Dry catalyst dust automatic recovery system and method

Abstract

The invention discloses a dry catalyst dust automatic recovery system and method, and belongs to the technical field of catalyst dust recovery. The system comprises an air blower; an air outlet of the air blower is connected to an air inlet of the dust collector; the bottom of the dust collector is connected with a dust collecting tank through a first pipeline, and a first electromagnetic valve is arranged on the first pipeline; an outlet of the dust collecting tank is respectively connected with a second pipeline and a third pipeline; the second pipeline is connected to the dust recovery tank, the third pipeline is connected to the pressure relief device, and a third electromagnetic valve is installed on the third pipeline. The dust recovery process is automatically completed in the whole process, and manual operation of workers is not needed. Direct contact between personnel and catalyst dust is avoided, and harm of the dust to human bodies is prevented.

Description

Technical Field

[0001] This invention belongs to the field of catalyst dust recovery technology, and relates to an automatic dry catalyst dust recovery system and method. Background Technology

[0002] The continuous reforming technology from the French company AXENS features an emergency shutdown system (SIS), a catalyst regeneration control system (CCRCS), and a compressor unit control system (MCS). The catalyst regeneration section utilizes AXENS' REGENC 2 technology. The core technology of this unit is the continuous flow of the catalyst, operating in a moving bed for continuous catalyst regeneration; therefore, catalyst flow is crucial. Catalyst flow relies primarily on two methods: 1) slow downward movement due to gravity; and 2) upward movement via gas lifting. The reforming catalyst is a PS-VI platinum-containing catalyst. With years of use and natural aging, the catalyst's mechanical strength continuously declines towards the end of its service life. This decrease in strength makes the catalyst more prone to breakage and pulverization during circulation due to interparticle friction, collision, and compression, thus generating a large amount of dust.

[0003] There are three main reasons for catalyst dust generation. First, most reforming processes currently employ pneumatic conveying technology for catalyst circulation. The catalyst flow in the riser is a dilute-phase flow process, involving mutual compression and collision of the catalyst itself, high-speed friction and collision between the catalyst and the riser wall, and refraction and rebound caused by changes in catalyst orientation due to bends and diameter changes, resulting in repeated impacts against the riser wall. All of these factors contribute to varying degrees of catalyst wear and dust generation. Second, once the catalyst enters the reactor, the flow becomes a dense-phase process with a slower velocity, but friction and compression between the catalyst and the conveying pipe wall and reactor internals still occur, generating catalyst dust. Third, when the catalyst carbon content is high, bed overheating is prone to occur during regeneration and coking, which can lead to catalyst breakage and sintering. When dust enters the reduction tank, the density and viscosity of the reduced hydrogen increase significantly, causing the catalyst particles in the reduction tank to fluidize in the high-density, high-viscosity gas flow. This fluidization exacerbates the friction and collision of catalyst particles, easily generating dust.

[0004] The impact of catalyst dust on the equipment is mainly twofold. First, it affects the lifting system. The flow of catalyst in the riser is a dilute-phase flow. When catalyst dust accumulates and gathers in the riser, its higher density compared to normal catalyst, coupled with its filling of the gaps between catalyst particles, hinders catalyst flow and affects the lifting process, resulting in significant fluctuations in the lifting height. Second, it affects the circulation system. The flow of catalyst in the reactor and regenerator is a dense-phase transport, primarily relying on gravity for free fall. Dust and particles entrained in the catalyst gradually adhere to the walls of the feed pipe and in dead zones within the equipment, areas with poor flow. Furthermore, dust entrained in the catalyst reduces its porosity, causing blockages in the feed pipe.

[0005] The main components of catalyst dust are powdery solid particles and metal powder, posing three main health hazards. First, pneumoconiosis: This disease is caused by the inhalation and accumulation of dust particles in the lungs, severely affecting respiratory function. Symptoms include coughing, shortness of breath, and chest pain; in severe cases, it can lead to permanent lung damage. Second, skin allergies, causing itching, redness, and swelling. Third, metal poisoning: Metal poisoning can cause dizziness, nausea, and vomiting; in severe cases, it can lead to organ failure and endanger life. Therefore, the recovery of catalyst dust is essential.

[0006] The existing technology uses two dust filters, SR301 and SR302. SR301 is the first filter after the upper hopper of the lifting system, used to collect dust generated during the catalyst reaction and lifting process. SR302 is the second filter after the upper hopper of the lifting system, used to collect dust generated during the catalyst regeneration process. After the dust is filtered through SR301 and SR302, it is blown into the funnel-shaped collector and pipeline at the bottom of the filter by N2 backflushing. The catalyst dust then needs to be collected in a dedicated recovery bin for recycling and metering, but this process requires manual operation. This process carries the risk of operational errors causing fluctuations in equipment production, and direct contact with dust poses occupational hazards and is detrimental to human health. Summary of the Invention

[0007] The purpose of this invention is to provide an automatic dry catalyst dust recovery system and method to solve the technical problems of existing recovery devices requiring manual operation, poor safety, and adverse effects on personnel health.

[0008] To achieve the above objectives, the present invention employs the following technical solution: In a first aspect, the present invention provides an automatic dry catalyst dust recovery system, comprising a blower; the outlet of the blower is connected to the inlet of a dust collector; a dust collection tank is connected to the bottom of the dust collector via a first pipe, and a first solenoid valve is installed on the first pipe; the outlet of the dust collection tank is connected to a second pipe and a third pipe respectively; the second pipe is connected to a dust recovery tank, the third pipe is connected to a pressure relief device, a second solenoid valve is installed on the second pipe, and a third solenoid valve is installed on the third pipe.

[0009] Furthermore, the pressure relief device is an FLG.

[0010] Furthermore, the blower is a purging gas blower.

[0011] Furthermore, the upper part of the dust collector has an air outlet, which is connected to the air inlet of the blower through a pipe.

[0012] Furthermore, the air inlet of the dust collector is located at the lower part of the dust collector; Furthermore, the bottom of the dust collector is funnel-shaped.

[0013] Secondly, the present invention provides an automatic method for recovering dry catalyst dust, based on the above-mentioned automatic dry catalyst dust recovery system, comprising the following steps: The air generated by the blower is fed into the dust collector, so that the catalyst dust is drawn into the dust collector; Open the first solenoid valve to allow the catalyst dust in the dust collector to enter the dust collection tank, and close the first solenoid valve after a first preset time. Open the third solenoid valve to depressurize the catalyst dust collection tank through the pressure relief device, and close the third solenoid valve after the second preset time. Open the second solenoid valve so that the catalyst dust in the dust collection tank falls into the dust recovery tank by gravity. After a third preset time, close the second solenoid valve.

[0014] Furthermore, the first preset time is 420 s to 540 s.

[0015] Furthermore, the second preset time is 20 s to 40 s.

[0016] Furthermore, the third preset time is 240 s ~ 360 s.

[0017] Compared with the prior art, the present invention has the following beneficial effects: This invention discloses an automatic dry catalyst dust recovery system and method. It cleverly utilizes the airflow power generated by a blower to effectively guide the airflow containing dry catalyst dust generated during the production process to a specially designed dust collector. This step not only achieves efficient capture of dry catalyst dust but also significantly improves dust recovery efficiency, greatly reducing the fugitive dispersion of dust in the production environment. Through this innovative design, the production environment is significantly improved, dust pollution is effectively controlled, and a healthier and safer working space is provided for employees, effectively reducing the potential threat of dust to the respiratory system and other health aspects of workers. After the dust is successfully captured and accumulates to a certain amount, the system automatically and safely transfers the accumulated catalyst dust in the dust collector to a dust collection tank through a precisely controlled first solenoid valve. This step ensures the stability and safety of the dust during the transfer process, avoiding secondary pollution and leakage. Subsequently, the system uses a pressure relief device to perform precise pressure relief on the dust collection tank. This step is crucial, as it ensures the safety and smoothness of the subsequent dust emission process. After the pressure is released, the second solenoid valve is automatically opened. At this time, the catalyst dust in the dust collection tank naturally falls into the dust collection trough below under the action of gravity, completing the closed-loop process of dust recovery. The dust recovery process of this invention is fully automated, requiring no manual operation, eliminating direct contact between personnel and catalyst dust, and preventing dust from harming the human body.

[0018] Furthermore, the dust collector of this invention has an air outlet at the top, which is connected to the air inlet of the blower via a pipe, forming a complete loop. This prevents dust from escaping and causing secondary pollution during the collection process, thereby improving dust removal efficiency. The airflow loop design enhances the stability of the entire dust removal system, avoiding problems such as poor dust removal performance or equipment damage caused by unstable airflow. Real-time monitoring and control of system parameters (such as wind speed and pressure) ensures the long-term stable operation of the dust removal system. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of an automatic dry catalyst dust recovery system according to the present invention.

[0021] Wherein: 1-Blower; 2-Dust collector; 3-First solenoid valve; 4-Second solenoid valve; 5-Third solenoid valve; 6-Dust collection tank; 7-Dust recovery tank; 8-Pressure relief device; 9-First pipeline; 10-Second pipeline; 11-Third pipeline. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0023] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0024] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0025] In the description of the embodiments of the present invention, it should be noted that if terms such as "upper," "lower," "horizontal," or "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, terms such as "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0026] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0027] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0028] Definitions: FLG: Gas flare, used for depressurization.

[0029] The present invention will now be described in further detail with reference to the accompanying drawings: See Figure 1 This invention discloses an automatic dry catalyst dust recovery system, comprising a blower 1, a dust collector 2, and a dust collection tank 6. The outlet of the blower 1 is connected to the inlet of the dust collector 2. The bottom of the dust collector 2 is connected to the dust collection tank 6 via a first pipe 9, on which a first solenoid valve 3 is installed. The outlet of the dust collection tank 6 is connected to a second pipe 10 and a third pipe 11. The second pipe 10 is connected to a dust recovery tank 7, and a second solenoid valve 4 is installed on the second pipe 10 between the dust collection tank 6 and the dust recovery tank 7. The third pipe 11 is connected to a pressure relief device 8, on which a third solenoid valve 5 is installed. By introducing dust-containing airflow into the dust collector 2 through the blower 1, effective capture of dry catalyst dust is achieved. This design can significantly improve dust recovery efficiency, reduce dust dispersion in the production environment, thereby improving the working environment and reducing the impact of dust on the health of workers. Then, the catalyst dust in the dust collector 2 is introduced into the dust collection tank 6 through the first solenoid valve 3. Next, the pressure in the dust collection tank 6 is released through the pressure relief device 8, and the second solenoid valve 4 is opened. The catalyst dust in the dust collection tank 6 will fall into the dust collection trough 7 by gravity. The dust recovery process of this invention is completed automatically throughout the entire process without the need for manual operation, eliminating direct contact between personnel and catalyst dust and preventing dust from harming the human body.

[0030] In one feasible embodiment of the present invention, the pressure relief device 8 preferably uses an FLG (Fluorescent Gas Generator) for pressure relief. The blower is preferably a cathartic gas blower. The bottom of the dust collector 2 is funnel-shaped. The funnel-shaped design allows dust to flow more smoothly into the bottom of the collector, reducing dust retention and accumulation during the collection process, thereby improving dust collection efficiency. This also makes it easier to discharge dust after it has accumulated to a certain amount, facilitating subsequent cleaning and treatment.

[0031] In one feasible embodiment of the present invention, the upper part of the dust collector 2 has an air outlet, which is connected to the air inlet of the blower 1 through a pipe, forming a complete loop. This can prevent dust from escaping and causing secondary pollution during the collection process, thereby improving dust removal efficiency. The airflow loop design can enhance the stability of the entire dust removal system and avoid problems such as poor dust removal effect or equipment damage caused by unstable airflow. Furthermore, by monitoring and controlling system parameters (such as wind speed and pressure) in real time, the long-term stable operation of the dust removal system can be ensured.

[0032] In one feasible embodiment of the present invention, the air inlet of the dust collector 2 is located at the lower part of the dust collector 2, and the air outlet of the dust collector 2 is located at the upper part. This arrangement is conducive to the formation of negative pressure in the dust collector 2, so that the catalyst dust in the production process can be more easily sucked in; in the dust collector 2.

[0033] This invention discloses an automatic method for recovering dry catalyst dust, based on the aforementioned automatic dry catalyst dust recovery system, comprising the following steps: Step 1: The air generated by the blower 1 is introduced into the dust collector 2, so that the catalyst dust is drawn into the dust collector 2; Step 2: Open the first solenoid valve 3 to allow the catalyst dust in the dust collector 2 to enter the dust collection tank 6, and close the first solenoid valve 3 after a first preset time; the first preset time is preferably 420 s to 540 s. Step 3: Open the third solenoid valve 5 and depressurize the catalyst dust collection tank 6 through the pressure relief device 8. After a second preset time, close the third solenoid valve 5. The second preset time is preferably 20 s to 40 s.

[0034] Step 4: Open the second solenoid valve 4, allowing the catalyst dust in the dust collection tank 6 to fall into the dust recovery tank 7 by gravity. After a third preset time, close the second solenoid valve 4. The third preset time is preferably 240 s to 360 s.

[0035] This invention achieves efficient, safe, and automated recycling of dry catalyst dust, mainly in the following aspects: First, the blower 1 introduces air into the dust collector 2, effectively capturing and collecting the dry catalyst dust, significantly improving dust recycling efficiency. The dust is orderly transferred to the dust collection tank 6, and after precise time control, falls into the dust recovery trough 7 by gravity, facilitating subsequent reuse or treatment, reducing resource waste, and ensuring the safety of personnel and equipment. Second, when the dust in the dust collection tank 6 accumulates to a certain level, the third solenoid valve 5 is opened, and the pressure relief device 8 promptly releases the pressure in the dust collection tank 6. This step effectively avoids pressure increases caused by dust accumulation, thereby preventing potential safety hazards. The precise setting of the pressure relief time (second preset time) ensures safe pressure relief while avoiding unnecessary energy consumption and time waste. Third, the entire recycling process is automated through the opening and closing of the solenoid valve, requiring no manual intervention, greatly improving work efficiency and safety. The time intervals between each step (first preset time, second preset time, and third preset time) are carefully set to ensure the continuity and stability of dust recovery, while avoiding excessive dust accumulation or loss. Fourth, the method of this embodiment is not only applicable to the dry catalyst dust recovery system described above, but can also be flexibly adjusted and optimized according to actual needs, such as adjusting the time intervals of each step, replacing or upgrading system components, etc. It can also provide useful reference and guidance for other similar dust recovery scenarios, demonstrating good scalability and application prospects.

[0036] Example 1: Open the first solenoid valve 3, put the catalyst dust into the dust collection tank 6, and close the first solenoid valve 3 after 480 seconds.

[0037] Open the third solenoid valve 5 to depressurize the dust collection tank 6, and close the third solenoid valve 5 after 30 seconds. Open the second solenoid valve 4 to allow the catalyst dust to fall into the dust recovery tank by gravity. Close the second solenoid valve 4 after 300 seconds.

[0038] From the opening of the first solenoid valve 3 to the closing of the second solenoid valve 4, it constitutes a complete program flow, and the program runs automatically once every 24 hours.

[0039] Example 2: Open the first solenoid valve 3, put the catalyst dust into the dust collection tank 6, and close the first solenoid valve 3 after 420 seconds.

[0040] Open the third solenoid valve 5 to depressurize the dust collection tank 6, and close the third solenoid valve 5 after 20 seconds. Open the second solenoid valve 4 to allow the catalyst dust to fall into the dust recovery tank by gravity. Close the second solenoid valve 4 after 240 seconds.

[0041] From the opening of the first solenoid valve 3 to the closing of the second solenoid valve 4, it constitutes a complete program flow, and the program runs automatically once every 24 hours.

[0042] Example 3: Open the first solenoid valve 3, put the catalyst dust into the dust collection tank 6, and close the first solenoid valve 3 after 540 seconds.

[0043] Open the third solenoid valve 5 to depressurize the dust collection tank 6, and close the third solenoid valve 5 after 40 seconds. Open the second solenoid valve 4 to allow the catalyst dust to fall into the dust recovery tank by gravity. After opening for 360 seconds, close the second solenoid valve 4.

[0044] From the opening of the first solenoid valve 3 to the closing of the second solenoid valve 4, it constitutes a complete program flow, and the program runs automatically once every 24 hours.

[0045] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An automatic dry catalyst dust recovery system, characterized in that, Includes a blower (1); the outlet of the blower (1) is connected to the inlet of the dust collector (2); the bottom of the dust collector (2) is connected to a dust collection tank (6) through a first pipe (9), and a first solenoid valve (3) is installed on the first pipe (9); the outlet of the dust collection tank (6) is connected to a second pipe (10) and a third pipe (11) respectively; the second pipe (10) is connected to a dust recovery tank (7), and the third pipe (11) is connected to a pressure relief device (8); a second solenoid valve (4) is installed on the second pipe (10), and a third solenoid valve (5) is installed on the third pipe (11).

2. The automatic dry catalyst dust recovery system according to claim 1, characterized in that, The pressure relief device (8) is an FLG.

3. The automatic dry catalyst dust recovery system according to claim 1, characterized in that, The blower is a cathodic gas blower.

4. The automatic dry catalyst dust recovery system according to claim 1, characterized in that, The dust collector (2) has an air outlet at its upper part, and the air outlet of the dust collector (2) is connected to the air inlet of the blower (1) through a pipe.

5. The automatic dry catalyst dust recovery system according to claim 1, characterized in that, The air inlet of the dust collector (2) is located at the bottom of the dust collector (2).

6. The automatic dry catalyst dust recovery system according to claim 5, characterized in that, The bottom of the dust collector (2) is funnel-shaped.

7. An automatic method for recovering dry catalyst dust, characterized in that, An automatic dry catalyst dust recovery system according to any one of claims 1 to 8 includes the following steps: The air generated by the blower (1) is introduced into the dust collector (2), so that the catalyst dust is drawn into the dust collector (2); Open the first solenoid valve (3) to allow the catalyst dust in the dust collector (2) to enter the dust collection tank (6), and close the first solenoid valve (3) after a first preset time. Open the third solenoid valve (5) and depressurize the catalyst dust collection tank (6) through the pressure relief device (8). After the second preset time, close the third solenoid valve (5). Open the second solenoid valve (4) so ​​that the catalyst dust in the dust collection tank (6) falls into the dust recovery tank (7) by gravity. After a third preset time, close the second solenoid valve (4).

8. The method for automatic recovery of dry catalyst dust according to claim 7, characterized in that, The first preset time is 420 s to 540 s.

9. The method for automatic recovery of dry catalyst dust according to claim 8, characterized in that, The second preset time is 20 s to 40 s.

10. The method for automatic recovery of dry catalyst dust according to claim 9, characterized in that, The third preset time is 240 s ~ 360 s.

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