Displacement or damage may occur in the support plates or within the bed layer, affecting the uniform distribution of the fluid. Methods to stabilize the pressure difference may include: 1. Checking and cleaning the water cap to ensure it is not clogged. 2. Inspect the catalyst bed; if necessary, replace the crushed or caked catalyst. 3. Optimize operating conditions, such as adjusting the water inflow rate and pressure, to ensure they remain within appropriate ranges. 4. Inspect the internal structure of the reactor and repair any damage or displacement that may be present. Based on the methods you’ve suggested, turning off the water supply completely for a while and then restarting it does not yield significant results, which indicates that the problem is likely more complex than just a simple matter of adjusting the operations. It is necessary to take into account factors such as the condition of the catalyst, the blockage of the water cap, and operating conditions; a systematic inspection and maintenance may be required. .
By observing, after two days of low-flow water inflow, the pressure difference decreased on its own and stopped fluctuating. After increasing the water flow rate again, it was observed that the reactor can only be inspected when the catalyst is replaced