Catalyst loading in a tubular reactor

Of course, it has to be filled one by one. If you want to speed things up, you need to block the gaps between the tubes and then pour it in directly; it takes all day just to fill them

Install them one by one, and proper labeling and recording should be kept during the installation process to prevent missing or extra installations； Generally, catalyst or reactor manufacturers provide catalyst management manuals, and operations such as storage, loading, production, maintenance, and replacement are carried out in accordance with these manuals

Install them one by one, and proper labeling and recording should be kept during the installation process to prevent missing or extra installations； Generally, catalyst or reactor manufacturers provide catalyst management manuals, and operations such as storage, loading, production, maintenance, and replacement are carried out in accordance with these manuals

Shell-and-tube reactors are no longer in use nowadays.

3 Loading of three doses 3.1 Loading scheme for purifiers and catalysts 1. Amount of purifiers and catalysts to be loaded, their locations, and other details The locations where the MTBE catalyst is loaded include: the methanol purifier 181-SR101A/B, the extract water purifier 181-SR102A/B, the etherification reactor 181-R101A/B, and the catalytic section of the catalytic distillation tower 181-C101B. Among them, the catalyst loaded in 181-C101B is a bundled catalyst, while the rest are packed in a dense phase. The service life of the methanol purifier is years; the service life of the extract water purifier is years. The service life of the etherification reactor is years. The service life of the 50 m3 catalytic distillation tower is 3 years. 1 ton of quartz sand with a particle size of 4–5 mm, 1 ton of quartz sand with a particle size of 2–3 mm, 1 ton of quartz sand with a particle size of 1–2 mm. 50 M2 of stainless steel wire mesh with a mesh size of 20 mesh (it must be stainless steel containing Ti, i.e., 0Cr18Ni9Ti). 50 M2 of stainless steel wire mesh with a mesh size of 80 mesh (it must be stainless steel containing Ti, i.e., 0Cr18Ni9Ti). 50 M of asbestos rope with a particle size of 10 mm. Notes regarding the filling of purification agents and catalysts. The catalyst must not come into contact with alkaline substances or water. When installing the catalyst, handle it gently to avoid breaking it. Strict safety rules must be followed when entering the reactor to prevent suffocation and falls inside it. All tools used in the reaction must be washed with pure water, and metal tools must not come into contact with the catalyst. Stop installing the catalyst when it is raining; make sure to check and count the relevant tools to ensure none are left inside the reactor. 3. Preparation work: Verify that all nitrogen lines of the loading system are isolated with blind flanges. Waterproofing measures have been properly implemented. Prepare the tools and other supplies needed for loading. Prepare the lifting equipment: a winch or crane. Prepare a canvas funnel, plastic ruler, flashlight, notebook, mask, etc. Compressed air was blown into the purifier and reactor interior using a rubber hose for a period of time; the oxygen content was found to be above 19%, and no other toxic gases were detected, meeting the requirements set by the safety authorities. According to the filling diagram, draw contour lines for quartz sand and catalyst filling markers inside the purifier and catalyst, and verify that everything is correct. Arrange for the personnel responsible for operating the purifier and reactor platforms, as well as those tasked with handling the purification agents and catalysts, loading/unloading materials, and providing supervision inside the purifier and reactor. Arrange personnel for ground operations, recording, handling, etc. 3.2 Loading of purifiers 181-SR101A/B, 181-SR102A/B. Steps for loading purifiers 181-SR101A/B, 181-SR102A/B: 1) Open the large top cover of the purifier as well as the flange covers for the access ports on the sides. 2) Remove trash and debris from the purifier to ensure its interior is clean ； Check whether the inner wall and other components are in good condition. 3) Install the support plate at the bottom of the purifier: use two layers of mesh with the GF1W 0.25/0.16 (twill) specification on the top and bottom, and one layer of mesh with the 2.5/0.63 (twill) specification in the middle. The mesh must be installed firmly and evenly, and it should be secured with asbestos rope around the edges to prevent leaks caused by excessive gaps. 4) Starting from the manhole at the lower side, evenly spread quartz sand with a particle size of 4–5 mm on the wire mesh; then spread quartz sand with a particle size of 2–3 mm on top of it; and finally, apply another layer of quartz sand with a particle size of 1–2 mm. The filling height for each layer is 50 mm, and it must be even and level during laying. 5) Install the manhole cover inside the manhole flange, making sure it is secured firmly so as to prevent any swaying from side to side ； Install the lower manhole flange cover. 6) After the quartz sand is laid, add the purifying agent slowly into the purifier from its top. During this addition process, be careful not to disperse the quartz sand or other debris into it, and level out any raised areas to ensure a uniform and smooth surface. If necessary, a long plastic bag with open ends can be used for drainage to allow the purifying agent to be added slowly into the purifier. 7) Fill the purifier at the pressure plate, leaving a slight space for expansion, and then install the pressure plate. Measure the filling height of the purifying agent, calculate the filling weight, and keep a record. Be careful not to fill the purifier too high. 8) Finally, install the upper manhole flange cover on the top head. Precautions for filling the purifier: 1) Do not put in the purifier any unnecessary items such as certificates, inner bags, or strings. 2) The purifying agent must not be rinsed with tap water, domestic water, fire-fighting water, or other untreated water. 3) Materials scattered on the ground or mixed with debris such as sediment and rust shall not be re-added to the purifier. 4) After the purifying agent is placed in the purifier, it should be immersed in methanol as soon as possible. The wet catalyst should not be stored in the reactor for more than 24 hours; if the conditions for immersing the purifying agent in methanol are not available, the insertion of the purifying agent into the purifier should be postponed. 181-SR101A/B, 181-SR102A/B Purifier Filling Diagram 3 Precautions (1) The purifier must be flushed and purged with dry purge air; only after the oxygen level inside the purifier meets the specified requirements may the filling personnel enter it. Throughout the loading process, the reactor must be continuously purged with purified air, while the rest of the apparatus is sealed to prevent moisture from entering. Unless someone is working inside the purifier, its inlet and outlet must be covered or sealed. (2) During the loading of the purifying agent, adequate ventilation, dust control, and lighting must be ensured. (3) To prevent the hopper from damaging the reactor flange surface, it should be lined with sturdy wooden boards or rubber gaskets. (4) Persons entering the purifier must not bring any unnecessary items inside it. (5) The loading personnel have the necessary personal protective equipment and communication devices. (6) Persons entering the purifier should place a wooden board under their feet to increase the pressure-bearing area and reduce the fragmentation of the purification agent. (7) The filling of the purifying agent should be carried out on good weather; it must not be done in rainy or foggy conditions. (8) During filling, the level of the purifying agent should rise evenly along the cross-section of the purifier. (9) The filling process, including its completion, requires that a dedicated person be responsible for checking each piece of necessary equipment as it enters and exits the purifier, to ensure that there are no items or debris left inside the purifier. (10) Keep detailed records of the quantity and size of the purifying agents and fillers placed inside the purifier. During the purification agent filling process, 5 milliliters are sampled from each barrel to form a mixed sample for storage.

Reference can be made to the loading of conversion agents in the converter tubes for hydrocarbon conversion to produce hydrogen. Key steps: Measure the pressure in the regenerator; fill it using a long cloth bag (a specialized filling tool); tap the furnace tubes to compact the material. It is necessary to record the amount of catalyst used for each tube. After filling, measure the pressure drop across the furnace tubes; if this value differs significantly from the average pressure drop across all tubes, re-filling is required.

Install them one by one, using caps of different colors for differentiation; typically a plug-in type is used, and the pressure drop should be measured after each one is installed.