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Catalyst Loading Method

The document describes different methods for loading catalyst into a reactor, including sock loading and dense loading. Sock loading involves placing catalyst into a hopper attached to a canvas sock that conveys the catalyst into the reactor in a controlled manner to distribute it evenly. Dense loading uses mechanical devices to distribute catalyst more uniformly throughout the reactor, increasing density by 10-20% and improving flow. It also reduces settling and extends the time between replacements. Specialized methods load multiple reactor tubes equally.

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3K views

Catalyst Loading Method

The document describes different methods for loading catalyst into a reactor, including sock loading and dense loading. Sock loading involves placing catalyst into a hopper attached to a canvas sock that conveys the catalyst into the reactor in a controlled manner to distribute it evenly. Dense loading uses mechanical devices to distribute catalyst more uniformly throughout the reactor, increasing density by 10-20% and improving flow. It also reduces settling and extends the time between replacements. Specialized methods load multiple reactor tubes equally.

Uploaded by

erwan_exe
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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SOCK LOADING METHOD

Sock Loading involves placing the catalyst into a hopper on the top of the reactor manway and
discharging it through a canvas or rubber sock. One end of the sock is attached to the loading hopper
discharging pipe and the other end travels to within 3 feet of the catalyst support grate/grid. The
loading technician will crimp the sock to restrict free fall of material as he spreads the catalyst evenly
and in a random pattern. As the bed level rises the sock is cut to keep the free fall of catalyst to the
required distance and the discarded sections are removed from the reactor.

SERVICES

- Reactor Unloading

- IDLH Confined Entry

- Reactor Passivation

- Catalyst Loading

- Catalyst Screening

- Mechanical Services

- Other Services

SAFETY & TRAINING

MISSION & VALUES

CONTACT

DENSE LOADING METHOD

“Dense Loading” is achieved by a mechanical device that insures a uniform distribution of catalyst
throughout the entire diameter of the reactor as the catalyst is being loaded. The catalyst is
discharged in a “sprinkling” fashion allowing each piece of material to fall randomly to the catalyst
bed ensuring a consistent loading. A dense loading system can increase the loading density by as
much as 10-20 percent depending on the type and shape of catalyst that is being loaded. It generally
will improve the liquid or gas flow, eliminates catalytic bed settling and generally allow for a longer
run cycle in between catalyst replacements.

SPECIALIZED LOADING

Catalyst Handling also offer multiple tube loading of tubular reactors using machines that will load
10 tubes at a time equally. Multiple machines can also be set up and used to allow the schedules to
be dramatically reduced while maintaining high quality.

Catalyst Handling has available Unidense technology for the loading of primary reformers. This
technology allows for consistent loading of catalyst into each tube ensuring that all DP’s are within
the pre determined range.

DENSE PHASE LOADING

Catalyst Handling have been using Dense Phase Loading equipment for over 20 years now and have
loaded many reactors without the requirement for a crane. This process comes into it's own for
loading horizontal vessels, Sulphuric Acid Converters or when high winds and inclement weather are
likely to occur. This equipment can be set up with limited access and can be very beneficial to our
clients. Loading rates can be up to 525-700 cubic foot/hr (15-20 m3/hr) depending on distance and
material to be transported.

John T. Wooten is president of Catalyst Handling Service Co., which is a joint-venture company of
Reactor Services international. He has spent 24 years in the catalyst-handling industry, managing
projects in the U.S., Asia Pacific rim, and South America.

Wooten holds a bachelors degree from the University of Houston.

Dense loading is preferable to sock loading in several in stances. 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 …

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