流化催化裂化（FCC）催化剂跑损机制及故障树分析

doi:10.16085/j.issn.1000-6613.2018-2052

摘要/Abstract

摘要：

炼油厂中流化催化裂化（FCC）装置催化剂跑损的故障原因分析多数来自现场工程师，在故障机理方面少有报道。为了解决这一问题，本文利用故障树分析方法（FTA），研究FCC装置催化剂跑损机制。采用催化剂跑损为顶事件，结合跑损途径和跑损机理，确定FCC装置故障、操作工艺异常和催化剂颗粒物性3个因素作为中间事件，并通过逐层向下深入分析，确定诸如翼阀磨损等21个因素作为底事件，建立催化剂跑损故障树模型。根据FCC装置故障树风险分析，得到任何一个底事件出现都有可能导致顶事件发生，且对FCC装置催化剂跑损的贡献度相同。研究结果表明：利用FTA方法可以更深层次了解装置跑剂原因，对考察FCC装置催化剂跑损机理具有指导意义，并提出了相应的故障判定流程和跑剂预防措施。

关键词: 流化催化裂化装置, 故障树分析方法, 催化剂跑损, 预防措施

Abstract:

Fault analysis of catalyst loss in fluid catalytic cracking (FCC) unit of refinery mostly comes from technicians and field engineers, and there are few reports on fault mechanism. In order to solve this problem, fault tree analysis (FTA) method was used to investigate the mechanism of catalyst loss in FCC unit. Catalyst loss was determined to be top event. FCC unit failure, abnormal operation process and physical properties of catalysts were identified as the intermediate events by combining the pathway and mechanisms of catalyst loss. 21 factors such as flutter valve wear were identified as the bottom events through in-depth analysis step by step. The fault tree model of catalyst loss was established. According to the fault tree risk analysis of FCC unite, it is concluded that any bottom event may lead to top event, and the contribution degree of any of these factors to catalyst loss of FCC unite is the same. The results showed that, FTA method can be used to further understand the causes of catalyst loss in FCC unit, which has guiding significance for investigating the mechanism of catalyst loss in FCC unit. At the same time, the corresponding process of fault determination and the preventive measures of catalyst loss were put forward.

Key words: fluid catalytic cracking (FCC) unit, fault tree analysis (FTA), catalyst loss, preventive measures

中图分类号:

TQ022

王迪,孙立强,严超宇,魏耀东. 流化催化裂化（FCC）催化剂跑损机制及故障树分析[J]. 化工进展, 2019, 38(08): 3534-3539.

Di WANG,Liqiang SUN,Chaoyu YAN,Yaodong WEI. Mechanisms and fault tree analysis of catalyst loss in fluid catalytic cracking (FCC) unit[J]. Chemical Industry and Engineering Progress, 2019, 38(08): 3534-3539.

图/表 4

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代码	底事件
X1	流化风分布器管路磨穿
X2	流化风分布器喷嘴磨损
X3	流化风分布器喷嘴堵塞
X4	旋风分离器顶部吊挂断裂
X5	旋风分离器器壁孔洞
X6	翼阀开关不畅
X7	翼阀磨损
X8	料腿堵塞
X9	料腿拉筋断裂
X10	取热管破损
X11	流化风不稳定
X12	旋风分离器入口气速过高
X13	旋风分离器入口气速过低
X14	原油喷嘴出口速度过速
X15	汽提蒸汽喷嘴出口速度过高
X16	流化风喷嘴出口速度过高
X17	再生器高温
X18	颗粒粒度分布较小
X19	颗粒机械强度低
X20	颗粒抗重金属污染能力低
X21	颗粒水热稳定性差

代码	底事件
X1	流化风分布器管路磨穿
X2	流化风分布器喷嘴磨损
X3	流化风分布器喷嘴堵塞
X4	旋风分离器顶部吊挂断裂
X5	旋风分离器器壁孔洞
X6	翼阀开关不畅
X7	翼阀磨损
X8	料腿堵塞
X9	料腿拉筋断裂
X10	取热管破损
X11	流化风不稳定
X12	旋风分离器入口气速过高
X13	旋风分离器入口气速过低
X14	原油喷嘴出口速度过速
X15	汽提蒸汽喷嘴出口速度过高
X16	流化风喷嘴出口速度过高
X17	再生器高温
X18	颗粒粒度分布较小
X19	颗粒机械强度低
X20	颗粒抗重金属污染能力低
X21	颗粒水热稳定性差

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