Synthesis tower leakage issue
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Is it necessary to passivate the catalyst in case of a leak in the synthesis tower, and then remove the catalyst for further treatment? Please share your opinions
In the event of a leak in the synthesis tower, it is necessary to passivate the catalyst and then remove it for further treatment!
If the boiler water from the shell side enters the tube side and saturates the catalyst, then passivation is not necessary. Otherwise, it must be passivated.
How to deal with it if it’s not unloaded? Is there a better way? Please give me some advice! ! ! ! !
Specialized in dealing with such issues. First principle: Control the shell side pressure to be lower than the tube side pressure. Second principle: Steam air defense; it should not be integrated into other pipeline systems to prevent secondary disasters. The synthesis process involves a cycle of introducing inert gas for displacement, in order to prevent the formation of wax; high pressure is used for this displacement. Once the displacement is complete, the temperature is lowered gradually while simultaneously reducing the pressure. As the temperature drops, water forms in the exhaust gas, followed by a passivation step. Heat exchange during passivation relies on a large circulation volume. After passivation is complete, water is sprayed to remove the catalyst.
If there is a leak in the synthesis tower and repairs are necessary, the synthesis catalyst must be passivated; otherwise, the copper-based catalyst will undergo a violent oxidation reaction with oxygen, generating a large amount of heat that can damage the catalyst or even the synthesis tower itself. The sintered catalyst is difficult to remove, so care must be taken regarding the amount of oxygen used during passivation, and overheating must be strictly avoided； Catalyst passivation results in a 15-50% decrease in activity. It is specifically determined by the level of skill.
If there is a leak in the synthesis tower, the catalyst must be passivated.
First, the outlet catalyst in the synthesis tower must be passivated before removal； Find a professional pressure vessel handling agency to carry out welding repairs and pressure testing, and establish an emergency response plan for accidents ； A comprehensive assessment of the synthesis tower to determine its viability is necessary; it’s best for the manufacturer to coordinate the replacement of the internal components. Welding repairs are only temporary solutions – if leaks occur over time, it indicates a problem with the material or the quality of the welding, and such conditions cannot be tolerated.
If it is a leak in the shell-and-tube water system, there is certainly no need to remove it. If the process system leaks into the water system, and the leak is small, production can continue at reduced capacity; it is necessary to quickly identify a catalyst manufacturer and develop a repair plan. Whenever there is an opportunity to shut down the system, maintenance should be carried out, and the catalyst must definitely be removed. If it is a cold-shock type, production can be maintained for now while keeping a close watch; continue as long as possible.
Sometimes, if the catalyst is not properly deactivated, it becomes unusable. If the catalyst has been in use for a long time, it is recommended to replace it.
In my personal opinion, it depends on the leakage level of your reactor; if the leakage is severe and it’s necessary to remove the catalyst, then the reactor will definitely need to be passivated, and this is a technical task as well； If the leakage is minor and it can be addressed without removing the catalyst, then nitrogen can be used for protection; the synthesis tower does not need to be at atmospheric pressure for this process to be carried out