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.