Dalian Petrochemical Company's technological transformation cures the two major "catalytic diseases"
The Dalian Petrochemical Corporation's 900,000-ton-per-year heavy oil catalytic cracking unit (second catalyst) faced challenges with high temperatures and elevated oil slurry solids content after the oil slurry was processed. These issues had long affected the stability, lifespan, and full capacity of the equipment. The unit was shut down for maintenance on August 6 this year. Through a series of technological upgrades, two major long-standing problems were fully resolved. By October 9, the plant had been operating for a full month, and production results met expectations.
Prior to the shutdown, when the oil slurry discharge exceeded 6 tons, the external temperature would surpass the process requirement of not exceeding 100 degrees Celsius. This significantly limited the unit’s processing capacity. After conducting an analysis, it was decided to replace the existing set of 80 cm diameter cooling coils with two 50 cm diameter coils connected in series, which increased the media flow rate. Following the upgrade, the oil slurry could be handled up to 9 tons, and the cold temperature was successfully maintained between 80 and 100 degrees Celsius, with no overheating incidents reported.
In the past, the solids content in the oil slurry remained consistently high, exceeding the process specifications. During a shutdown inspection, three leaks were discovered in the gas cylinders of the reactor cyclone separators. These were traced back to long-term steam purging from the coke-prevention nozzles. The leaks reduced the catalyst flow into the cyclone inlet, causing some catalyst to bypass the cyclones and directly enter the fractionator. During the maintenance period, the leaks were repaired, and the nozzles were properly sealed. After the unit resumed operation, the solids content in the slurry dropped to 2 g/L, far below the process limit of 6 g/L.
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