What is the difference between complete catalytic regeneration and incomplete regeneration?

Adjust the issue of the main air volume being adjusted repeatedly.

In fact, it’s equivalent to two regenerators (some of which are burnout tanks); the catalyst exits the settler and goes through regeneration once, during which about 40% is burned off. These partially regenerated catalysts then go through regeneration a second time to be completely burned out and regenerated.

Complete regeneration refers to complete regeneration at high temperature with an oxygen-rich environment, during which the coke burns completely; the regenerated flue gas contains a sufficient amount of excess oxygen, and it is free of carbon monoxide. Incomplete regeneration is generally used in a two-stage regeneration process; it involves repeatedly burning off the majority of the hydrogen and about 80% of the carbon in the catalyst under conditions of low oxygen and low temperature. This allows the catalyst to be charred at high temperatures, preventing hydrothermal deactivation. It improves the effectiveness of carbonization and enhances the catalyst’s activity. The flue gas in this process contains no oxygen, and a certain amount of carbon monoxide is present. The ratio of carbonization in the first and second stages is adjusted by controlling the ratio of the main air flow in these stages. It is generally used in heavy oil catalytic processes.

Two-stage regeneration is something familiar to everyone; in fact, even with single-unit single-stage regeneration, it is still possible to switch between complete regeneration and incomplete regeneration. May I ask the owner on the first floor: what type of regeneration do these two devices use, and how are they arranged?

If a CO boiler is installed, incomplete regeneration can be considered. This allows heat to be recovered from the CO boiler, while preventing energy loss due to excess in the main unit. In the absence of CO boilers, the regenerator should operate in a full regeneration mode; this requires an increased main air flow (even with two regenerators, the total air flow remains high), as well as the use of an oxidizer. Otherwise, it will cause CO to burn back in the flue. The switching between the two modes is primarily aimed at controlling the main air flow rate; during full regeneration, an excess amount of air is required to ensure that all of the CO is burned under the conditions provided by the combustion aid. During incomplete regeneration, the air flow rate is relatively low; since a large amount of CO remains, this is referred to as incomplete combustion. Therefore, it is necessary to use a CO boiler to recover its chemical energy and heat, while ensuring that the dilute phase does not overheat. This post was last edited by zhonghe998 on 2009-3-11 23:11]

Regardless of the form, there are two sets of catalytic main air distribution pipes; only one regenerator is equipped with two such sets. The main air enters in two streams, referred to as primary and secondary main air. The primary main air distribution pipe is located near the riser or inclined tube that leads into the regenerator. The primary main air zone is the hydrogen combustion zone, where all of the hydrogen is used for combustion; 60–80% of the coke is burned there, and under conditions of low oxygen levels, as little as 40% of the coke can be burned. Near the regenerative riser or inclined tube, the second-stage air duct is used for peroxide treatment. It is possible to determine whether complete regeneration has occurred by analyzing the oxygen content in the flue gas; an oxygen content of more than 3% indicates complete regeneration. For the first and second repetitions, it is only necessary to adjust the main air volume, but the dilute-phase temperature should be controlled.

If the device’s processing capacity has reached its limit, it is impossible to change from partial regeneration to full regeneration. . . . Unless a larger fan is used. . . :lol

Complete regeneration: high temperature, oxygen-rich environment, oxidizing agent

The regenerator is primarily used to restore catalyst activity to its maximum level. Our system uses the regeneration of series-connected coking tanks. The temperature of the calciner is around 680°C, with oxygen-deficient regeneration to burn off about 80% of the coke on the catalyst (i.e., incomplete regeneration). In the two-stage process, oxygen-enriched regeneration is carried out, with the temperature controlled at around 700°C to achieve complete regeneration. Reduce the carbon content of the catalyst to below 0.1%.