Catalyst Loading
Catalyst loading may be done in either of two ways: Sock loading or
dense loading.
Sock-loading method
Sock loading is the simpler loading method, which requires both less
equipment and less operator
training. Catalyst is delivered to the bed being loaded, through a
flexible sock and is spread and
raked to a level condition during loading. Sock loaded catalyst forms a
more open bed structure, has
both a lower density and lower initial start-of-run (SOR) pressure drop.
Over the course of a run, the
sock-loaded bed tends to slump to a more dense
structure. At end-of-run (EOR), a sock loaded bed
will often have a pressure drop equal to that of a
dense loaded bed.
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
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.
Problems Caused by Sock Loading
When catalyst is loaded by sock loading, less
catalyst is loaded into the bed. The bed density
is not uniform, causing possible ‘Hot Spots’ and
‘Channeling’. Channeling will severely shorten the
catalyst life. Poor distribution of catalyst can lead
to coke formation.
Dense Loading
The dense loading method fills a reactor with
less open volume in the catalyst beds. The basic
principal is to allow the individual catalyst particles
to free-fall to the bed where they bounce around
settling in their lowest energy state. This means
that the particles fall onto their long axis and form
a horizontal mat with the long dimension of the
particles aligned with the bed diameter.
Benefits From Good Dense Loading
• Maximum performance from the catalyst
• More catalyst loaded per bed
• Even distribution of flow
• Prevents channelling
• No need for a technician to walk over the
catalyst during loading
• Catalyst grains get to lay flat optimising reaction/activity
• Less chance of ‘Hot Spots’
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.
Air-propelled vs. kinetic-propulsion systems
Air propelled and kinetic energy dense-loading systems have common catalyst-delivery
systems, described as follows:
A hopper or funnel feeds catalyst particles into a vertical pipe
which extends into the reactor. Catalyst passes down through the
pipe and exits horizontally through an annular space or gap. The
gap is varied in vertical width by adjusting the spacing between
the loader pipe and flat deflector plate, or cone, attached to the
bottom of the pipe.
The difference between air-propelled and a kinetic-propulsion
systems is the manner in which the catalyst is distributed to the
catalyst bed.
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.
Advantages of dense loading
In existing vapor-only reactors or two-phase units at low conversions, dense-loading
may:
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.
In existing two-phase, liquid-gas systems at high conversion, dense loading may:
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.
