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John T. Wooten Catalyst Handling Service Wilmington, Del. Dense loading is preferable to sock loading in several instances. The advantages of dense loading include increased density, capacity, run length, reactor integrity, and product quality. Sock loading, as a result of its tendency to create void spaces, may not maximize a reactor's capacity. Sock loading, on the other hand, because it is more tolerant to particulate matter in the feed and distributes catalyst in a less dense state, may be preferable to dense loading in some situations. Sock loading often comes at a lower cost. For those refiners who do not require or cannot handle the increased capacities that dense loading allows, it is a viable option. Maximum performance for catalytic processes will require that those involved with the catalyst handling are well trained and aware of the desired results expected by the catalyst manufacturer and the refiner. It is most important that discussions are conducted with the facility operations, engineering, and maintenance departments, and with a representative of the catalyst manufacturer.
Sock-loading method
Prior to the 1970s, the standard method for loading catalyst in a fixed bed reactor was sock loading. In sock loading, a canvas tube conveys the catalyst from the reactor inlet manway to the bottom of the reactor catalyst bed. The sock is attached to a loading hopper or funnel at the reactor inlet, which discharges the catalyst through the sock upon the bed surface in a manner which prevents the individual cylinders from finding a stable, horizontal rest position. The cylinders stack in various horizontal and vertical positions. The positioning of catalyst cylinders in random orientations encourages bridging of cylinders and void spaces between cylinders. During reactor operations, these bridges and void spaces tend to collapse. Bed density then increases as the bed depth shrinks.
Dense-loading methods
Since 1970, refiners, catalyst manufacturers, and catalyst-loading contractors have developed dense-loading devices that dramatically reduce void spaces and bridging. Dense loading can increase catalyst bed densities by as much as 17%. Moreover, unlike sock loading, dense loading does not require personnel inside the reactor to distribute the catalyst evenly from the sock. Workers inside the reactor require breathing air and weight distribution shoes to prevent crushing of the catalyst underneath their weight. Dense loading is accomplished by introducing the catalyst cylinders into the reactor in a manner that allows each cylinder to fall freely to the catalyst surface. Individual cylinders separately assume a horizontal rest position before being impinged by other cylinders. Under this regime, cylinders tend to pack horizontally, minimizing the possibility of bridging or creating void spaces. The dense-loading technologies used today are largely similar in design and produce similar results. These dense-loading technologies mainly vary in the mode with which the catalyst is propelled from the loader. Some use air or nitrogen pressure as a propellant, and some use kinetic energy to move the catalyst from the loading apparatus.
The difference between air-propelled and a kinetic-propulsion systems is the manner in which the catalyst is distributed to the catalyst bed. Fig. 1 [113,980 bytes] shows an example of each method. With kinetic energy, the catalyst is distributed by an air motor that rotates a particle distributor. Kinetic systems use propellers, rotating blades, or a series of rubber strips to distribute catalyst from the loader to the outer walls of the reactor. The loading rate and the horizontal distance of travel for the catalyst are controlled, in part, by rpm settings on the air motor. In an air-propelled system, air is introduced into a sparger situated in the center of the loader pipe, above the deflector plate. Jets of air emerge from horizontal radial holes in the sparger, directed outward through the annular gap. The air pressure is 7-14 psig in a standard apparatus. The RSI (Reactor Services International) Super COP is a modified version of the Atlantic Richfield Co. (ARCO) Catalyst Oriented Packing (COP) method for dense loading. Both methods use air to distribute the catalyst. The Super COP uses two deflector plates, and the ARCO COP uses one. In the Super COP, the lower deflector plate feeds catalyst to the center of the reactor, while the upper plate feeds catalyst to the outer walls of the reactor.
Catalyst manufacturers have arranged to have their catalyst tested for adequate strength. The primary test, called simply a drop test, tests the ability of the catalyst to withstand striking the catalyst-bed surface at vertical terminal velocity. This impact is far greater than that striking the reactor wall. Catalysts strong enough to withstand the abrasion of falling between particles in an elongated sock have generally proven satisfactory for COP loading.
Increase capacity or run length, with no additional capital investment for reactors Permit operation at lower severity to up product quality and give higher yields Cut down on internal reactor damage due to catalyst slumping and elimination of hot spots or temperature gradients.
Increase throughput or run length, at no increase in capital costs for reactors Permit use of less catalyst because of improved liquid-catalyst contacting Lead to production of higher product quality for a given reactor configuration.
For units being designed, dense loading can lower investment costs by cutting reactor volume by 10% or more and eliminate or reduce the need for internals, such as redistributors.
The function of a redistributor is to redirect the flow of the feed gas to compensate for uneven loading. Redistributors include scale baskets and mechanical pieces welded to the reactor.