Hydrocarbon Processing - December 2022 - 17
Catalysts
cal density, caused by fines and dust, can
also lead to higher pressure drops across
the catalyst bed, which can significantly affect
the reactor catalyst cycle length.
Uneven bed profile. If the top surface
of the catalyst bed is tilted or uneven, then
liquid/gas will preferentially converge toward
the lowest point of the top surface
and create a preferential flow path (FIG. 5).
This will occur even if the overlying distributor
trays are well-installed, perfectly
leveled and running optimally.
What controls the quality of catalyst
loading? The quality of catalyst loading
is ultimately controlled by two key factors:
operator's mindset and technology choice.
How an operator's mindset impacts
catalyst loading. When considering the
most important factors that determine
reactor performance, most operators will
list their operational processes, the reactor
internals and the catalyst as their star
performers. However, the importance of
catalyst loading is often overlooked, despite
the significant impact it can have on
reactor performance.
When it comes to catalyst loading activities,
most refiners want to have them
executed as fast as possible and at the
lowest possible cost. According to the authors,
as many as 90% of refinery personnel
are uninformed about the signs, causes
and impacts of poorly loaded catalyst; this
is a conversation that commonly only happens
when a reactor is already suffering
liquid/gas maldistribution.
How technology choice impacts catalyst
loading. The desire for cheap and
quick catalyst loading often dictates the
choice of loading technology. Two methods
are in widespread use: sock loading
and dense loading.
Sock loading. Sock loading involves
the loading of catalyst via a large canvas
tube (FIG. 5) and is the favored method
for operators looking for a low-cost loading
solution. However, despite its relatively
low cost, sock loading has the following
significant drawbacks:
* Low density: With sock loading, the
catalyst is essentially " dropped " out
of the end of the sock in a manner
and at a rate that inhibits the settling
of well-aligned catalyst particles.
This results in lower-density packing
with large void spaces between
particles, which reduces the mass
of catalyst that can be loaded.
FIG. 5. Sock loading and conventional dense loading often lead to an uneven catalyst bed top
surface that channels fluid flow through preferential zones (light blue shading). High-quality
homogeneous dense loading creates a flat top surface that, in combination with optimized
distributor trays, enables even wetting of the catalyst volume.
* Low homogeneity: Improper
settling and non-homogeneous
distribution of catalyst particles
make the catalyst bed vulnerable to
differential compaction as particles
shift and void spaces collapse under
the weight of overlying catalyst.
This leads to the formation of
localized pockets of higher-density
packing and inhomogeneities
that promote the development
of liquid/gas maldistribution.
* Uneven profile: Because sock
loading only distributes particles
over a narrow area, catalyst
handlers are required to work
inside the reactor to direct the
sock. However, despite their best
efforts, the result is invariably poor
catalyst distribution, a tilted or
uneven top catalyst surface, and
inhomogeneities caused by the
trampling of catalyst underfoot.
Conventional (lower-quality) dense
loading. Conventional
dense loading
(CDL) involves the distribution of catalyst
in a rain-like fashion from a particle
dispenser lowered through an overlying
manway. As the catalyst is allowed to fall
freely, the particles settle in a more stable
and uniform way, thus increasing bed
density and homogeneity. Yet, although
CDL technologies-some of which are
decades old-are generally superior to
sock loading, they also have drawbacks:
* Poor catalyst integrity and
inhomogeneity: CDL technology
typically uses a set of rapidly
rotating whips to propel catalyst
outward, forming a diverging
shower of particles. However, the
whips are very aggressive, and
FIG. 6. HDL technology (left) is designed to load catalyst at the optimal rate and disperse particles,
using centrifugal force gently and evenly across the full diameter of the catalyst bed (right).
Hydrocarbon Processing | DECEMBER 2022 17
Hydrocarbon Processing - December 2022
Table of Contents for the Digital Edition of Hydrocarbon Processing - December 2022
Hydrocarbon Processing - December 2022 - 1
Hydrocarbon Processing - December 2022 - 2
Hydrocarbon Processing - December 2022 - 3
Hydrocarbon Processing - December 2022 - 4
Hydrocarbon Processing - December 2022 - 5
Hydrocarbon Processing - December 2022 - 6
Hydrocarbon Processing - December 2022 - 7
Hydrocarbon Processing - December 2022 - 8
Hydrocarbon Processing - December 2022 - 9
Hydrocarbon Processing - December 2022 - 10
Hydrocarbon Processing - December 2022 - 10A
Hydrocarbon Processing - December 2022 - 10B
Hydrocarbon Processing - December 2022 - 11
Hydrocarbon Processing - December 2022 - 12
Hydrocarbon Processing - December 2022 - 13
Hydrocarbon Processing - December 2022 - 14
Hydrocarbon Processing - December 2022 - 15
Hydrocarbon Processing - December 2022 - 16
Hydrocarbon Processing - December 2022 - 17
Hydrocarbon Processing - December 2022 - 18
Hydrocarbon Processing - December 2022 - 19
Hydrocarbon Processing - December 2022 - 20
Hydrocarbon Processing - December 2022 - 21
Hydrocarbon Processing - December 2022 - 22
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Hydrocarbon Processing - December 2022 - 24
Hydrocarbon Processing - December 2022 - 25
Hydrocarbon Processing - December 2022 - 26
Hydrocarbon Processing - December 2022 - 27
Hydrocarbon Processing - December 2022 - 28
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Hydrocarbon Processing - December 2022 - 30
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Hydrocarbon Processing - December 2022 - 68
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