Excess CO transformation

The impact of excessive CO levels on subsequent process stages is mainly manifested as follows: 1. The temperature of the syngas catalyst rises, resulting in an increase in CO levels in the gas after alcohol treatment； 2. The refining load increases, the amount of regenerated gas rises, the volume of effective gas vented increases, and gas losses increase ； 3. It can easily lead to slight excess levels of refined gas and poisoning of the synthesis catalyst. The treatment methods include: 1. Increase the circulation rate of the combined alcohol and control the catalyst temperature, striving to maintain the composition of the gas after alcohol treatment ； 2. To refine the process, measures such as reducing the ammonia cooling temperature, increasing the circulation rate of the copper melt, and appropriately raising the regeneration temperature are taken to ensure that trace elements do not accumulate to high levels ； 3. Increase the frequency of microanalysis, closely monitor minor changes, and take prompt action whenever limits are exceeded ； 4. The synthesis team should strengthen monitoring of catalyst temperature and address any abnormalities promptly.

Excessive CO transformation reduces the yield of ammonium bicarbonate and ammonia. The transformation process is a purification step relative to the subsequent processes; if substandard CO is sent to these subsequent processes, it can cause problems in the refining process and even poison the synthetic catalyst. When the CO level exceeds the limit, it is necessary to contact the dispatch and refining department promptly, so that they can take preventive actions such as activating additional copper pumps to prevent the situation from worsening!

It depends on the processes in the subsequent stages. In our company’s process, the subsequent stages mainly involve copper washing and synthesis. 1. When carbon monoxide with a high concentration enters the copper washing stage, it makes it more difficult to produce qualified refined gas (the main symptom is an increase in the temperature at the inlet of the reflux tower). The main measure taken is to increase the flow rate of the copper melt; if this still does not ensure that the refined gas meets the required standards, then it is necessary to reduce the flow rate. 2. When carbon monoxide with a high concentration enters the synthesis stage, it can cause poisoning of the catalyst. Once poisoning occurs, it is necessary to immediately stop the supply of gas to the synthesis process, open the vent valve, close the cold bypass line, reduce the circulation volume, and, if necessary, use an electric furnace to maintain the temperature of the catalyst bed.

The high and low transformation process in Kellogg can be handled as follows: 1. Slightly increase the inlet temperature for low transformation, but not too much; monitor the operation and conduct sample analyses to check for any significant changes. 2. Check and analyze whether the carbon monoxide level at the high-temperature shift outlet exceeds the specified limit. 3. If the level is too high, the temperature at the high-temperature shift inlet should be increased, as well as the load on the high-temperature shift unit. 4. Increase the water vapor ratio in the shift unit. 5. Adjust and optimize the operating conditions of the conversion unit to minimize the carbon monoxide content as much as possible. 6. Examine whether the shift catalyst has reached an advanced stage of degradation, resulting in reduced activity, and assess its impact on subsequent units: 1. The methanation temperature rises significantly; 2. The inert gas content in the synthesis loop increases, leading to a significant decrease in ammonia production.

Excessive CO levels after the transformation process can easily increase the load on subsequent units; in severe cases, it may cause a slight excess of this substance at the inlet of the synthesis tower, leading to reduced production or even shutdown of the system. Handling: 1. The transformation operator must check whether all process parameters are within the specified ranges; if not, adjustments should be made promptly. If the values exceed the limits significantly, it may indicate air leakage, and the liquid level in the saturated hot water tower should be adjusted immediately. And contact the dispatcher promptly to take appropriate action. 2. The scheduling department must promptly notify the relevant teams to make adjustments (the fermentation unit should increase the circulation volume to the tower in a timely manner to prevent overheating) ； For the refining unit, it is necessary to increase the copper melt circulation rate in a timely manner; the dispatch team should reduce it promptly based on the set indicators.