Table of Content

12 March 2026, Volume 57 Issue 3

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CONCEPTION AND EXPLORATION OF TECHNICAL PATHWAYS FOR LIGHT HYDROCARBON AND NAPHTHA CONVERSION UNDER THE CONTEXT OF “OIL REDUCTION AND CHEMICALS INCREASE”

2026, 57(3):  1-8. 

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The challenges and opportunities faced by existing light hydrocarbon and naphtha processing technologies under the “oil reduction and chemicals increase” strategy are analyzed. The critical issues are highlighted, such as naphtha surplus and a significant decline in benzene yield due to the lightening of steam cracking feedstocks, an excess of C₉+ heavy aromatics from catalytic reformer, and a lack of effective processing technologies for refinery light hydrocarbons (e.g., liquefied petroleum gas, raffinate, and heavy C4). The study proposes optimizing feedstocks and improving technologies for catalytic reforming and steam cracking by matching hydrocarbon structures with reaction characteristics to increase the production of light aromatics and light olefins. Light hydrocarbon aromatization technology offers flexible product adjustability, while high-selectivity naphtha conversion can transform surplus naphtha into benzene, ethane, and propane, complementing catalytic reforming. Combining optimized existing technologies with new ones based on hydrocarbon structure and reaction characteristics is a key direction for light hydrocarbon and naphtha conversion in the context of “oil reduction and chemicals increase”.

ANALYSIS OF IMPACT OF LIGHT/HEAVY RAW MATERIAL ON SEPARATION UNIT OF ETHYLENE PLANT

2026, 57(3):  9-18. 

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The operation and running of the ethylene plant are greatly affected by changes in raw materials, which can cause changes in the load of various systems and equipment in the ethylene plant, thereby affecting the operating efficiency and product quality of the plant. Therefore, it is necessary to conduct targeted accounting for each system of the device to ensure that each unit can adapt to new operations after changes in raw materials. Taking a domestic ethylene plant as an example, a detailed comparison is made on the impact of light and heavy raw material conditions on various systems of the separation unit, and specific analysis is given on the adjustments required for each system. The results indicate that the changes in raw materials in the ethylene plant have different degrees of impact on each process unit. The comprehensive impact of raw materials on ethylene production is reflected in the energy consumption of the ethylene plant, that is, the production cost of ethylene. When the raw materials have a certain amount of lightweight space, the ethylene yield is higher, the energy consumption is reduced, and the operating cost of the plant is reduced.

SEPARATIONANDREFININGOFETHYLENEOLIGOMERIZATIONBY-PRODUCTWAXESANDCOMPOSITIONANALYSIS

2026, 57(3):  19-27. 

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The by-product polyethylene wax from ethylene oligomerization contains impurities such as high-carbon olefins and ash, leading to low value and limited applications if sold with minimal processing. To enhance its utilization, refining treatments are necessary. This study examined the effect of different solvents on the separation of the polyethylene wax and identified optimal refining conditions. Using a Soxhlet extraction system with n-hexane, the wax was separated into four fractions（Fraction 1 to Fraction 4）in descending order of melting point, with mass percentages of 30.60%, 38.05%, 13.00%, and 18.35%, respectively. The physicochemical properties and ash composition of each fraction were systematically analyzed, revealing that metallic elements in the ash derived from the catalyst system used in ethylene oligomerization.

APPLICATION OF PARTIAL CUT-OUT TECHNOLOGY FOR GUARD REACTOR IN FIXED-BED RESIDUE HYDROTREATING UNIT

2026, 57(3):  28-33. 

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Aiming at the technical bottlenecks of a 2.0 Mt/a fixed-bed residue hydrotreating unit in a refinery, such as the need to reduce the residue blending ratio before cutting out the guard reactor and the significant fluctuation of bed temperature rise after the complete cut-out, an optimized process for partial cut - out of the guard reactor was studied and applied. Compared with the conventional complete cut-out process of the guard reactor, this method can maintain a higher residue blending ratio. At the same time, the fluctuation range of bed temperature rise can be controlled within ±5 °C, and the stability of process operation is significantly improved. The implementation of this method has successfully extended the operation cycle of the unit by about 3 months, providing an engineering solution for the long-period operation of fixed-bed residue hydrotreating units.

A QUICK WAY FOR CHECKING INTERNAL LEAKAGE OF HIGH-PRESSURE HEAT EXCHANGER OF FEED IN RDS UNIT

2026, 57(3):  34-37. 

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At one RDS unit in a refinery , following extended operation beyond the design cycle and partial catalyst change-out, the HDS, CCR removal, and HDM performance of the catalyst after unit startupwas lower than expected. To check whether high-pressure heat exchanger (residue feed/reactor effluent) was leak, the resid feed was switched to 100% high-sulfur VGO feed under normal operating condition. Based on the evaluation of sulfur content and sulfur distribution in the resid product, it was successfully confirmed that there was no internal leakage in the high-pressure heat exchanger. This avoided the shutdown of the RDS unit and the inspection process of opening the high-pressure heat exchanger, ensured the online rate of the unit.

STUDY ON CATALYTIC REFORMING OF HYDROGENATED COAL-BASED NAPHTHA FOR AROMATICS PRODUCTION

2026, 57(3):  38-42. 

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Using hydrogenated coal-based naphtha as the feedstock and semi-regenerative reforming catalysts, the effects of reaction temperature, pressure, and space velocity on the liquid yield and composition of the product oil were investigated. The results showed that as the reaction temperature increased, the liquid yield of the reformed oil decreased, while the aromatic content increased. With pressure increasing, the liquid yield of the reformed oil decreased, and the aromatic content also decreased. Space velocity had a relatively minor impact on both the liquid yield and aromatic content of the reformed oil. Under optimized conditions, the conversion rate of naphthenes reached as high as 98.95%. The reformed oil mainly consisted of aromatics, iso-paraffins, and n-paraffins, with an aromatic content of 84.87% and an aromatic yield of 71.79%. Hydrogenated coal-based naphtha is a high-quality feedstock for the production of aromatics.

DEVELOPMENT STRATEGY OF TAILORED START-UP CATALYST AND THE INDUSTRIAL APPLICATION PRACTICES IN MULTIPLE SCENARIOS

2026, 57(3):  43-51. 

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The lack of high-value utilization methods for catalytic cracking E-Cat has been a persistent challenge. Tailored start-up catalyst as an efficient solution, with the core principle being the scientific utilization of equilibrium catalysts from diverse sources. Based on the process characteristics of catalytic cracking units and different requirements for product distribution, while also considering the physicochemical properties (such as fluidization) of the start-up catalyst, the TSC tailored start-up catalyst was developed through the scientific blending of selected equilibrium catalyst, tailored fresh catalyst, and inert additives. This series can meet the industrial application needs of multiple scenarios, including start-up of new units, start-up after maintenance, rapid replacement after equilibrium catalyst poisoning, and replenishment during abnormal catalyst loss. Compared to traditional start-up catalyst, the tailored start-up catalyst exhibit excellent physical properties, can quickly align with the start-up requirements of the target unit, assist in rapidly achieving the desired product distribution, and enhance the overall economic efficiency of the unit. Industrial applications in units such as the 4.00 Mt/a DCC unit at Yulong Petrochemical Co., Ltd., the 2.80 Mt/a MIP unit at SINOPECYangzi Petrochemical Company, the 3.00 Mt/a RTC unit at SINOPEC Zhenhai Refining & Chemical Company and the 3.00 Mt/a RTC unit at SINOPEC Anqing Company demonstrated that the catalyst reaction activity reached a stable state quickly, contributing to a faster achievement of the designed product distribution and significantly reducing the unit adjustment time, thereby ensuring economic benefits. The development and application of tailored start-up catalyst achieve high compatibility with target units, pioneer a high-value utilization pathway for catalytic cracking equilibrium catalyst, and fully leverage the leading role of green refining technology.

PREPARATION OF BARIUM/ZIRCONIUM MODIFIED IRON-BASED CATALYST AND ITS PERFORMANCE IN FISCHER-TROPSCH SYNTHESIS OF α -OLEFINS

2026, 57(3):  52-63. 

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Fischer-Tropsch synthesis (FTS) is one of the main industrial routes for the preparation of α-olefins, but it is plagued by low α-olefin selectivity, severe methane side reactions and insufficient catalyst stability. This study aims to prepare Fe-xBa and Fe-yZr catalysts with different Ba or Zr loading by co-precipitation and equal volume impregnation methods, and explore their effects on the performance of FTS for α-olefin production. The physicochemical properties of the catalysts were characterized by XRF,XRD,TEM,etc. The experimental results show that the introduction of Ba enhances the density of surface basic sites and the electron transfer effect, significantly improving the CO dissociative adsorption capacity and inhibiting the methane side reaction, resulting in an α-olefin content (mass fraction) of 48.17% in the liquid product of the catalyst. The Zr additive optimizes the pore structure and promotes the dispersion of Fe particles, enhancing the catalytic stability. The catalyst achieved a CO conversion rate of 78.98% and an α-olefin selectivity of 48.63% in a 48-hour reaction, while the selectivities of CO₂ and CH₄ were reduced to 37.73% and 6.54%, respectively. Appropriate Ba/Zr modified iron-based catalysts can both enhance the α-olefin selectivity and suppress the selectivities of CH₄ and CO₂.

THE FIRST REGENERATION AND COMMERCIAL APPLICATION OF TORH-1 CATALYST FOR LIQUID PHASE DEOLEFINNATION FROM CONTINUOUS REFORMING OIL

2026, 57(3):  64-67. 

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This article provides a systematic introduction to the regeneration and post-regeneration performance of the olefin removal catalystTORH-1, which had been in operation for 36 months in the liquid-phase hydrodeolefining unit of 1.0 Mt/a continuous catalytic reforming unit at CNOOCTaizhou Petrochemical Co., Ltd . After the first regeneration, the chlorine, carbon, and sulfur content of the catalyst all met the regeneration index requirements, with a specific surface area increase of 10 m²/g and a pore volume increase of approximately 5%. Data from 20 months of operation after regeneration show that under the conditions of a reaction pressure of 1.2 MPa, a temperature range of 120－160 ℃, and a hydrogen-to-oil volume ratio of 4.5:1, when the feedstock bromine index was 3,500－4,200 mgBr/(100 g), the average product bromine index remained stable at 53.48 mgBr/(100 g). The olefin removal rate reached 98.68%, and the average aromatics loss rate meets the specification requirements. The bromine index of the benzene, toluene, and xylene products met the national standards for product shipment, indicating effective catalyst regeneration. Compared to the clay treatment process, the use of the TORH-1 olefin removal catalyst resulted in cost savings of 12.6 million yuan.

THE FIRST COMMERCIAL APPLICATION OF HIGH ANTIOXIDANT TRUE SULFURIZED DIESEL HYDROGENATION CATALYST

2026, 57(3):  68-73. 

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The high antioxidant true sulfurized diesel hydrogenation catalyst has completed its first industrial application on the 1.8 Mt/a diesel hydrogenation unit of the Refining Department 4 of Zhongke (Guangdong) Refining and Chemical Co., Ltd. The start-up process has shown that the high antioxidant true sulfurized hydrogenation catalyst effectively solves the technical bottleneck of conventional sulfurized hydrogenation catalysts being prone to self heating during transportation and loading. Catalyst loading can operate in a flowing air environment with low dust, stable catalyst performance, and convenient start-up process. It significantly simplifies the start-up process and reduces the workload of operators, reducing safety and environmental risks, energy consumption, and material consumption during the start-up phase. The product properties of the device are stable during long-term operation, and the raw materials of the catalyst have strong applicability. The product meets the requirements of automotive diesel indicators.

FORCE FIELD DEVELOPMENT AND VAPOR-LIQUID PHASE EQUILIBRIUM PROPERTY SIMULATION OF ALKYLBENZENES BASED ON Mie POTENTIAL

2026, 57(3):  74-83. 

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The realization of molecular management of refinery processes relies on physical property data. However, experimental data are scarce for many molecules present in petroleum fractions. To bridge this data gap, molecular simulation has emerged as an effective approach for generating high-quality property data. To address the insufficient accuracy of existing general force fields (e.g., TraPPE) in predicting key properties like saturated vapor pressure, a high-precision and transferable united-atom Mie potential force field applicable for vapor-liquid equilibrium simulations of alkylbenzenes was developed. This development was based on the high-precision n-6 Mie potential and Gibbs ensemble Monte Carlo simulation methods, accelerated via an analytical equation-of-state surrogate optimization approach. Results demonstrate that the developed Mie potential force field achieves average relative deviations of 1%–2% in predicting saturated vapor pressure, vaporization enthalpy, and liquid density for benzene and ethylbenzene across a wide temperature range, significantly outperforming TraPPE series force fields. Simultaneously demonstrating excellent prediction accuracy for vapor-liquid equilibrium compositions in binary systems such as benzene-cyclopentane, ethylbenzene-cyclohexane, and m-xylene-cyclohexane; Notably, the developed Mie potentialforce field parameters exhibit excellent transferability, with an average absolute deviation of only 2.95 K in predicting the boiling points of various alkylbenzene compounds, offering a highly promising approach for expanding physical property data in refining and chemical processes.

REMOVAL CHARACTERISTICS AND CHEMICAL CONVERSION MECHANISMS OF DIBENZOFURAN DURING THERMAL DESORPTION OF OIL-CONTAMINATED SOIL

2026, 57(3):  84-93. 

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This study investigated the removal characteristics of dibenzofuran and its mechanisms of physical desorption and chemical conversion during the thermal desorption of oil-contaminated soil. The results demonstrated that after remediation at 300 °C, the residual mass fraction of dibenzofuran in the soil was below 24.46 μg/g, which is lower than the risk screening values for Class I construction land as stipulated by the local standards of Hebei and Guangdong provinces. Among the kinetic models, three types of exponential decay models (basic, composite, and modified) were found to be more suitable for exploring the physical desorption behavior of dibenzofuran under heating conditions than first/second-order kinetic models. Analysis based on the Criado and Coats-Redfern models revealed that the most appropriate models for describing the chemical transformation behavior of dibenzofuran were the power function model P2 (initial stage), the contracting surface model R2 (middle stage), and the contracting surface model R2, contracting model R1, and contracting volume model R3 (late stage). The frequency of effective molecular collisions of dibenzofuran was significantly higher during the Contracting model R1 stage than in other model stages. Furthermore, the initial pyrolysis stage required the highest activation energy, substantially greater than that required in the middle and late stages.

APPLICATION OF THERMAL INTEGRATION TECHNOLOGY IN CARBON FIVE DISTILLATION SEPARATION PROCESS

2026, 57(3):  94-101. 

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Taking the debutane column and the carbon fivepre-separation column in the carbon five separation process as the research object, the conventional distillation process model was established by using UniSim Design software, and the thermal integration of the debutane column and the carbon five pre-separation column was carried out. The simulation results showed that the energy consumption of the condenser and the reboiler was reduced by 19.26% and 19.02%, respectively, after the optimization of the thermal integration technology. Annual operating cost and annual total costwere reduced by 19.19% and 15.05%, respectively. Based on the steady-state model, a dynamic distillation process model was established, and a dynamic control scheme was designed to investigate the effects of feed flow and feed composition on the key parameters of distillation separation process (output at the top and bottom, mass fraction of key components and temperature at the top and bottom). The results of dynamic response analysis show that the fixed reflux ratio control structure has good anti-interference performance in the separation process, and can realize the stable control of dynamic simulation.

STUDY ON SAFETY EARLY WARNING MODEL FOR NATURAL GAS DESULFURIZATION PURIFICATION UNIT BASED ON ETCN-LSTM NETWORK

2026, 57(3):  102-108. 

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To address the false alarm issue caused by abnormal sensor fluctuations due to cavitation in natural gas desulfurization purification unit, this study proposes a multi-sensor data fusion technology based on an expanded time-convolutional neural network (ETCN) enhanced long short-term memory (LSTM) network. The ETCN-LSTM model integrates data from multiple sensors related to cavitation to predict foaming behavior. Results demonstrate that the ETCN-LSTM model effectively fuses multi-sensor data and accurately predicts foaming levels over time, with predictions showing strong alignment with actual values. Compared to the standard LSTM, the ETCN-LSTM reduces root mean square error (RMSE) and mean absolute error (MAE) by 12.0% and 26.4%, respectively, while maintaining low computational cost and improving long-term prediction stability.

PERFORMANCE EVALUATION AND MECHANISM ANALYSIS OF CYLINDER OIL

2026, 57(3):  109-116. 

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The lubricating performance and anti-scuffing properties of two 40BN cylinder oils were evaluated using a reciprocating friction and wear tester under simulated conditions of engine boundary lubrication and adhesive wear. Tests were conducted to measure the friction coefficient, wear loss, and anti-scuffing time. The results indicated that cylinder oil 1 exhibited a lower friction coefficient, less wear loss, and a longer anti-scuffing time, demonstrating superior friction reduction and wear resistance compared to cylinder oil 2.Analyses employing optical microscopy, ultra-high resolution scanning electron microscopy combined with focused ion beam-time-of-flight secondary ion mass spectrometry, and X-ray photoelectron spectroscopy revealed that the wear scar surface lubricated with cylinder oil 1 retained clearer honing marks and exhibited less severe wear. A boundary lubrication film, approximately 340 nm thick and composed of phosphates, sulfates, metal oxides, and carbonates, formed on the friction surface. This film is responsible for the excellent friction reduction and anti-wear performance of cylinder oil 1.

PHYSICAL AND CHEMICAL PROPERTIES OF DIESEL ENGINE EXHAUST AND LUBRICATING OIL PARTICULATES

2026, 57(3):  117-122. 

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To systematically investigate the differences in physical and chemical properties between diesel engine exhaust particulates (DS) and in-use lubricating oil particulates (LS), the exhaust particulates from a China VI diesel engine and the in-use lubricating oil particulates from the same engine were collected. The differences in physical and chemical properties between the two types of particulates were examined using high-resolution transmission electron microscopy, Raman spectroscopy, X-ray photoelectron spectroscopy, and thermogravimetric analyzer, and the reasons for the differences in particulate properties were discussed.The results show that both types of particulates exhibit a typical "core-shell" structure. The average particle sizes of DS and LS particulates are 58.2 nm and 52.6 nm, respectively. Both types of particulates are mainly composed of C and H. Functional elements of lubricating oil such as Ca, S, P, and Zn are found in LS particulates, and Ca mainly exists in the forms of CaSO₄ and CaO. Compared with DS, LS had the following characteristics: slightly higher graphitization degree and slightly thinner graphite shell; slightly higher fractal dimension and greater particle structure compactness; slightly higher oxidation activity, making it more prone to oxidation reactions.

RESEARCH ON DEEP PURIFICATION TECHNOLOGY FOR TRACE IMPURITIES IN CHEMICAL WASTE SALT

2026, 57(3):  123-128. 

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Chemical waste salt contains substantial insoluble substances (SS) and trace impurities such as calcium, magnesium, silicon, and TOC, which hinder its reutilization. In order to remove these impurities, this study investigated the removal efficiency of inorganic impurities through stepwise and synchronous removal methods, as well as the effectiveness of activated carbon adsorprion, resin adsorprion, heterogeneous ozone oxidation, and homogeneous ozone oxidation in TOC removal. Results demonstrate that synchronous impurity removal delivers superior inorganic impurity elimination. Under optimized conditions (pH 10.5, MgCl₂/SiO₂ molar ratio of 1.5, Na₂CO₃ excess dosage of 300 mg/L), effluent concentrations of SS, calcium, magnesium, and silicon can be reduced to 32, 0, 0.39, and 1.9 mg/L, respectively, with SS exhibiting synergistic removal effects on calcium, magnesium, and silicon. Compared to activated carbon adsorprion, resin adsorprion, and heterogeneous ozone oxidation processes, homogeneous ozone oxidation achieves a lower effluent TOC of 5.2 mg/L. The integrated "synchronous chemical precipitation + homogeneous ozone oxidation" process enables deep purification of micro-pollutants in chemical waste salt.

ANALYSIS OF CO₂ EMISSION REDUCTION PATHWAYS FOR REGIONAL REFINERIES BASED ON MULTI-OBJECTIVE OPTIMIZATION

2026, 57(3):  129-139. 

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To assist the petrochemical industry in formulating reasonable carbon reduction strategies and achieving low-carbon transformation, this study conducted carbon emission accounting for 21 refineries of varying scales and regions in China by combining Monte Carlo simulation with the LEAP model. The study quantified the emission reduction effects and costs of energy-saving and consumption-reduction technologies, CCUS technologies, green electricity substitution technologies, and green hydrogen substitution technologies from 2025 to 2060.Subsequently, with the dual objectives of "maximizing carbon reduction effects and minimizing reduction costs," a multi-objective optimization model for refineries was constructed. The NSGA-II algorithm was employed to solve the model, yielding the optimal carbon reduction pathway combinations and their evolution trends for refineries in different regions from 2025 to 2060.The results indicate that after introducing the corresponding optimal technology pathway combinations based on the multi-objective optimization outcomes, the carbon emissions of refineries in different regions will decline steadily from 2025 to 2060. By 2060, the overall carbon emissions reduction will exceed 40%.

COMPREHENSIVE UTILIZATION AND ENERGY-SAVING OPTIMIZATION OF LOW-TEMPERATURE HEAT FOR STEAM GENERATION AND UPGRADING IN AROMATICS COPLEX UNIT

2026, 57(3):  140-144. 

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To address the issue of low-temperature heat being wasted in cooling within aromatics complex units, a steam generator and steam booster were added to utilize the low-temperature waste heat from the toluene column overhead. This system generates 0.6 MPa steam, which is then boosted to 1.8 MPa, achieving comprehensive utilization of low-temperature waste heat and energy-saving and emission-reduction goals in the unit. The operational requirements, operating parameters, and energy-saving and emission-reduction effects of the steam generator and booster unit were systematically analyzed, and optimizations were made for operational issues. The results show that the equipment in this low-temperature waste heat steam generation project operates stably and meets all design specifications. The 1.8 MPa steam produced reaches a flow rate of 25.57 t/h, enabling energy savings of 16150.5 tCE/a (1 kgCE = 29.3 MJ) and a reduction in CO₂ emissions of 40263.2 t/a. The economic and social benefits are significant.

MECHANISM ANALYSIS AND COUNTERMEASURES FOR THE WEAR OF MAIN AIR DISTRIBUTION PIPE IN THE DMTO REGENERATOR

2026, 57(3):  145-151. 

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In response to the severe erosion problem of the main air distribution pipe in the Methanol to Olefins (DMTO) unit regenerator, this study focuses on the industrial system at a certain company. By integrating field operating data with numerical simulation results, the underlying erosion mechanism is elucidated. Within the branched distribution pipes, the abrupt change in airflow direction from branch to sub-branch causes the near-wall flow to be hindered and locally detached, giving rise to a typical flow separation phenomenon. Under these conditions, the velocity on the windward side exceeds that on the leeward side, and pressure drop anomalies create low-pressure recirculation zones that entrain external catalyst particles back into the pipes. The entrained particles, subjected to the combined action of forward airflow and reverse recirculation, impinge upon and erode the nozzle surfaces. To mitigate this effect, structural optimization strategies were introduced, including elliptical cross-section design and gradually expanding transitions for the sub-branches, reinforcement of ceramic nozzle edges, and the application of high-hardness protective coatings. The results demonstrate that these measures effectively suppress catalyst backflow, restore the designed pressure drop characteristics of the main air distribution pipe, and ensure stable fluidization within the regenerator.

RESEARCH PROGRESS ON BIFUNCTIONAL CATALYSTS FOR DIRECT HYDROGENATION OF CO₂ TO AROMATICS

2026, 57(3):  152-165. 

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Research on bifunctional catalysts for direct hydrogenation of CO₂ to aromatics provides a new approach for exploring the synthesis of aromatics using CO₂ as a carbon source, which is conducive to promoting the low-carbon emission reduction and green transformation of the chemical industry. This work focuses on the design and performance optimization of bifunctional catalysts aimed at enhancing CO₂ conversion efficiency and aromatic selectivity through advanced catalytic material development. A systematic analysis is conducted on the synergistic mechanisms of the methanol-mediated and Fischer–Tropsch synthesis pathways, with particular emphasis on the influence of active site structure, pore architecture, and acid site distribution on reaction pathway regulation. Furthermore, the effects of key operational parameters, such as the metal-to-zeolite mass ratio and reaction temperatureon product distribution are elucidated. The study demonstrates that constructing bifunctional catalysts with spatial and acidic synergistic effects enables both efficient CO₂ conversion and selective aromatics formation. Future research directions will focus on the development of novel hierarchical pore-structured catalyst systems, dynamic mechanistic investigations, and integrated process optimization, providing technological support for CO₂ valorization.

RESEARCH PROGRESS ON SOLID-STATE ION EXCHANGEOF TECHNOLOGY FOR ZEOLITE MODIFICATION

2026, 57(3):  166-172. 

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Ion exchange is a crucial technique for precisely tuning the acidity, pore size, and active site distribution of zeolites. Although the traditional liquid ion exchange (LIE) method is widely used, it suffers from issues such as long processing times, large wastewater generation, and low exchange capacity. Enhancing the efficiency of zeolite ion exchange while reducing energy consumption and pollution remains a significant challenge in the field. Solid-state ion exchange (SSIE) offers advantages such as low wastewater production and faster exchange rates, overcoming many limitations of LIE. However, fundamental research on the principles and process optimization of SSIE is still limited. This paper provides a comprehensive discussion of the ion exchange mechanism in SSIE, focusing on the influence of zeolite types, metal types, and thermal treatment conditions on exchange efficiencyas well as the existing challenges. It also offers a detailed comparison of the characteristics of LIE and SSIE, providing valuable insights for future research on green modification methods for zeolites.