What are the common reasons for excessive powder generation in the catalytic regeneration system?
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Dear seniors: The regenerative system of our refinery unit generates a large amount of powder, and the catalyst consumption is as high as over 3. The cause has not been identified yet; please help us determine what might be the reason. Thank you
High powder production! Does it refer to the large number of catalyst variants within the anti-reformation system, as well as severe catalyst loss, which results in a catalyst consumption rate of over 3? The reasons for the numerous catalyst subtypes are mainly as follows: 1. High levels of heavy metals in the raw materials accumulate on the surface of the catalyst, reducing its strength and making it prone to breaking. 2. The steam temperature in the reaction zone is low, or even contains water, resulting in thermal degradation of the catalyst. 3. The structure design of the anti-reformation system is unreasonable, resulting in severe catalyst collision and wear. 4. The wear index of the catalyst used is too high. 5. Heat extraction from the outside or from the inside is lost, resulting in thermal collapse of the catalyst.
1. The wear resistance of the catalyst is rather poor, as its mechanical strength is insufficient. 2. Whether the raw material contains water. 3. Low steam temperature leading to water presence. 4. Leakage in the internal and external heat exchangers. 5. Check whether the steam valve for the sleeve air accident is leaking. 6. Is the steam volume at each loose point excessive?
Have the screening of system balancers and tri-rotators been done? How was it?
I haven’t carried out system balancing or three-screen separation yet; please help me come up with some ideas. Thank you
You can ask the catalyst manufacturer to help with an analysis. If a large amount of material larger than 20 μm is separated by the three-stage centrifuge, it indicates that there is a problem with your regeneration centrifugation system. If the separation by the three-stage centrifuge is normal but a large amount of fine powder is separated by the system’s balance agent, then consider investigating the cause of the crushing issue. Wish you solve the problem soon.
There are two reasons for the catalyst turning into fine powder: one is the rapid impact of steam on the catalyst, and the other is the pyrolysis of the catalyst caused by water vapor coming into contact with the high-temperature catalyst. Do you mean that the large amount of powder produced occurs when pressing waste materials regularly? Has this been the case for a long time, or did it start only recently? If this keeps happening, it’s definitely a problem with the design of your equipment or the steam speed is too high. If it started recently, I think it’s probably because the raw material contains water, or you have started using a dilute-phase water spray system
What is the dilute-phase density of your unit? Is a distribution plate or a distribution tube used for the main air distribution? What is the pressure drop?