A process for continuously agitated, shear-induced preparation of catalyst slurries

Abstract

The application discloses a process for continuously stirring and shearing to prepare catalyst slurry, and relates to the technical field of fine chemical industry and special chemical manufacturing, and comprises the following steps: according to a preset proportion, catalyst active powder components, a binder and deionized water are put into a first-stage combined paddle stirring tank, stirring is started to preliminarily mix, and each component is preliminarily dispersed to form mixed slurry. The design scheme of the application adopts a continuous preparation mode of two-stage stirring and two-stage shearing in series, the first-stage stirring makes the powder and the binder quickly immerse and blend to form uniform mother slurry, the first-stage shearing repeatedly impacts and tears the agglomerates through high-speed relative movement, the powder agglomerated structure is effectively dispersed, the second-stage stirring makes the additional components and the once-sheared slurry quickly blend and mutually dissolve, and the second-stage shearing further disperses and separates the active components, so that the key physical and chemical properties of the final shaped catalyst, such as sphericity, abrasion index and activity stability, are reliably guaranteed.

Description

Technical Field

[0001] This invention relates to the field of fine chemical and specialty chemical manufacturing technology, and in particular to a process for preparing catalyst slurry by continuous stirring and shearing. Background Technology

[0002] In catalyst industrial production, the homogeneous dispersion effect of the slurry directly affects the physicochemical properties of the finished catalyst obtained from subsequent processes such as spray granulation, drying and molding, and high-temperature calcination, including sphericity, wear index, and activity stability. The traditional catalyst slurry preparation process generally involves feeding sol to prepare colloidal material, stirring and dispersing powder raw materials, stirring, dispersing and dissolving water-soluble raw materials, and synthesizing the catalyst slurry. This is a typical single-reactor batch preparation process. This process can achieve continuous production when the requirements for the finished microspherical catalyst indicators are not strict. However, as customers have increasingly strict requirements for the finished catalyst indicators, such as appearance sphericity, wear index, and microreactor activity, the single-reactor batch process has significant limitations.

[0003] In existing technologies, in the single-reactor batch process, the active powder component and binder are mixed in the stirred tank by the rotation of the impeller. However, due to the limited flow field of the stirring, the fine catalyst powder is prone to agglomeration, forming secondary particles. This results in uneven dispersion of the active component in the slurry and low interphase fusion, affecting the homogeneity and stability of the slurry. At the same time, there are deviations in parameters such as stirring time, feeding sequence, and temperature control between batches in the batch operation, making it difficult to avoid fluctuations in the slurry performance between batches. In order to meet the requirements of subsequent spray granulation for slurry solid content and particle size distribution, traditional processes often adopt measures such as reducing solid content, extending stirring time, or purchasing ultrafine powder raw materials. However, these measures all lead to a decrease in production efficiency or an increase in cost. In addition, single-reactor operation cannot achieve continuous and stable output of materials, which restricts the pace of large-scale production. Moreover, there are many manual operation links on site, making quality control difficult. Therefore, a process for preparing catalyst slurry by continuous stirring and shearing is proposed to solve the above-mentioned problems. Summary of the Invention

[0004] In order to overcome the above-mentioned defects in the prior art, the present invention provides a process for preparing catalyst slurry by continuous stirring and shearing.

[0005] The technical solution adopted by this invention to solve its technical problem is: a process for preparing catalyst slurry by continuous stirring and shearing, comprising the following steps: S1: According to the preset ratio, the catalyst active powder components, binder and deionized water are put into the first-stage combined paddle mixer. Start the stirring to carry out preliminary mixing. The mixing time is not less than 30 minutes, so that the components are initially dispersed to form a mixed slurry. The strong vortex generated by the combined stirrer in the kettle allows the powder and binder to be quickly wetted and blended. S2: After the initial mixing is completed, the first-stage hose pump is started, and the mixed slurry is fed into the first-stage shear pump at a constant speed according to the preset delivery flow rate. The powder agglomeration structure is broken by the high-speed shearing action of the dense toothed moving and stationary disc assembly, and a homogeneous dispersion is completed to obtain a shear slurry. The material is subjected to repeated impacts and tearing in the high-speed relative motion of the dense toothed moving and stationary discs, so that the powder agglomerates are effectively dispersed, the active sites are fully exposed, the interfacial tension between the slurry phases is significantly reduced, and a preliminary stable suspension dispersion system is formed. S3: The first-stage sheared slurry is directly fed into the second-stage combined paddle mixer. The remaining components of the formula are added to adjust the slurry parameters. The mixer is started and mixed again for no less than 30 minutes to obtain a second-stage mixed slurry. After the first-stage sheared slurry is supplemented with new components, the strong stirring of the second-stage mixer makes the supplemented components quickly blend and dissolve with the original slurry, ensuring that the concentration is consistent in all areas of the system. S4: Start the second-stage hose pump and send the secondary mixed slurry into the second-stage shear pump at a preset flow rate for secondary shear dispersion to refine and disperse the active components and obtain the catalyst slurry product. The first-stage hose pump and the second-stage hose pump are both hose-type peristaltic pumps. After secondary fine shearing, the active components are further depolymerized and dispersed to the submicron scale, and the phases achieve molecular-level fusion and bonding. S5: Detect the particle size and dispersion uniformity of the finished catalyst slurry. If it does not meet the standard, the unqualified slurry is sent back to the first-stage combined paddle agitator through the reflux pipeline. Repeat steps S1 to S4 in sequence until the indicators meet the standard and then output. The unqualified slurry is automatically returned to the front end for reprocessing through the closed-loop reflux mechanism. There is no need to discard it in the middle or make offline remediation. After recycling and reprocessing, the slurry quality can be effectively improved to the qualified range, while avoiding the waste of raw materials.

[0006] Furthermore, the first-stage combined paddle agitator and the second-stage combined paddle agitator are each independently equipped with two sets of inclined blades arranged vertically and axially and one set of anchor-type combined agitators, as well as two pairs of baffles arranged on the inner wall of the agitator. The height-to-diameter ratio of the agitator is not greater than 1.5, and the agitator is equipped with a communication temperature transmitter. The inclined blades and anchor-type agitators work together to make the slurry form a three-dimensional circulating flow. The baffles enhance the turbulent shearing effect, effectively eliminate the stirring dead zone and prevent material deposition, and ensure uniform concentration in all areas of the agitator. Both the first-stage shear pump and the second-stage shear pump adopt dense toothed moving and stationary disc shearing components, and the drive motor is a two-stage synchronous speed of 3000 rpm. The outlet of the shear pump is equipped with a communication pressure transmitter and a local pressure gauge. The dense toothed moving and stationary discs perform high-frequency repeated cutting on the passing slurry at high speed, effectively breaking the agglomerates into an ideal dispersion state. The first-stage and second-stage flexible hose pumps are respectively installed on the short-distance process pipeline between the corresponding mixing vessel outlet and the shear pump inlet. The flow hose of the flexible hose pump is made of EPDM rubber. The peristaltic pump outlet is equipped with a communication pressure transmitter and a local pressure gauge. The matching process pipeline is made of 316L stainless steel. The pipeline layout can realize the continuous operation of the first-stage mixing and shearing and the second-stage mixing and shearing, and can also realize the closed-loop control of the material return from the second-stage process to the first-stage process. The EPDM rubber hose is resistant to acid and alkali corrosion and has no shaft seal structure, avoiding the risk of leakage during the transportation process.

[0007] Furthermore, S1 specifically includes: Based on the production capacity, the preset ratio of catalyst active powder components, binder and deionized water is calculated. Each component is added to the first-stage combined paddle agitator in sequence according to the calculated ratio. The precise metering and feeding of materials adapted to the production capacity ensures that the material ratio of each batch is highly consistent, avoiding batch-to-batch quality fluctuations caused by human weighing errors, and laying a reliable foundation for continuous and stable production. The anchor-type combined agitator is remotely started by a frequency converter. The two sets of inclined blades arranged vertically and horizontally are driven to operate synchronously with the anchor-type combined agitator according to the preset agitation rate. This causes the slurry to form a turbulent vortex in the reactor and flow up and down. The frequency converter remote control enables smooth adjustment of the agitation speed. Operators can make precise control without approaching the operating equipment, which improves the safety of operation and the convenience of operation. During the mixing process, the anchor-type combined agitator continuously scrapes and pushes the material deposited at the bottom of the vessel. At the same time, two pairs of baffles arranged on the inner wall of the mixing vessel backflow shears the upward slurry. The initial mixing is completed after running continuously for no less than 30 minutes. The anchor-type combined agitator runs close to the bottom of the vessel to prevent powder settling and accumulation, ensuring that the heavy components participate in the mixing process without being trapped in dead corners.

[0008] Furthermore, in S1, the tilt angle of the inclined blade is no greater than 30°, the distance between the bottom outer edge of the anchor-type combined agitator and the bottom of the first-stage combined blade agitator is no greater than 10cm, the inclined blade drives the slurry downward at a small angle, forming a strong axial flow that runs through the entire height of the agitator, quickly eliminating the concentration difference between the upper clear liquid and the lower thick slurry, and shortening the overall mixing time. The baffle is located at the middle position of the vertical distance between the inner wall of the agitator, and the length of the baffle is two-thirds of the height of the inner wall of the agitator. The distance between the end of the inclined blade and the outer edge of the baffle is 15cm. The anchor-type agitator is arranged close to the bottom of the agitator so that the bottom deposited material is forcibly scraped up and pushed to the mainstream area, avoiding the accumulation of catalyst active components in dead corners and ensuring that the material concentration in the agitator is uniform when the material is discharged.

[0009] Furthermore, S2 specifically includes: After the initial mixing is completed, the outlet valve of the first-stage combined paddle mixer is opened, the outlet pressure value of the first-stage flexible pump is preset, and the first-stage flexible pump is started through frequency converter interlock control and the speed is automatically adjusted according to the preset pressure. The timing of the outlet valve opening and the start of the flexible pump is coordinated to ensure that the material enters the conveying state smoothly, avoiding pressure buildup or dry running, and ensuring that the feeding stage is stable and controllable from the beginning. The frequency converter automatically corrects the pump speed according to the pressure feedback, so that the actual operation always follows the set working conditions, ensuring that the feeding rhythm and the shearing process capacity are precisely matched, and ensuring that the equipment load is balanced and stable. The material is uniformly conveyed to the first-stage shear pump through the EPDM rubber flow hose. The drive motor of the first-stage shear pump drives the dense toothed moving and stationary disc assembly at a speed of 3000 rpm, which repeatedly impacts and breaks up the powder agglomeration structure in the material. The EPDM rubber hose is resistant to acid and alkali corrosion and has a smooth inner wall, ensuring that there is no secondary pollution of the material during the entire conveying process and that the flow resistance is constant, reducing the impact and interference of pulsation fluctuations on the shearing process. The pressure transmitter at the outlet of the first-stage shear pump monitors the outlet pressure in real time and feeds it back to the central control system. At the same time, a local pressure gauge is used for on-site inspection and reading to ensure that the material throughput is constant and the shearing action is sufficient during one shearing process. The pressure transmitter transmits the outlet pressure signal to the central control system, and the operator can monitor the operating status of the shear pump in the central control room. In case of abnormality, the operator can quickly analyze and handle the situation to reduce the risk of production interruption.

[0010] Furthermore, in S2, the material of the densely toothed moving and stationary disc assembly is zirconium metal. Zirconium metal moving and stationary discs have excellent wear resistance and can maintain the integrity of the tooth shape even after long-term high-speed impact and shearing, ensuring that the shearing effect does not decrease with the extension of operating time. The shell material of the first-stage shear pump is duplex stainless steel 2205 or 304 stainless steel lined with silicon nitride. The duplex stainless steel or silicon nitride lined shell has the dual advantages of high strength and corrosion resistance, resisting long-term erosion by acid and alkali components in the slurry. The shaft seal of the first-stage shear pump adopts a water-cooled, cartridge-type moving and stationary ring shaft seal, and the outlet of the first-stage shear pump is equipped with both a communicable pressure transmitter and a local pressure gauge to realize dual pressure monitoring of remote monitoring and local reading.

[0011] Furthermore, S3 specifically includes: After the first stage of shearing is completed, the first shearing slurry is directly fed into the second stage combined paddle agitator through a 316L stainless steel process pipeline. The 316L stainless steel pipeline is corrosion-resistant, wear-resistant and has a smooth inner wall, which avoids secondary agglomeration or residue on the wall caused by the rough pipe wall during the transportation process, ensuring that all materials are transferred without loss. The transportation path is completely closed and there is no intermediate buffer link. The direct transportation without buffer link eliminates the risk of sedimentation and stratification caused by intermediate temporary storage. According to the preset formula requirements, the remaining raw material components for adjusting the slurry parameters are added to the second-stage combined paddle mixer. After the addition is completed, the anchor-type combined mixer is started and mixed again according to the preset mixing rate. The addition operation is completed before the mixing is started so that the newly added components and the existing slurry in the kettle are stirred at the same time, avoiding local high concentration or uneven reaction caused by the addition delay. During the second-stage mixing process, the two sets of axially arranged inclined blades and the anchor-type combined agitator work together with the two pairs of baffles on the inner wall of the vessel to mix the added components with the primary shear slurry. The secondary mixing is completed after continuous mixing for no less than 30 minutes. The inclined blades and the anchor agitator, together with the baffles, form a multi-directional composite flow field, so that the added components are subjected to multiple shearing and tumbling actions at various points in the vessel, achieving uniform dispersion at the molecular level.

[0012] Furthermore, in S3, the first-stage combined paddle agitator and the second-stage combined paddle agitator are arranged in parallel on the same steel frame platform. The parallel and consistent elevation layout eliminates the need for pipelines to climb or detour between the two agitators. The material can be smoothly transferred based on the pressure and elevation difference within the agitators, reducing additional power transmission links and lowering operating energy consumption. The top and bottom elevations of the two agitators are consistent and they are connected by equal-length short-distance process pipelines. This equal-length short-distance connection ensures that the material flow time within the pipeline is fixed and controllable, avoiding quality fluctuations caused by inconsistent material residence time in the pipeline due to differences in path length. Each agitator is independently equipped with a communicable temperature transmitter to collect slurry temperature data in real time and upload it to the central control system. The independently configured temperature transmitters of each agitator monitor the thermal state of the slurry in each stage agitator. Operators can remotely adjust the process temperature of each agitator to ensure that each process operates stably under suitable thermal conditions.

[0013] Furthermore, step S4 specifically includes: After the second stage of mixing is completed, the outlet valve of the second stage combined paddle mixer is opened, the outlet pressure value of the second stage hose pump is preset, and the second stage hose pump is started by frequency converter interlock control and the conveying speed is automatically adjusted according to the preset pressure. The timing of the outlet valve and the start of the hose pump are coordinated to ensure that the slurry in the reactor is smoothly transferred to the conveying state, avoiding pressure shock caused by valve opening delay or sudden pump speed, and ensuring pipeline operation safety. The material is quantitatively delivered to the second-stage shear pump via the second-stage hose pump. Under the action of the dense toothed moving and stationary disc assembly driven by a speed of 3000 rpm, a second shear is performed to further refine and disperse the active components. The second shear causes the small agglomerates remaining in the slurry after the first treatment to be deagglomerated again, the active component particles are further refined, and the interfacial bonding between the phases of the slurry is more compact and uniform. After the second shearing is completed, the catalyst slurry is output through the outlet pipeline of the second-stage shear pump. The pressure transmitter at the outlet and the local pressure gauge monitor the discharge pressure synchronously to ensure that the output slurry flow is stable and the dispersion is uniform, and it is directly sent to the subsequent spray granulation process. Both the first-stage and second-stage hose pumps use EPDM rubber flow hoses with no shaft seal. The drive motors are equipped with communicable frequency converters to enable remote start / stop and speed adjustment. The outlet pressure transmitters of each hose pump form an interlocked closed-loop control with the corresponding hose pump drive motors, automatically adjusting the delivery flow rate according to the outlet pressure set value. The shaft-seal-free hose structure completely eliminates the leakage risk at the shaft seal of traditional pumps, preventing slurry leakage and environmental pollution.

[0014] Furthermore, S5 specifically includes: After the second shearing is completed, a sample of catalyst slurry is collected at the sampling port of the outlet pipeline of the second-stage shearing pump. The solid content, particle size distribution and dispersion uniformity of the sample are tested. The test data are compared with the preset quality index threshold. The sampling port is set in the outlet pipeline to facilitate the collection of representative slurry samples at any time, so that the test results can truly reflect the actual quality status of the current slurry and avoid misjudgment due to sampling deviation. If the judgment result shows that the particle size or dispersion uniformity of the slurry does not meet the preset index, the process pipeline valve configuration is switched and adjusted. The return branch valve is opened and the discharge valve is closed at the same time. The unqualified slurry is introduced into the first-stage combined paddle agitator through the 316L stainless steel return pipeline and merged with the new batch of materials in the agitator. The valve configuration switching operation is simple and clear. The rapid conversion between discharge and return can be completed without stopping the machine, avoiding the interruption of continuous production process due to the handling of unqualified slurry. After the substandard slurry re-enters the first-stage combined paddle mixer, the initial mixing operation is performed again according to step S1. Then, the mixing and shearing process of steps S2 to S4 is repeated in sequence until the slurry index meets the preset quality requirements when tested again. Then, the valve configuration is switched to close the reflux branch and open the discharge valve to output the qualified slurry to the next process. The substandard slurry is mixed with fresh material and then processed. The original defective components undergo complete mixing and shearing action together with the fresh material in the secondary processing. The cyclic reprocessing does not require machine shutdown for waste discharge or separate treatment.

[0015] The beneficial effects of this invention are: 1. The design scheme of this invention adopts a continuous preparation method of two-stage stirring and two-stage shearing in series. The first-stage stirring enables the powder and binder to quickly wet and blend to form a uniform parent slurry. The first-stage shearing uses high-speed relative motion to repeatedly impact and tear the agglomerates, effectively breaking up the powder agglomerates. The second-stage stirring enables the added components to quickly fuse and dissolve with the slurry from the first shearing. The second-stage shearing further decomposes and disperses the active components, so that the key physicochemical properties of the final catalyst, such as sphericity, wear index and activity stability, are reliably guaranteed.

[0016] 2. The design scheme of this invention adopts a continuous preparation method with two-stage stirring and two-stage shearing in series. The material flows through each processing unit in sequence, and each part of the material undergoes the same processing process. There are no operational differences between batches. At the same time, the closed-loop reflux mechanism allows unqualified slurry to return to the front end to undergo the complete processing process again without stopping the machine. This ensures that each batch of slurry in the final output has undergone sufficient quality verification, eliminates the fluctuation of slurry performance caused by batch production, and achieves continuous and stable production.

[0017] 3. The anchor-type combined agitator of this invention continuously scrapes and pushes the material close to the bottom of the vessel, effectively preventing powder settling and accumulation, avoiding the waste of active components deposited at the bottom of the vessel, and returning unqualified slurry to the first-stage mixing vessel for reprocessing via the return pipeline, eliminating the need for separate discharge of waste slurry and reducing raw material waste. Attached Figure Description

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0019] Figure 1 This is a schematic diagram of the equipment and slurry flow for a process of continuously stirring and shearing to prepare catalyst slurry according to the present invention; Figure 2 This is a schematic flow diagram of a process for preparing catalyst slurry by continuous stirring and shearing according to the present invention. Figure 3 This is an appearance diagram of the finished catalyst produced by the process of this invention. Detailed Implementation

[0020] To more clearly illustrate the technical solution of the present invention, the present invention will be further described below with reference to the accompanying drawings. Obviously, the drawings described below are only one embodiment of the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings and embodiments without creative effort, and all of them fall within the protection scope of the present invention.

[0021] Example 1, according to Figure 1 , Figure 2 As shown, a process for preparing catalyst slurry by continuous stirring and shearing includes the following steps: S1: According to the preset ratio, the catalyst active powder components, binder and deionized water are put into the first-stage combined paddle mixer. The mixer is started to carry out preliminary mixing for no less than 30 minutes, so that the components are initially dispersed to form a mixed slurry. The strong vortex generated by the combined mixer in the kettle allows the powder and binder to be quickly wetted and blended, ensuring that the components have formed a parent slurry of uniform concentration before entering the shearing process, laying the foundation for subsequent high-precision dispersion. S2: After the initial mixing is completed, the first-stage hose pump is started, and the mixed slurry is fed into the first-stage shear pump at a constant speed according to the preset delivery flow rate. The powder agglomeration structure is broken by the high-speed shearing action of the dense toothed moving and stationary disc assembly, and a homogeneous dispersion is completed to obtain a shear slurry. The material is subjected to repeated impacts and tearing in the high-speed relative motion of the dense toothed moving and stationary discs, so that the powder agglomerates are effectively dispersed, the active sites are fully exposed, the interfacial tension between the slurry phases is significantly reduced, and a preliminary stable suspension dispersion system is formed. S3: The primary shear slurry is directly fed into the secondary combined paddle mixer. The remaining components of the formula are added to adjust the slurry parameters. The mixer is started and mixed again for no less than 30 minutes to obtain a secondary mixed slurry. After the primary shear slurry is supplemented with new components, the strong stirring of the secondary mixer makes the supplemented components quickly blend and dissolve with the original slurry, ensuring that the concentration in each area of ​​the system is consistent, and providing a uniform material basis for secondary fine shearing. S4: Start the second-stage hose pump to send the secondary mixed slurry into the second-stage shear pump at a preset flow rate for secondary shear dispersion, refine the dispersion of active components, and obtain the catalyst slurry product. The first-stage hose pump and the second-stage hose pump are both hose-type peristaltic pumps. After secondary fine shearing, the active components are further depolymerized and dispersed to the submicron scale, and molecular-level fusion and bonding are achieved between the phases. The overall homogeneity of the slurry is significantly improved, which meets the requirements of the subsequent molding process for high dispersion of the slurry. S5: Detect the particle size and dispersion uniformity of the finished catalyst slurry. If it does not meet the standard, the unqualified slurry is sent back to the first-stage combined paddle agitator through the reflux pipeline. Repeat steps S1 to S4 in sequence until the indicators meet the standard and then output. The unqualified slurry is automatically returned to the front end for reprocessing through the closed-loop reflux mechanism. There is no need to discard it in the middle or make offline remediation. After recycling and reprocessing, the slurry quality can be effectively improved to the qualified range. At the same time, raw material waste is avoided, and the quality stability and consistency of the slurry produced throughout the production process are guaranteed.

[0022] It should be noted that the first-stage combined paddle agitator and the second-stage combined paddle agitator are each independently equipped with two sets of axially arranged inclined blades and one set of anchor-type combined agitators, as well as two pairs of baffles correspondingly arranged on the inner wall of the vessel. The height-to-diameter ratio of the agitator is no greater than 1.5, and the agitator is equipped with a communication-enabled temperature transmitter. The synergistic action of the inclined blades and anchor-type agitators creates a three-dimensional circulating flow of the slurry. The baffles enhance the turbulent shearing effect, effectively eliminating dead zones and preventing material deposition, ensuring uniform concentration in all areas of the vessel. The communication-enabled temperature transmitter uploads the temperature signal in real time, allowing operators to remotely monitor the thermal state inside the vessel and adjust process parameters in a timely manner to ensure stable slurry quality. Both the first-stage and second-stage shear pumps use densely toothed moving and stationary disc shearing components, and the drive motors are two-stage synchronous speeds of 3000 rpm. The shear pump outlet is equipped with a communication-enabled pressure transmitter and a local pressure gauge. The densely toothed moving and stationary discs perform high-frequency repeated cutting of the passing slurry at high speed, effectively breaking up agglomerates to an ideal dispersion state. The system features a dual configuration of a transmitter and a local pressure gauge, enabling remote monitoring of the outlet pressure and facilitating rapid assessment of pump operating conditions during on-site inspections, ensuring continuous and stable shearing performance. The first and second stage flexible hose pumps are respectively located on short-distance process pipelines between the corresponding mixing vessel outlet and the shear pump inlet. The hoses of the flexible hose pumps are made of EPDM rubber. The peristaltic pump outlet is equipped with a communicable pressure transmitter and a local pressure gauge. The supporting process pipelines are made of 316L stainless steel. This pipeline layout allows for continuous operation of both the first and second stage mixing and shearing processes, as well as closed-loop control of material return from the second stage to the first stage. The EPDM rubber hoses are resistant to acid and alkali corrosion and have no shaft seal, avoiding leakage risks during transport. The dual pressure monitoring configuration ensures stable and pulsation-free flow from the peristaltic pump, providing a constant feed for the shearing process. The 316L pipelines are corrosion-resistant, wear-resistant, and compact, ensuring smooth continuous production while enabling closed-loop return of substandard slurry, reducing intermediate buffering and material sedimentation / stratification.

[0023] In this embodiment, S1 specifically includes: calculating the preset ratio of catalyst active powder components, binder, and deionized water based on production capacity; sequentially adding each component into the first-stage combined paddle mixer according to the calculated ratio; ensuring precise metering and feeding tailored to production capacity to guarantee a high degree of consistency in the material ratio of each batch, avoiding batch-to-batch quality fluctuations caused by human weighing errors, and laying a reliable foundation for continuous and stable production; sequential feeding so that each component begins initial contact and wetting upon entering the mixer, reducing subsequent mixing time and improving overall operational efficiency; remotely starting the anchor-type combined mixer via a frequency converter, driving two sets of axially arranged inclined blades to operate synchronously with the anchor-type combined mixer at a preset stirring rate, causing the slurry to form a turbulent vortex and flow up and down within the mixer; and remotely controlling the stirring speed via the frequency converter. The sliding adjustment allows operators to precisely control the equipment without approaching it, improving operational safety and ease of operation. The dual-blade and anchor-type agitator work together to circulate and tumble the slurry, eliminating the concentration gradient between the upper clear liquid and the lower thick slurry, and accelerating the uniform mixing of each component. During the mixing process, the anchor-type combined agitator continuously scrapes and pushes the material deposited at the bottom of the vessel. At the same time, two pairs of baffles arranged on the inner wall of the mixing vessel perform backflow shearing on the upward slurry. The initial mixing is completed after running continuously for no less than 30 minutes. The anchor-type combined agitator runs close to the bottom of the vessel to completely prevent powder settling and accumulation, ensuring that heavy components participate in the mixing process without being trapped in dead corners. The baffles force the upward slurry to change its flow direction and generate local high-speed shearing, increasing the collision frequency between the powder and the liquid phase, and causing the agglomerates to begin to loosen and disintegrate during the mixing stage. In addition, in S1, the tilt angle of the inclined blade is no more than 30°, and the distance between the bottom outer edge of the anchor-type combined agitator and the bottom of the first-stage combined blade agitator is no more than 10cm. The inclined blade drives the slurry downward at a small angle, forming a strong axial flow that runs through the entire height of the agitator, quickly eliminating the concentration difference between the upper clear liquid and the lower thick slurry, and shortening the overall mixing time. The baffle is located in the middle of the vertical distance of the inner wall of the agitator, and the length of the baffle is two-thirds of the height of the inner wall of the agitator. The distance between the end of the inclined blade and the outer edge of the baffle is 15cm. The anchor-type agitator is arranged close to the bottom of the agitator so that the bottom deposited material is forcibly scraped up and pushed to the mainstream area, avoiding the accumulation of catalyst active components in dead corners, ensuring that the material concentration in the agitator is uniform when the material is discharged. The baffle is set in the center and its specific length extension effectively intercepts the upward slurry and changes its flow direction, forming a local high shear zone between the blade end and the baffle, promoting the dispersion and disintegration of agglomerates during the stirring stage.

[0024] Furthermore, S2 specifically includes: After preliminary mixing, opening the outlet valve of the first-stage combined paddle mixer, preset the outlet pressure value of the first-stage flexible pump, and starting the first-stage flexible pump through frequency converter interlock control to automatically adjust the speed according to the preset pressure. The timing of the outlet valve opening and the flexible pump starting ensures that the material smoothly enters the conveying state, avoiding pressure buildup or idling, and ensuring that the feeding stage is stable and controllable from the beginning. The frequency converter automatically corrects the pump speed based on pressure feedback, so that the actual operation always follows the set working conditions, ensuring that the feeding rhythm and shearing process capacity are precisely matched, and ensuring that the equipment load is balanced and stable. The material is uniformly conveyed to the first-stage shearing pump through the EPDM rubber flow hose. The drive motor of the first-stage shearing pump drives the dense toothed moving and stationary disc assembly at a speed of 3000 rpm, repeatedly impacting and breaking the powder agglomerates in the material. The EPDM rubber hose is resistant to acid and alkali corrosion and the inner wall is... The smooth surface ensures that the material is free from secondary pollution and maintains constant flow resistance throughout the entire conveying process, reducing the impact and interference of pulsation fluctuations on the shearing process. The relative motion of the densely toothed moving and stationary discs generates high-frequency mechanical impact and shear stress field, causing agglomerates to rapidly disintegrate under the dual effects of impact and tearing, significantly increasing the exposure of active components. The pressure transmitter at the outlet of the first-stage shear pump monitors the outlet pressure in real time and feeds it back to the central control system. At the same time, a local pressure gauge is used for on-site inspection readings to ensure that the material throughput is constant and the shearing action is sufficient during a single shearing process. The pressure transmitter transmits the outlet pressure signal to the central control system, allowing operators to monitor the operating status of the shear pump in the central control room. In case of abnormalities, rapid analysis and handling can be carried out to reduce the risk of production interruption. The local pressure gauge provides intuitive readings for on-site inspections, facilitating maintenance personnel to quickly confirm the local operating conditions and compare them with remote data to improve the reliability of equipment operation. It should also be noted that in S2, the densely toothed moving and stationary disc assembly is made of zirconium metal. Zirconium metal moving and stationary discs have excellent wear resistance and can maintain the integrity of the tooth shape even after long-term high-speed impact and shearing, ensuring that the shearing effect does not decrease with the extension of operating time. The housing material of the first-stage shear pump is duplex stainless steel 2205 or 304 stainless steel lined with silicon nitride. The duplex stainless steel or silicon nitride lined housing has the dual advantages of high strength and corrosion resistance, resisting long-term erosion by acid and alkali components in the slurry, effectively extending the service life of the equipment. The shaft seal of the first-stage shear pump adopts a water-cooled, cartridge-type moving and stationary ring shaft seal, and the outlet of the first-stage shear pump is equipped with a communication pressure transmitter and a local pressure gauge to achieve dual pressure monitoring of remote monitoring and local reading. The cartridge-type moving and stationary ring shaft seal, combined with water cooling, continuously removes frictional heat, avoids overheating and deformation of the sealing surface leading to leakage, and ensures long-term continuous reliable and trouble-free operation of the shear pump.

[0025] Example 2, according to Figure 1 , Figure 2As shown, based on Example 1, the present invention provides a technical solution: S3 specifically includes: the first-stage sheared slurry after the first-stage shearing is directly fed into the second-stage combined paddle mixer through a 316L stainless steel process pipeline. The 316L stainless steel pipeline is corrosion-resistant, wear-resistant, and has a smooth inner wall, avoiding secondary agglomeration or residue on the wall due to rough pipe walls during transportation, ensuring that all materials are transferred without loss. The transportation path is completely sealed and has no intermediate buffering links. The direct transportation without buffering links eliminates the risk of sedimentation and stratification caused by intermediate storage, ensuring that the homogeneous state after the first shearing is completely maintained until the second-stage mixing process, avoiding quality regression. According to the preset formula requirements, the remaining raw material components for adjusting the slurry parameters are added to the second-stage combined paddle mixer. After the addition is completed, the anchor-type combined agitator is started, and the mixture is mixed again according to the preset mixing rate. The addition operation is completed before the mixing is started. The newly added component is stirred simultaneously with the existing slurry in the reactor, avoiding localized high concentrations or uneven reactions caused by delayed addition. After the anchor-type combined agitator is started, it quickly entrains the added component into the main slurry flow. The strong axial circulation enables the new and old materials to be homogenized in a short time, shortening the adjustment cycle. During the second-stage stirring process, the two axially arranged inclined blades and the anchor-type combined agitator work together with the two pairs of baffles on the inner wall of the reactor to mix the added component with the primary sheared slurry. The secondary mixing is completed by continuous stirring for no less than 30 minutes. The inclined blades and the anchor agitator, together with the baffles, form a multi-directional composite flow field, so that the added component is subjected to multiple shearing and tumbling actions in all parts of the reactor, achieving uniform dispersion at the molecular level. The baffles force the upward slurry to change direction, generating local turbulence, effectively eliminating the stirring dead zone and accelerating the interface renewal between different components, which greatly improves the mixing efficiency and ensures that the properties of the slurry are highly consistent throughout the reactor. Furthermore, in S3, the first-stage combined paddle agitator and the second-stage combined paddle agitator are arranged in parallel on the same steel frame platform. The parallel and consistent elevation layout eliminates the need for pipelines to climb or detour between the two agitators. The material can be smoothly transferred based on the pressure and elevation difference within the agitators, reducing additional power transmission links and lowering operating energy consumption. The top and bottom elevations of the two agitators are consistent and connected by equal-length short-range process pipelines. This equal-length short-range connection ensures that the material flow time within the pipeline is fixed and controllable, avoiding quality fluctuations caused by inconsistent material residence time in the pipeline due to differences in path length. Each agitator is independently equipped with a communicable temperature transmitter to collect slurry temperature data in real time and upload it to the central control system. The independently configured temperature transmitter in each agitator monitors the thermal state of the slurry in each stage agitator. Operators can remotely adjust the process temperature of each agitator to ensure that each process operates stably under suitable thermal conditions. The real-time upload of temperature data allows the central control system to continuously track the temperature rise trend. If abnormal changes are detected, timely intervention and adjustment can be made to ensure that the thermal state of the slurry preparation process is safe and controllable throughout.

[0026] Step S4 specifically includes: After the second-stage mixing is completed, the outlet valve of the second-stage combined paddle mixer is opened, the outlet pressure value of the second-stage flexible pump is preset, and the second-stage flexible pump is started via frequency converter interlock control, automatically adjusting the conveying speed according to the preset pressure. The timing coordination between the outlet valve and the start of the flexible pump ensures that the slurry in the reactor smoothly transitions to the conveying state, avoiding pressure shocks caused by delayed valve opening or sudden pump speed changes, thus ensuring pipeline operation safety. The frequency converter automatically adjusts the pump speed according to the preset pressure value, ensuring that the slurry is always supplied to the shearing process at a constant conveying rate, ensuring that each batch of material stays in the shearing chamber for a certain period of time. To ensure consistency and avoid over-shearing or under-shearing, the material is quantitatively delivered to the second-stage shear pump via a second-stage hose pump. Under the action of a densely toothed moving and stationary disc assembly driven at 3000 rpm, secondary shearing is performed, further refining and dispersing the active components. This secondary shearing deagglomerates any remaining fine aggregates in the slurry after the first treatment, further refining the active component particles. The interfacial bonding between the different phases of the slurry becomes tighter and more uniform. The high-speed drive of the densely toothed moving and stationary discs provides continuous high-frequency action on the slurry, improving the distribution of solid particles in the liquid phase from suspension and dispersion to near-molecular-level fusion. The overall homogeneity of the slurry reaches its optimal level. After the secondary shearing, the catalyst slurry is output through the outlet pipeline of the second-stage shear pump. The pressure transmitter at the outlet and the local pressure gauge synchronously monitor the discharge pressure to ensure stable slurry flow and uniform dispersion. It is then directly fed into the subsequent spray granulation process. The coordinated monitoring by the pressure transmitter and the local pressure gauge allows for remote traceability and on-site confirmation of the discharge pressure data, ensuring no fluctuations in the discharge flow and avoiding uneven feeding in the spray granulation process due to flow pulsation. Under stable pressure, the output slurry always maintains the optimal dispersion state at the time of shearing, eliminating the need for secondary adjustments. Direct supply to spray granulation ensures consistent powder forming quality throughout. Both the first-stage and second-stage hose pumps utilize EPDM rubber flow hoses with a seal-free structure. The drive motors are equipped with communicable frequency converters for remote start / stop and speed adjustment. Furthermore, the outlet pressure transmitters of each hose pump form an interlocked closed-loop control with the corresponding drive motors, automatically adjusting the delivery flow rate based on the outlet pressure setpoint. The seal-free hose structure completely eliminates the leakage risk at the traditional pump shaft seal, preventing slurry leakage and environmental pollution. Simultaneously, the elastic compression delivery of the hoses prevents the slurry from mechanical shearing, maintaining its original dispersed state.

[0027] S5 specifically includes: After the secondary shearing is completed, a catalyst slurry sample is collected at the sampling port of the outlet pipeline of the second-stage shear pump. The solid content, particle size distribution, and dispersion uniformity of the sample are tested. The test data are compared with the preset quality index thresholds for judgment. The sampling port is set at the outlet pipeline to facilitate the collection of representative slurry samples at any time, so that the test results can truly reflect the actual quality status of the current slurry and avoid misjudgment caused by sampling deviation. The test data is compared with the preset thresholds in a standardized manner to make the quality judgment basis objective and quantifiable, avoid subjective errors caused by human experience judgment, and ensure that the quality judgment standard of each batch of output is consistent. If the judgment result shows that the slurry particle size or dispersion uniformity does not meet the preset index, the process pipeline valve configuration is switched and adjusted. The return branch valve is opened and the discharge valve is closed at the same time, so that the unqualified slurry is introduced into the first-stage combined paddle agitator through the 316L stainless steel return pipeline and merged with the new batch of materials in the agitator. The valve configuration switching operation is performed. The system is simple and clear, allowing for rapid switching between discharge and recirculation without shutting down the machine. This avoids interrupting continuous production due to the handling of substandard slurry. The recirculation line returns substandard slurry directly to the front-end process, where it mixes with fresh material and undergoes a complete processing cycle. This process gradually corrects and eliminates quality defects during the cyclical processing. After the substandard slurry re-enters the first-stage combined paddle mixer, it undergoes preliminary mixing again according to step S1. Subsequently, the mixing and shearing processes of steps S2 to S4 are repeated sequentially until the slurry indicators meet the preset quality requirements upon retesting. At this point, the valve configuration is switched to close the recirculation branch and open the discharge valve, outputting the qualified slurry to the next process. The substandard slurry is then mixed with fresh material and processed again. The original defective components undergo a complete mixing and shearing process together with the fresh material during the secondary processing. This cyclical reprocessing eliminates the need for machine shutdown for waste removal or separate treatment, ensuring that each batch of output undergoes thorough quality verification and preventing substandard slurry from flowing into subsequent processes.

[0028] Example 3, according to Figures 1 to 3As shown, based on Embodiments 1 and 2, this invention provides a technical solution: Two sets of combined paddle mixers are arranged parallel to each other on a steel frame platform. The top and bottom elevations of the two mixers are the same, which facilitates the connection and transportation of materials through equal-length short-distance process pipelines, reducing pipeline pressure drop and material residue. Two high-speed shear pumps are respectively fixedly installed on the frame platform on the discharge side of the corresponding combined paddle mixers. The height of the shear pump inlet matches the height of the mixer outlet, shortening the length of the inlet pipeline. Two flexible peristaltic pumps are respectively installed on the pipeline between the mixer outlet and the shear pump inlet. The entire equipment is arranged in the order of primary mixing, primary shearing, secondary mixing, and secondary shearing. The equipment is connected by 316L stainless steel process pipelines. After the overall installation and layout of the device is completed, no-load debugging is carried out according to the design parameters to confirm that the frequency conversion speed regulation of each device is normal, the instrument communication is normal, and the valve switching is smooth. After the single-machine trial debugging is completed and qualified, it can be ready for feeding and production. After the single-unit trial run and debugging are completed, a water-based integrated trial run is conducted. A measured amount of deionized water is added to the first-stage combined paddle mixer, and the mixer is started. The mixer speed is changed at motor operating frequencies of 20 Hz, 25 Hz, 30 Hz, and 35 Hz respectively. The optimal water movement state in the mixer is observed to be turbulent eddies without splashing. The outlet valve of the mixer is opened, and the outlet pressure of the peristaltic pump is preset to 0.1 MPa. The peristaltic pump and the shear pump are started. The outlet pressure of the peristaltic pump is observed to be stable at 0.1 MPa. The outlet pressure setting of the peristaltic pump is increased to 0.2 MPa. It is checked whether the motor operating frequency increases automatically and whether the outlet pressure of the peristaltic pump rises to 0.2 MPa and remains stable. The outlet pressure and discharge rate of the shear pump are checked. The water in the first-stage mixer is transferred to the second-stage mixer through the shear pump. The operation process of the first-stage mixer is repeated. After the operating parameters are normal, the water-based integrated trial run can be stopped. For the initial feed and commissioning test, start the first-stage mixing vessel at 20Hz and sequentially add the prepared raw materials: deionized water, binder, and powder. Gradually increase the agitator speed until the slurry inside the vessel exhibits a rapid, turbulent vortex without splashing. After mixing for 30 minutes, open the mixing vessel outlet valve. Set the peristaltic pump outlet pressure to 0.1 MPa, start the peristaltic pump and then the shear pump. Observe that the peristaltic pump outlet pressure stabilizes at 0.1 MPa. Increase the peristaltic pump outlet pressure setting to 0.2 MPa and check if the motor operating frequency automatically increases and the peristaltic pump outlet pressure rises to 0.2 MPa and stabilizes. Check the shear pump outlet pressure and discharge rate. Then, add the first-stage... The slurry in the stirred tank is transferred to the second-stage stirred tank by a shear pump. The operation process of the first-stage stirred tank is repeated. After the operating parameters are normal, the slurry can be output to the next process for spray granulation, drying and molding, and high-temperature calcination. Finally, a finished catalyst with complete crystal phase, good particle sphericity, wear index meets the standard, and stable activity is obtained. If the slurry particle size and dispersion uniformity are found to be below the preset index when the discharge sample is tested, the return pipeline valve is opened and the unqualified slurry is sent back to the first-stage combined paddle stirred tank. The process of first-stage stirring, first-stage shearing, second-stage stirring, and second-stage shearing is repeated. The slurry is output again after the index is qualified, so as to ensure that the slurry quality entering the subsequent process is stable and consistent. Throughout the production process, parameters can be flexibly adjusted according to the characteristics of the catalyst to be prepared. If the catalyst requires a finer slurry with higher interphase integration, the peristaltic pump flow rate can be appropriately reduced to extend the residence time of the material in each stage of the stirred tank, while the shear pump speed can be increased to enhance the shearing and crushing effect. If a high solids content catalyst slurry is to be prepared, the stirring speed can be appropriately increased to ensure the stability of the slurry flow state in the tank, avoid material sedimentation, and still maintain a good mixing and dispersion effect without sacrificing the yield per batch by reducing the solids content. This process can be continuously operated throughout, with small performance fluctuations between batches, high raw material utilization, and can stably meet the requirements of large-scale production. The catalyst slurry, prepared through first-stage continuous stirring and shearing and second-stage continuous stirring and shearing, is then spray-granulated, dried, and calcined at high temperature. The resulting catalyst, as determined by micro-electronic imaging, exhibits excellent sphericity, uniform particle size distribution, and a low abrasion index. The average particle size distribution is 68.30 μm, with 1.3% being 20 μm, 11.69% being 40 μm, and 94.2% being 150 μm. The tested abrasion index is 1.13% / h, far below the industry standard requirement of ≤3.5% / h, demonstrating significant effectiveness. The appearance is similar to... Figure 3 As shown.

[0029] The above embodiments are merely exemplary embodiments of the present invention and are not intended to limit the present invention. The scope of protection of the present invention is defined by the claims. Those skilled in the art can make various modifications or equivalent substitutions to the present invention within its spirit and scope of protection, and such modifications or equivalent substitutions should also be considered to fall within the scope of protection of the present invention.

Claims

1. A process for continuously stirring and shearing to prepare a catalyst slurry, characterized in that, Includes the following steps: S1: According to the preset ratio, the catalyst active powder components, binder and deionized water are put into the first-stage combined paddle mixer, and the stirring is started to carry out preliminary mixing, so that the components are initially dispersed to form a mixed slurry; S2: After the initial mixing is completed, start the first-stage hose pump and feed the mixed slurry into the first-stage shear pump at a uniform speed according to the preset delivery flow rate. Through the crushing of the powder agglomeration structure, a homogeneous dispersion is completed to obtain a shear slurry. S3: The primary shear slurry is directly fed into the second-stage combined paddle mixer, the remaining components of the formula are added to adjust the slurry parameters, and the mixer is started to mix again to obtain a secondary mixed slurry. S4: Start the second-stage hose pump to send the secondary mixed slurry into the second-stage shear pump at a preset flow rate for secondary shear dispersion, refine the dispersion of active components, and obtain the catalyst slurry product. The first-stage hose pump and the second-stage hose pump are both hose-type peristaltic pumps. S5: Detect the particle size and dispersion uniformity of the finished catalyst slurry. If it does not meet the standard, the unqualified slurry is sent back to the first-stage combined paddle mixer through the return pipeline. Repeat steps S1 to S4 in sequence until the indicators meet the standard and then output.

2. The process for preparing catalyst slurry by continuous stirring and shearing according to claim 1, characterized in that, The first-stage combined paddle agitator and the second-stage combined paddle agitator are each independently equipped with two sets of inclined blades arranged vertically and axially and one set of anchor-type combined agitators, as well as two pairs of baffles arranged on the inner wall of the agitator. The height-to-diameter ratio of the agitator is not greater than 1.5, and the agitator is equipped with a communication temperature transmitter. Both the first-stage shear pump and the second-stage shear pump adopt densely toothed moving and stationary disc shearing components, and the outlet of the shear pump is equipped with a communication pressure transmitter and a local pressure gauge. The first-stage hose pump and the second-stage hose pump are respectively installed on the short-distance process pipeline between the discharge port of the corresponding mixing vessel and the inlet of the shear pump, and the flow hose of the hose pump is made of EPDM rubber.

3. The process for preparing catalyst slurry by continuous stirring and shearing according to claim 2, characterized in that, S1 specifically includes: Based on the production capacity, calculate the preset ratio of catalyst active powder components, binder and deionized water, and add each component into the first-stage combined paddle agitator in sequence according to the calculated ratio. The anchor-type combined agitator is remotely started by the frequency converter. The two sets of inclined blades arranged vertically and horizontally are driven to operate synchronously with the anchor-type combined agitator according to the preset agitation rate, so that the slurry forms a turbulent vortex in the kettle and flows vertically. During the mixing process, the anchor-type combined agitator continuously scrapes and pushes the material deposited at the bottom of the vessel, while two pairs of baffles arranged on the inner wall of the mixing vessel backflow shears the upward slurry. The process continues for no less than 30 minutes to complete the initial mixing.

4. The process for preparing catalyst slurry by continuous stirring and shearing according to claim 2, characterized in that, In S1, the tilt angle of the inclined blade is no greater than 30°, the distance between the bottom outer edge of the anchor-type combined agitator and the bottom of the first-stage combined blade agitator is no greater than 10cm, the baffle is located at the middle position of the vertical distance between the inner wall of the agitator, and the length of the baffle is two-thirds of the height of the inner wall of the agitator, and the distance between the end of the inclined blade and the outer edge of the baffle is 15cm.

5. The process for preparing catalyst slurry by continuous stirring and shearing according to claim 2, characterized in that, S2 specifically includes: After the initial mixing is completed, the outlet valve of the first-stage combined paddle mixer is opened, the outlet pressure value of the first-stage hose pump is preset, and the first-stage hose pump is started by the frequency converter interlock control and the speed is automatically adjusted according to the preset pressure. The material is conveyed at a constant speed through the flow tube to the first-stage shear pump. The drive motor of the first-stage shear pump drives the dense toothed moving and stationary disk assembly to operate at a speed of 3000 rpm, which repeatedly impacts and breaks up the powder agglomeration structure in the material. The pressure transmitter at the outlet of the first-stage shear pump monitors the outlet pressure in real time and feeds it back to the central control system. At the same time, the local pressure gauge is used for on-site inspection readings.

6. The process for preparing catalyst slurry by continuous stirring and shearing according to claim 5, characterized in that, In S2, the material of the dense toothed moving and stationary disc assembly is zirconium metal, the housing material of the first-stage shear pump is duplex stainless steel 2205 or 304 stainless steel lined with silicon nitride, the shaft seal of the first-stage shear pump is a water-cooled, cartridge-type moving and stationary ring shaft seal, and the outlet of the first-stage shear pump is equipped with a communication pressure transmitter and a local pressure gauge.

7. The process for preparing catalyst slurry by continuous stirring and shearing according to claim 2, characterized in that, S3 specifically includes: After the first stage of shearing is completed, the shearing slurry is directly fed into the second stage combined paddle agitator through a 316L stainless steel process pipeline. The conveying path is completely closed and there is no intermediate buffer. According to the preset formula requirements, the remaining raw material components for adjusting the slurry parameters are added to the second-stage combined paddle mixer. After the addition is completed, the anchor-type combined mixer is started and mixed again according to the preset mixing rate. During the second stage of mixing, the two sets of axially arranged inclined blades and the anchor-type combined agitator work together with the two pairs of baffles on the inner wall of the vessel to blend the added components with the primary shear slurry. The secondary mixing is completed by continuous mixing for no less than 30 minutes.

8. The process for preparing catalyst slurry by continuous stirring and shearing according to claim 7, characterized in that, In S3, the first-stage combined paddle agitator and the second-stage combined paddle agitator are arranged in parallel on the same steel frame platform. The top and bottom elevations of the two agitators are the same, and they are connected by equal-length short-range process pipelines. Each agitator is independently equipped with a communicable temperature transmitter to collect slurry temperature data in real time and upload it to the central control system.

9. The process for preparing catalyst slurry by continuous stirring and shearing according to claim 2, characterized in that, The S4 step specifically includes: After the second stage of mixing is completed, open the outlet valve of the second stage combined paddle mixer, preset the outlet pressure value of the second stage hose pump, and start the second stage hose pump through frequency converter interlock control to automatically adjust the conveying speed according to the preset pressure; The material is quantitatively delivered to the second-stage shear pump via the second-stage hose pump, and undergoes secondary shearing under the action of the dense toothed moving and stationary disc assembly driven at 3000 rpm, further refining and dispersing the active components. After the secondary shearing is completed, the catalyst slurry is output through the outlet pipeline of the second-stage shear pump. The pressure transmitter at the outlet and the local pressure gauge monitor the discharge pressure synchronously. The first-stage and second-stage hose pumps both use EPDM rubber flow hoses with no shaft seal, and the outlet pressure transmitters of each hose pump form an interlocked closed-loop control with the corresponding hose pump drive motors, automatically adjusting the delivery flow rate according to the outlet pressure set value.

10. The process for preparing catalyst slurry by continuous stirring and shearing according to claim 2, characterized in that, S5 specifically includes: After the second shearing is completed, a catalyst slurry sample is collected at the sampling port of the outlet pipeline of the second-stage shearing pump. The solid content, particle size distribution and dispersion uniformity of the sample are tested. The test data are compared with the preset quality index thresholds for judgment. If the judgment result shows that the slurry particle size or dispersion uniformity does not meet the preset index, the process pipeline valve configuration is switched and adjusted, the return branch valve is opened and the discharge valve is closed at the same time, so that the unqualified slurry is introduced into the first-stage combined paddle agitator through the 316L stainless steel return pipeline and merged with the new batch of materials in the agitator. After the substandard slurry re-enters the first-stage combined paddle mixer, the initial mixing operation is performed again according to step S1. Then, the mixing and shearing process of steps S2 to S4 is repeated in sequence until the slurry index meets the preset quality requirements when tested again. Then, the valve configuration is switched to close the reflux branch and open the discharge valve to output the qualified slurry to the next process.

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