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<p>Catalyst fragmentation frequently occurs during the loading and unloading processes in the chemical industry. Currently, there is limited experimental or simulation research on the breakage of irregularly shaped catalysts. To control product quality and enhance catalyst recovery efficiency, it is necessary to investigate the fragmentation mechanisms of catalysts. For this purpose, this study employs the Discrete Element Method (DEM) combined with the Bonded Particle Model (BPM) to simulate the impact-induced fragmentation of cylindrical catalyst particles and reveals their fragmentation characteristics. By integrating uni-axial compression tests and impact experiments with DEM simulations, the bonded particle model of catalyst was established and validated. Experimental studies reveal that a 6&#xa0;mm-long catalyst exhibits a critical fracture velocity of 3.6&#xa0;m/s. Breakage severity transitions through three distinct regimes with increasing impact velocity: unbroken, fragmentation, and shattering. Impact angle critically influences breakage mechanisms. Furthermore, axial length governs mechanical strength. These findings clarify the microstructure–property relationships in catalyst fracture, providing a reference for potential structural optimization.</p>

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Impact fracture characteristics of single particle columnar catalyst based on discrete element method

  • 期刊论文

  • 发表日期：

    2025年10月4日

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  • Jiang Tao,
  • Xuedong Liu,
  • Siduo Song,
  • Sheng Yao

摘要

Catalyst fragmentation frequently occurs during the loading and unloading processes in the chemical industry. Currently, there is limited experimental or simulation research on the breakage of irregularly shaped catalysts. To control product quality and enhance catalyst recovery efficiency, it is necessary to investigate the fragmentation mechanisms of catalysts. For this purpose, this study employs the Discrete Element Method (DEM) combined with the Bonded Particle Model (BPM) to simulate the impact-induced fragmentation of cylindrical catalyst particles and reveals their fragmentation characteristics. By integrating uni-axial compression tests and impact experiments with DEM simulations, the bonded particle model of catalyst was established and validated. Experimental studies reveal that a 6 mm-long catalyst exhibits a critical fracture velocity of 3.6 m/s. Breakage severity transitions through three distinct regimes with increasing impact velocity: unbroken, fragmentation, and shattering. Impact angle critically influences breakage mechanisms. Furthermore, axial length governs mechanical strength. These findings clarify the microstructure–property relationships in catalyst fracture, providing a reference for potential structural optimization.