High reactor pressure difference issue
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Our plant uses a mixed benzene hydrogenation process, with four hydrogenation reactors. Recently, the pressure difference in the last two reactors has been abnormally high; the first reactor shows no such issue. The crude oil is sent to the buffer tank through automatic backwashing, and then pumped into the hydrogenation system using high-pressure reciprocating pumps. The catalyst has already been replaced once, but the problem persists after some time of operation. If it were a problem with the quality of the crude oil, the pressure difference in the first reactor would not be so high. By checking the reactor head, carbon buildup was found in the sediment basket. Can anyone tell what’s wrong?
It is up to you to make the final decision: 1. Check whether the differential pressure gauge is malfunctioning; it requires inspection by a gauge maintenance technician； 2. Damage to internal components ； 3. Catalyst pulverization in the previous reactor
Agree to check whether the temperature rise in the first reactor is abnormal, as well as whether the reaction in the second reactor is too intense. It causes catalyst coking.
For the first reaction, the temperature rise is abnormally low, with almost no increase in temperature; is there a solution for this? The second reaction is intense, and catalyst coking occurs.
Catalyst pulverization is a problem; we replaced the catalyst, and after 2 months of operation the issue reappeared. There are no major problems with the internal components, nor are there any issues with the instruments, and the temperature rise in the first reactor is almost negligible. Are there any effective solutions? Should we increase the temperature of the first reactor?
You need to find out what is causing the problem – whether it’s a decrease in catalyst activity or deactivation, etc. Start by analyzing the data from the time operations began