Test Your Knowledge: Refinery Catalyst Safety & CRU Operations Quiz

1. During a CRU catalyst regeneration, you observe a rapid, unexpected increase in the reactor outlet temperature despite stable air and fuel gas flow. What is the most likely immediate cause, and what action should be prioritized?

• a) Insufficient air flow leading to incomplete coke burning; increase regeneration air flow immediately.
• b) A localized hotspot due to poor catalyst distribution; initiate a gradual nitrogen purge.
• c) A runaway reaction indicating an uncontrolled burn; initiate emergency quenching procedures.
• d) Catalyst deactivation causing reduced activity; continue regeneration as per schedule and plan for replacement.

2. Following a CRU runaway reaction caused by an air compressor leak, what long-term preventive measure would be most effective in mitigating future similar incidents?

• a) Implementing a higher frequency of catalyst sampling and analysis.
• b) Upgrading to a more robust emergency shutdown system with faster response times.
• c) Enhancing the preventative maintenance schedule and leak detection protocols for regeneration air compressors and associated piping.
• d) Decreasing the target regeneration temperature to reduce the risk of thermal excursions.

3. During an emergency quench of a CRU catalyst runaway, what is the primary purpose of introducing steam or nitrogen into the reactor?

• a) To increase the catalyst bed temperature for more efficient coke removal.
• b) To dilute the hydrocarbon feed to prevent further reaction.
• c) To cool the catalyst bed and remove oxygen, thereby stopping the exothermic runaway reaction.
• d) To prepare the catalyst for immediate re-commissioning after the upset.

4. After a CRU catalyst experiences a significant thermal excursion due to a runaway reaction, why is catalyst sampling and integrity checking crucial before resuming normal operation?

• a) To optimize the regeneration parameters for the next cycle.
• b) To determine the remaining coke content on the catalyst surface.
• c) To assess potential damage (e.g., sintering, pore collapse) that could permanently reduce catalyst activity and selectivity.
• d) To verify the proper functioning of temperature sensors in the reactor.

5. In the context of CRU operations and safety, what is the primary benefit of continuous operator training and scenario-based drills, especially concerning emergency procedures?

• a) To reduce the frequency of scheduled maintenance activities.
• b) To improve the efficiency of routine catalyst loading and unloading.
• c) To ensure operators can respond quickly, correctly, and effectively to abnormal situations, minimizing incident impact and preventing escalation.
• d) To provide advanced theoretical knowledge for academic research.