Abstract: Through a systematic analysis of the process, operation, equipment, and design, combined with the actual working conditions, an in-depth study was conducted on the failure of the internal deflector in the dehydrogenation reactor of a styrene unit. The analysis identified overpressure, improper operation, and inherent design defects as the primary causes of deflector failure. By optimizing the design, performing structural repairs, and improving operational procedures, the recurrence of equipment failure was effectively mitigated. The results indicate that, these improvements significantly enhanced the operational stability of the internal deflector in the dehydrogenation reactor, thereby increasing the safety and reliability. This study provides valuable reference for the design and operational control of similar equipment.

Key words: styrene, dehydrogenation reactor, deflector, purge, failure