The specific meaning of light-load production
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Generally, when operating the machine in its original mode, it operates under light load. I would like to ask what exactly is meant by light load operation? Is it just that the fresh air flow rate is lower than usual? Is the fresh air flow rate and system pressure still lower than usual?
This is purely my personal understanding for reference only. In devices where catalytic reactions take place under low load conditions, the catalysts have relatively high initial activity, which leads to an abundance of reaction by-products. This is especially true for exothermic reactions, as it is difficult to control the temperature at the hot spots. There have been accidents where the load was increased too quickly, resulting in the burning of some of the catalysts and the bed material. Therefore, at the beginning of catalyst use, it is necessary to operate at a low load for a period of time; this can also be considered a catalyst deactivation phase, with the aim of stabilizing the catalyst’s structure and extending its service life. Full load can be considered only after stabilization. During this period, the various operational parameters can also be adjusted to prepare for full-load normal production.
Generally, when a new installation is first brought online, various equipment, especially the moving parts, require a running-in period; it is necessary to proceed step by step. Since there is only a theoretical load for such an installation, it takes time through practical testing to determine how much load can actually be applied. Therefore, the load during the initial startup is usually relatively low, but it cannot be too low either, as this would severely affect production or even prevent the installation from operating. Typically, the load is kept between 75% and 85% of the full capacity
The initial operation at light load was carried out to further evaluate the production capacity of the facility and the performance of coordinated production. Also take into account the equipment’s running-in period. Exploring basic driving data is helpful for comparison.
According to what was said upstairs, what about driving after the major repair? The catalyst was not replaced during the major overhaul; is it necessary to operate at reduced load for a period of time?
From a process perspective, it’s not necessary; we increase the load according to the reaction load-up curve, and that’s how our production is organized. Floors 3 and 4 are analyzed from an equipment perspective, which is also correct