Analyze the reasons why the conversion rate per attempt is high while the overall conversion rate is low

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This post was last edited by Oath-taking on 2011-8-25 at 14:08. Our company uses imported catalysts; after 3 years of operation, the conversion rate for the first stage remains above 93.5%, while the conversion rate for the second stage is only around 99.3%. The main reason for this, according to our analysis, is related to the catalysts themselves. However, since the reaction temperature for the second-stage conversion is lower, the catalysts should not age as quickly as those used in the first stage. During a major maintenance session, it was discovered that severe corrosion had occurred due to a short circuit in one of the dew eliminators, causing the gas to take a shortcut and resulting in significant foam formation. This led to more than 1/3 of the tubes in the heat exchanger being corroded, which allowed SO3 gas to leak directly into the fourth reactor bed. We believe this is the main factor responsible for the low overall conversion rate.