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    催化裂化烟气轮机内催化剂结垢的高温动态模拟

    High-Temperature Dynamic Simulation of Catalyst Fouling in FCC Flue Gas Turbine

    • 摘要: 本文自主设计搭建了一套 FCC 催化剂高温动态冲刷实验装置。该装置通过火焰喷枪实现催化剂颗粒的同步加热与定流速喷射,模拟工业烟机内叶片遭受颗粒冲刷的真实工况,进而观察颗粒在叶片表面的沉积、粘附及结垢完整过程。实验中采用 PIV 粒子图像测速技术与高温热电偶,对气固两相速度场、温度场进行实时标定与调控,确保实验工况与工业烟机内流动特性在关键参数上接近。同时,引入 “临界破碎力” 量化垢样力学强度,并结合 SEM(扫描电子显微镜)与 XRD(X 射线衍射)技术对结垢产物进行微观形貌与物相组成表征,系统证明了实验垢样与工业垢样高度相似。为深入明确驱动结垢的因素,本文选取同一 FCC 装置不同工艺流程处的取样催化剂,开展高温动态冲刷对比实验,重点探究催化剂中特定元素及其含量对叶片结垢行为的影响机制。证明特定元素富集是驱动烟气轮机内催化剂结垢的重要因素。本文首次在实验室尺度复现了工业烟气轮机内催化剂高温动态结垢关键过程,不仅为揭示 FCC 烟气轮机叶片催化剂结垢机理提供了关键实验支撑,也为工业阻垢技术的开发与优化奠定了理论与实践基础。

       

      Abstract: This study independently designed and constructed a high-temperature dynamic erosion experimental apparatus for FCC catalysts. Leveraging a flame spray gun, the apparatus achieves synchronous heating and constant-velocity injection of catalyst particles, accurately simulating the real working conditions where turbine blades in industrial flue gas turbines endure particle erosion. It thereby enables observation of the complete processes of particle deposition, adhesion, and fouling on blade surfaces. In the experiments, we adopted particle image velocimetry (PIV) and high-temperature thermocouples to conduct real-time calibration and precise regulation of the gas-solid two-phase velocity field and temperature field, ensuring consistency between the experimental conditions and the flow characteristics inside industrial flue gas turbines. Meanwhile, we introduced the concept of critical crushing force to quantify the mechanical strength of fouling samples, and combined scanning electron microscopy (SEM) with X-ray diffraction (XRD) techniques to characterize the micro-morphology and phase composition of fouling products. These efforts systematically verified the high analogy between the experimentally prepared fouling samples and industrial ones. To further clarify the driving factors of fouling, we selected catalyst samples collected from different process sections of the same FCC unit and conducted comparative high-temperature dynamic erosion experiments, focusing on investigating the influence mechanism of specific elements and their contents in the catalysts on blade fouling behavior. The results demonstrate that the enrichment of specific elements is a crucial factor driving catalyst fouling inside flue gas turbines. This study for the first time reproduces the key process of high-temperature dynamic catalyst fouling in industrial flue gas turbines at the laboratory scale. It not only provides crucial experimental support for revealing the catalyst fouling mechanism on FCC flue gas turbine blades but also lays a theoretical and practical foundation for the development and optimization of industrial anti-fouling technologies.

       

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