Ceramic ball installation height

I don’t quite understand it, but I’m still paying attention. I hope the experts will come and provide answers

We are hydrogenation reactors, and ceramic balls are also added inside; the filling scheme was provided by the research institute (the catalyst supplier), with specifications of 13, 6, and 3

The main purpose of filling with ceramic balls is to prevent catalyst leakage; the particle size of these ceramic balls is related to the size of the catalyst particles, and manufacturers generally provide filling plans. The thickness ranges from 10 mm to 20 mm. Most are three stories, as mentioned above. Then fix it with a screen grid

The ceramic balls filled at the upper and lower parts of the catalyst bed in the reactor serve the following main functions: 1. To hold the catalyst bed in place, preventing the high-speed reaction medium from impacting the bed and causing disturbance in it. 2. It can partially act as a filter to remove impurities such as iron filings and char from the medium, thereby protecting the catalyst. 3. Installing ceramic balls at the upper part can improve the distribution of the gas (liquid) reaction medium ； The reaction medium passes through the lower head, and the axial lengths of various flow channels differ, which can easily lead to uneven flow distribution ； Especially for highly exothermic reactions, the catalyst in the “dead zone” may overheat. Therefore, ceramic balls also need to be filled in the lower head. Taking all the above factors into account, along with the specifications and particle size of the ceramic balls and catalysts, as well as the pressure drop in the ceramic ball layer, the packing height of the ceramic balls is determined. The typical experience value ranges from 50 to 200. Additionally, the filling height of the ceramic balls can be adjusted based on the actual stack ratio of the supplied catalyst and the actual filling conditions. We just finished loading it this year. The bottom head is around 80. Ceramic balls of 18, 13, and 6 are used; the one of size 18 is placed at the bottom to prevent the ceramic balls and catalyst from sinking, a small amount of it is used, and then those of sizes 13 and 6 are used. However, the filling varies among different factories. Sometimes there is a difference between theoretical loading and actual loading; it’s not necessary to stick strictly to the book when carrying out actual operations. But the difference shouldn’t be too large; a gap of 1-3 centimeters still gives the same result. Specific figures can be discussed if needed

Regarding the selection of the size of inert ceramic balls, it should be determined based on the size of the catalysts. Generally, the 2X rule (or grading principle) is followed: the diameter of the ceramic balls should be twice that of the adjacent catalysts. This ensures the most even distribution of the flow, minimizes pressure drop, and optimizes the reactor performance. For example, if the diameter of the catalyst is 1/16'', the selection and packing of the ceramic balls are as follows: 1/2'' inert ceramic balls, 1/4'' inert ceramic balls, 1/8'' inert ceramic balls, 1/16'' catalyst, 1/8'' inert ceramic balls, 1/4'' inert ceramic balls, 1/2'' inert ceramic balls. 100–150 millimeters of ceramic balls are packed in each layer

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