(Hydrogen production converter) What are the possible reasons for an excessive pressure difference in the converter?

During the catalyst loading process, the catalyst inside some furnace tubes gets crushed due to falling from a height. Poor mechanical strength or thermal stability of the catalyst leads to its fragmentation during use. Accidents such as poisoning or imbalances in the water-to-carbon ratio can cause thermodynamic carbon deposition in the catalyst bed. As the catalyst operates for an extended period, this carbon deposition increases, leading to a sharp drop in pressure or intense carbon burning reactions that result in catalyst fragmentation. Catalyst hydration also causes it to become powdered – all these factors contribute to an increase in the pressure difference across the conversion furnace tubes. The specific analysis is as follows: (1) Partial fragmentation of the catalyst leads to an increase in resistance loss. During the loading and use of the catalyst, sudden pressure changes can cause the catalyst to break apart, which increases its packing density and reduces the gaps, thereby leading to an increase in the pressure difference within the converter system. (2) Catalyst fouling causes an increase in the pressure difference in the converter. During use, carbon deposition on the catalyst surface will block the gas flow channels, causing obstruction to the gas flow and an increase in pressure difference. Furthermore, during the carbon burning regeneration process after catalyst coking, excessive burning speed can cause the catalyst to break apart or experience \"peeling.\" The fragments or powder of the catalyst that block the gas outlet at the bottom of the conversion tube can also lead to an increase in the pressure difference within the conversion furnace. (3) Increasing the reaction load and the water-to-carbon ratio also lead to an increase in the pressure difference in the converter. The increase in reaction load raises the gas flow rate, thereby increasing the system resistance.

Catalyst deactivation due to poisoning, poor packing leading to bridging, and catalyst coking are also contributing factors