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Loading of the reforming catalyst I. Catalyst loading locations and explanations The locations where the reforming catalyst is loaded include: the reactor top reduction zone R-205, the four reactors R-201 to R-204, the catalyst collector, the separation hopper D-303, the regenerator R-301, and the lock hopper D-308. The catalyst is loaded in two groups as follows: 1. The reactor top reduction zone R-205, the four reactors R-201 to R-204, and the catalyst collector form one group, totaling 61 tons of catalyst. The loading point is located at the catalyst inlet in the reactor buffer zone; this is referred to hereafter as catalyst loading in the reaction zone. 2. The separation hopper D-303, regenerator R-301, nitrogen seal tank D-307, and lock hopper D-308 form another group, totaling 16.7 tons; the loading port is located at the catalyst inlet on top of the separation hopper D-303, which will hereinafter be referred to as catalyst loading in the regeneration zone. II. Preparation Work 1. Verify that all nitrogen lines of the systems are isolated using blind flanges (see Section 6, Point 4, Article 26 of Chapter 5 for details). Proper waterproofing and moisture-proofing measures have been implemented. 2. The hydrogenation system has been reorganized, and all systems have been replaced with dried instrument air; the oxygen content in R-205, R-201～R-204, D-303, R-301, and D-308 has reached 20%. This step has been completed in the “Firing, Boiling, Drying” step of the equipment. 3. Preparation and inspection of the reactor (1) Required conditions: a. The permit for entering the tank or tower must be obtained. b. Connect the explosion-proof lighting fixtures properly, ensuring that the cables can reach the bottom of each reactor. c. A scaled plumb line, 7.5 m long. d. Two 15-meter-long rope ladders. e. The fan-shaped cylinder covers for the four reactors. f. For industrial vacuum cleaners, the hose length should be 19 meters or more to enable cleaning of the fan-shaped cylinder. g. Asbestos rope used to block the two discharge nozzles. h, 0.1 m3 of porcelain balls with a diameter of 3 mm. i、0.1 m3 of ceramic balls with a diameter of 6 mm. j, 19mm diameter porcelain ball, 0.1m3. k. Stainless steel wire, used to secure the reactor lid pins. l. Four catalyst loading hoppers, equipped with screens. m. Set up scaffolding so that the charging hopper can be placed above the reduction zone of the reactor and on top of the flange of separation hopper D-303. n. A loading platform. o. Two forklifts. New gaskets are required for manholes, blind flanges, and connections, as these parts need to be opened during the cleaning of the container and the loading of the catalyst. (2) Preparation of the reactor manhole: a. After drying and evacuating the reactor, continue with cooling. b. Blind off the inlet of the first reverse R-201 and the outlet of the fourth reverse R-204. c. Loosen the bolts of the 8-shaped blind plate located between the catalyst collector outlet and the manual ball valve, drain the water from within the reactor and catalyst collector; there may be a significant amount of water accumulated at the bottom of the reactor. Note: There may be debris, fragments, or water on top of the blind plate; therefore, care must be taken to prevent these substances from falling into the catalyst pipeline. d. Begin blowing dry instrument air into the bottom of catalyst collector R-204; the purpose is to prevent air (with high humidity) from entering the reactor. Adjust the flow rate of the instrument air to the highest possible level, without disturbing the pressure of the instrument air supply. Open the vent valve at the top of the reactor to allow the instrument air to be discharged. e. Loosen the bolts on the reactor manhole. When no work is being carried out inside the reactor, manually tighten two bolts on the manhole flange to keep it in a relatively loose closed state, thereby maximizing the effectiveness of air purging for the instruments. (3) Preparation work for the reduction section: a. The two inlet nozzles and one outlet nozzle of the reduction section are blocked with blind flanges ； b. Disconnect the regenerated catalyst lift line, thermowell, and Reduction Gas Line No. 1 at the top of the reduction zone; cover them with plastic sheeting to protect them from rain. These will be needed during both the instrument air venting and catalyst loading processes. Note: Remove the ball valve XV0202 from the catalyst lift pipe, cover it, and store it in a dry place. c. Analyze the gas in the reduction section; once the oxygen content reaches 20%, issue a permit for entry into the container. d. Contact the instrumentation team to turn off the nuclear level gauge in the reduction zone and lock it to prevent nuclear radiation. e. Enter the reduction section for thorough cleaning; in the presence of UOP personnel, inspect each catalyst transfer pipe vertically to ensure there are no debris. (4) Prepare the internal components of the reactor. a. Analyze the gas inside the reactor; once the oxygen content reaches 20%, issue a permit allowing safe entry into the reactor. Note: The container should only be entered after it has been blinded, cooled down, and the actual oxygen content has reached 20%. b. Begin cleaning the cover area of R-201; use a vacuum pump to remove all debris from the covers and the fan-shaped elements. After each fan-shaped element has been cleaned, it should be covered with a metal lid, and these lids must remain in place until all the catalyst has been installed. The covers can be removed only after they have been completely cleaned. c. Remove the three pieces from the removable cover plate, which are located around the central tube at approximately equal intervals, in order to inspect the bottom of each catalyst delivery pipe. Lower the soft ladder from the opening closest to the manhole until it reaches the bottom of the reactor, and inspect and clean the bottom of the reactor. d. Thoroughly clean each reactor, including the inside of the bottom of the fan-shaped cylinder, and remove everything that remains inside. e. The catalyst delivery pipe should be checked vertically to ensure that it is not blocked inside. f. After cleaning each reactor, begin inspecting its internal components to determine whether there are any issues resulting from thermal expansion during drying. g. After inspecting Reactor R-201, proceed with the inspection of subsequent reactors by repeating the aforementioned steps for R-202, R-203, and R-204. Once all reactors have been inspected, the ladder is removed, and the manhole is closed loosely; no one is permitted to enter the reactors for further inspections. (5) Filling of the discharge short pipe for Si Fan R-204: a. From the outside of Si Fan, remove the two DN100 blind flanges; clear all debris from inside the discharge short pipe, place asbestos rope on the support plate, reinstall the blind flanges, and use new gaskets. b. Inspect from inside the R-204 reactor to verify whether the asbestos rope is installed correctly. First, lay porcelain balls with a diameter of 19 mm in the discharge short tube, covering a thickness of 75 mm; then lay porcelain balls with a diameter of 6 mm over that layer, also to a thickness of 75 mm. Finally, fill the discharge short tube with porcelain balls of 3 mm diameter until it is level with the reactor wall. (6) Preparation of the catalyst collector: a. Set up scaffolding to reach the location of the circular flange of the catalyst collector. b. After the internal inspection of R-204 is completed, close all reactor manholes loosely to stop the instrument air purge to the catalyst collector. c. Remove the bolts, take off the bottom flange of the catalyst collector, and clean this area carefully; there may be water inside the catalyst collector. Note: There may be debris and water on the blind plate, so be careful not to let these substances fall into the catalyst pipeline. d. Open the catalyst collector for cleaning. e. The ring flange can now be closed, using new gaskets that meet the specifications. f. Restore the instrument air for purging as soon as possible. g. Restore the catalyst tube under the catalyst collector; ensure that the \"8\"-shaped blind plate under the catalyst collector is open, and that the manual ball valve under the catalyst collector is closed. 4. Preparation and inspection of the regenerated part. The hydrogen-handling section of the CCR has undergone two consecutive vacuum evacuations, followed by breaking the vacuum using dry instrument air; thus, it should have been transitioned from a nitrogen atmosphere to a dry instrument air atmosphere. Similarly, after purging, the regeneration section has also changed from a nitrogen atmosphere to a dry instrument air atmosphere. Nevertheless, the regeneration section must still be isolated from the reaction section. (1) Isolate hopper D-303 a, and ensure that all N2 connection lines leading to hopper D-303 have been blinded. b、Blind the leaching gas inlet flange. c. Turn off the nuclear source of the level detector in the separation hopper, and lock it. d. Open the manhole of the separation hopper D-303. e. Analyze the gas inside the container; upon passing the analysis, issue the ‘Equipment Entry Permit’. Note: Entry is permitted only when all containers are blinded and the analyzed oxygen content meets the requirements. f. After the drying process, there may be debris inside the container; it should be inspected and cleaned if necessary. g. UOP checks the cleaning condition. h. Remove the temporary blind flange on the catalyst transfer pipe below the separation hopper D-303. Note: There may be debris and water on the blind plate; be careful not to let these substances fall into the catalyst pipeline. (2) Regenerator R-301 a: Ensure that all nitrogen pipelines feeding into regenerator R-301 are completely isolated. b. Analyze the gas composition inside the container; once it meets the requirements, issue the ‘Equipment Entry Permit’. Note: Entry is permitted only after all containers have been blinded and the oxygen content analysis yields satisfactory results. c. Remove the regenerator gas outlet line of regenerator R-301, and place a ladder to reach the bottom of the combustion zone. d. Open the internal manholes and inner cone to access the chlorination zone, drying zone, and cooling zone of the regenerator. e. After the drying process, there may be debris inside the container; it should be inspected and cleaned if necessary. f. If thermocouples or thermocouple sheaths are damaged during the drying process, they should be replaced; the new thermocouple sheaths must be inserted into the inner cylinder through the sealing plate. g. UOP must check the cleanliness. h. Remove the rope ladder, close the internal manhole and inner cone, and reinstall the regenerated gas outlet flange in the presence of UOP consultants. i. Set the \"8\"-shaped blind plate below regenerator R-301 to the open position. Note: There may be debris and water on the blind plate, so special care must be taken to prevent it from falling into the catalyst pipeline. Verify that the manual V-ball valve below regenerator R-301 is closed. (3) Nitrogen seal tank D-307 a: Confirm that all nitrogen pipelines leading to nitrogen seal tank D-307 have been blind-ended. b. Open the manhole of nitrogen seal tank D-307. c. Analyze the gas composition inside the tank; upon passing the analysis, issue the “Permit for Work on Equipment”. Note: Entry is permitted only when the container is completely blind or the gas oxygen content analysis is satisfactory. d. After the drying process, there may be debris inside the container; the container should be inspected and cleaned if necessary. Note: The riser inside the nitrogen-purged tank must be inspected. It is particularly important to ensure there are no debris, as debris can impede the flow of the catalyst. e. UOP shall inspect the cleaning condition. f. Open the \"8\"-shaped blind flange on the catalyst transfer pipe beneath nitrogen seal tank D-307. Note: There may be debris and water on the blind flange; therefore, great care must be taken to prevent them from falling into the catalyst pipeline. Confirm that the regeneration catalyst isolation valve below nitrogen seal tank D-307 is closed. (4) Lock Hopper D-308 a: turn off the level sensors LE1001 and LE1003 of the Hopper, and lock them. b. Open the three DN200 inspection doors. c. Check the gas composition inside the container; upon passing the inspection, issue the “Permit for Work on Equipment”. Note: Entry into the tank is only permitted after all blind plates have been installed and the oxygen level inside the tank has been found to be within acceptable limits. d. After the drying process, there may be debris inside the container. Inspect the container and clean it if necessary. It is very important to inspect the closed hoppers, the areas around these hoppers, and the vertical pipes in the buffer zone to ensure that there are no debris, as this could affect the flow of the catalyst. e. UOP will check the cleanliness through each inspection port. f. Place the two \"8\"-shaped blind flanges under the closed hopper in the open position. Note: There may be debris and water on the blind plate, so be very careful to prevent them from falling into the catalyst pipeline. Ensure that the two manual ball valves are closed. 5. Preparation of catalyst loading equipment. (1) Preparation of the reactor catalyst charging hopper. a. The charging hopper must be placed on the DN80 catalyst transfer pipeline above the reduction section. b. Construct a windproof scaffold and cover it with canvas to prevent strong winds at the top of the frame from directly hitting the loading hopper. Once this windproof structure is in place, it becomes much easier to pour the catalyst from the lifting hopper into the loading hopper, thereby preventing the catalyst from leaking out. c、The lifting hopper and the feeding hopper must be equipped with 3-mesh stainless steel screens made of wire with a diameter of 2 mm, having pore lengths of 6.4 mm; the sieve points are spot-welded to the frame. d. The outlet of the feeding hopper requires a hose with a DN50 diameter, which extends 700 millimeters below the flange of the DN80 catalyst lifting line at the top of the reduction section; the personnel responsible for loading the catalyst use a slide valve on the feeding hopper to control the catalyst flow rate. (2) Separate hoppers, loading hoppers, and other facilities. a. Build a wind-resistant scaffold and cover it with canvas to prevent strong winds at the top of the frame from directly hitting the loading hopper. With the wind shield in place, it becomes very convenient to pour the catalyst from the lifting hopper into the feeding hopper, thereby preventing the catalyst from leaking out. b. The lifting hopper and the feeding hopper should be equipped with 3-mesh stainless steel screens made of wire with a diameter of 2 mm, and the pore length should be 6.4 mm; the screens need to be spot-welded to the frame. c. A hose with a diameter of 3″ enters the center of separation hopper D-303 through the top outlet flange of DN200; the loader should control the catalyst flow by adjusting the slide valve on the loading hopper. (3) Loading platform, lifting hopper, and storage area for catalysts and tanks. a. There should be a loading platform to fill the lifting hopper on the ground. While one lifting hopper is loading at the loading platform, another lifting hopper is feeding material into the feeding hopper. The loading platform should be large enough to accommodate two catalyst tanks, and it should be 300 mm lower than the lifting hoppers. b. Use a flatbed truck to transport the catalyst tank from the warehouse to the CCR reformer, and then use a forklift to unload the entire catalyst tank from the flatbed truck onto the loading platform. c. Additionally, there needs to be a clear area for placing empty buckets. Note: The empty barrels must remain in good condition, as they will be used in the future to hold fine catalyst powder or spent catalyst for metal recycling. III. Precautions 1. During the loading of the catalyst, ensure that no debris remains or falls into the reactor; if anything falls in or stays inside the reactor, it will cause problems with the catalyst circulation, and it may be necessary to remove the catalyst from the reactor. The mesh size of the screen in the charging hopper must meet the required standards, to prevent foreign objects larger in diameter than the catalyst from falling into the reactor. 2. All equipment used for transporting catalysts, such as hoppers, hoses, screens, etc., must be cleaned thoroughly before use. The reforming catalyst must not be mixed with other catalysts or catalyst dust. 3. Since the reforming catalyst is expensive, avoid letting it spill out during loading. If it does spill, sweep it up and pour it into fine powder for metal recovery. A dedicated bucket for storing waste catalysts should be placed on site; any catalyst or catalyst dust that falls on the reactor cover can be sucked out using a vacuum pump and placed into this bucket for waste catalysts. 4. Do not discard the empty catalyst drums; store them along with their lids and bands in a dry place, being careful not to damage them. In actual use, these drums are used for recovering catalyst fines or green catalyst, or for holding catalyst during its unloading. 5. Catalyst should not be loaded in rainy weather, as exposure to rain or moisture can severely damage it. If the catalyst tank is stored outdoors, it must be completely covered with canvas and placed on a pallet; it must not be left on the ground directly. 6. Since air will enter when the reactor is opened, it is necessary to close the reactor as soon as possible. After all work inside the reactor is completed, the manhole should be closed promptly; do not keep two manholes open at the same time (including the top manhole), as wind can bring in moisture. The reactor’s manhole should not remain open if it is raining or about to rain. IV. Step of loading catalyst into the reactor: Two lifting hoppers are used for loading the catalyst – one is used to fill the catalyst into the feeding hopper above the reduction section, while the other is used to add catalyst on the ground. The seal of the catalyst tank must be removed only just before the catalyst is loaded into the lifting hopper. Empty tanks should be stored in an organized manner, without mixing them with those that are currently being filled. When storing empty tanks for the recovery of waste catalyst, it is necessary to record the batch number of each tank that is used to feed catalyst into the feeding hopper. Furthermore, mixed catalyst samples are collected during loading for future reference, with a sampling amount of 6g per bucket. The mixed catalyst should be stored in a moisture-proof, sealed steel container. 1. The Si Fan R-204 is loaded in. a. Ensure that the two \"8\"-shaped blind flanges below the catalyst collector are open, and ensure that the two manual valves are closed. b. Ensure that there are no debris or foreign objects in the loading hopper and the two lifting hoppers. c. Begin feeding the catalyst into the reactor from the charging hopper on the self-reduction section. d. For each catalyst barrel that contains catalyst in the hopper, 6 g of catalyst sample should be reserved, and their barrel numbers should be recorded. e. On the cover plate of the SiFan R-204, observe the steady insertion of the catalyst into the reactor, and watch how the catalyst flows through the various catalyst transfer pipes. Loading should be stopped when the bed level rises to about 500 mm from the catalyst transfer pipes; then, loading should be paused after every two barrels added, and the remaining capacity measured until the reactor is filled. f. Record how many catalyst barrels were used to fill the reactor, and note the remaining capacity before the last barrel was added. 2. Loading steps for R-203/202/201 (three-reverse, two-reverse, one-reverse). a. Install following the same steps as for SiFan (steps a–f). b. The table below shows the number of barrels required to fill each reactor. Container volume, amount of catalyst required for treatment, approximate number of barrels needed, cumulative number of barrels: m3, kg. R274 catalyst: 113.5 kg per barrel. Reduction section: 3.81, 2134, 18.8, 538.2. First reactor: 19, 10640, 93.7, 519.4. Second reactor: 21.83, 12225, 107.7, 425.7. Third reactor: 25.94, 14526, 128, 318. Fourth reactor: 36.68, 20541, 181, 190. Catalyst collector: 1.82, 1019, 9, 9. 3. Calibration of the reduction zone: After the last barrel of catalyst is added to the reactor, it is necessary to calibrate the level gauge in order to verify its response and linearity. The detailed steps for calibrating the level gauge are provided by UOP’s instrumentation consultants. Note: Once the catalyst is added to the bottom of the catalyst transfer pipe in Reactor 1, the addition of catalyst stops. Adding catalyst to the reduction section can only be carried out in the presence of a UOP consultant. a. The reactor is currently located below the catalyst delivery pipe attached to Reactor R-201. b. Add the catalyst again to reach the position of the radiation point source LE0202 in the reduction section, and ensure that it is in the correct location. c. Add another barrel of catalyst to the reduction section, raising the material level from point LE0202 to 0% at LT0201 of the continuous level gauge; then add 0.5 barrels of catalyst at a time until the radiation level measured by the detector begins to decline. When the interface detector responds, stop loading the catalyst. d. Set the zero point of the detector on the nuclear level gauge interface as required by the UOP instrument consultant. e. Adding another 0.5 barrel of catalyst to the reduction section will also raise the catalyst interface, and the output from the interface transmitter will increase accordingly. f. Once again, follow the requirements of the UOP Instrument Advisor to calibrate the level gauge interface detector and enter the measured interface level. g. Repeat the steps from e to f until the measured interface reaches 100%. h. Once the calibration of the continuous interface detector LIC0201 in the reduction section is completed, enter the total number of points and store the calibration curve. V. Loading of the regenerated catalyst portion 1. Prepare the loading tool for inserting the catalyst through the flange at the top outlet of the separation hopper D-303. 2. Verify that the 8-shaped blind plates under separator hopper D-303, regenerator R-301, nitrogen seal tank D-307, and lock hopper D-308 are open. 3. Confirm that the regeneration isolation valves XV1005 and XV1006 are closed. These valves must be closed when calibrating the nuclear level gauge in separator hopper D-303. Once the core level gauge of the separation hopper has been calibrated, these valves are opened by switching CRCS to the “charging” mode. 4. Verify that the manual V valve below regenerator R-301 is closed; this valve must remain closed until the calibration of the level indicator in the separation hopper is completed. 5. During the loading process, accurate records of the amount of catalyst loaded into the regeneration zone must be kept, and catalyst samples should continue to be collected. 6. The specific steps for loading the catalyst into the regeneration section are as follows: (1) Ensure that the catalyst flows into regenerator R-301. (2) Calibrate the continuous interface detector LE0301 of the separation hopper; see ① below for details. (3) The interface indicator for calibrating the locked hopper buffer is LE1003; see ② below for details. (4) After the catalyst circulation is established, the load capacity of the lockhopper shall be calibrated; this process will be discussed in the CCR startup steps. ① Calibration of the separation hopper: First, check the switch status of the radiation source on the level detector LE0302. At the same time, the nuclear level gauge LE0301 must be calibrated to check its response and linearity when catalyst is added. To accurately calibrate the continuous interface meter, catalyst must be added according to the meter’s range; addition should be stopped when 50% of the catalyst has been added, as the total volume of catalyst in the reforming reactor increases as the reactor temperature rises. The detailed calibration requirements for the nuclear level gauge will be provided by the UOP instrument consultant. Note: Once the regenerator catalyst is full, catalyst loading stops, and the catalyst must not be added to separator hopper D-303 immediately. a. Verify that the blind flanges under the separation hopper, regenerator, and nitrogen seal tank have all been removed. b. Confirm that the regeneration isolation valves XV1005 and XV1006 are closed. c. Begin adding catalyst to the separation hopper through the top outlet flange, and add catalyst to regenerator R-301 and separation hopper D-303 until it reaches the radiation source at core level indicator LE0302. d. Continue to add catalyst to the separation hopper, starting from the point source, until it reaches the 0% mark on the continuous nuclear level gauge LT0301. To ensure that the interface detector of the nuclear level gauge responds to the correct interface. Add 1 barrel of catalyst first, then add 0.5 barrel of catalyst at a time, and stop adding catalyst once the interface detector starts to respond. e. Set the nuclear level detector at position 0. f. Continue to add 0.5 barrels of catalyst into the separation hopper each time. The catalyst interface will increase, and the number of interface transmitters will also rise accordingly. g. Calibrate the nuclear level gauge detector again and enter the measured interface. h. Continue repeating steps f and g until the measured interface reaches 50%. i. Once the calibration of the continuous interface detector LE0301 in the separation hopper is completed, enter the total number of points and store the calibration curve. ② Calibration of the closed hopper buffer zone. The nuclear level gauge LE1003 in the closed hopper buffer needs to be calibrated in order to check its response and linearity when catalyst is added to the container. To properly calibrate the continuous interface detector, it is necessary to add catalyst within the range specified by the gauge’s measurement limits. The detailed steps for calibrating this nuclear level gauge are provided by the UOP instrument consultant. a. Ensure that the inspection port of the closed hopper buffer is open; it is also used to calculate the amount of catalyst reserve when calibrating the level gauge for the closed hopper buffer. b. Confirm that the manual V-ball valve below regenerator R-301 is closed. In addition, it was confirmed that XV1008 beneath the closed hopper and one manual ball valve were closed. c. Set the switch to the “feeding” position, and open the regeneration isolation valves XV1005 and XV1006. d. By opening and closing the manual V-ball valve beneath the regenerator, load the catalyst into the lockhopper buffer until the catalyst level is exactly at the zero point of LT1003. e. Set the nuclear level gauge detector to zero. f. Calibrate the nuclear level LT1003 by opening and closing the manual ball valve below the regenerator. g. Calibrate the nuclear level gauge again, then enter the measured interface. h. Continue repeating steps f and g until the measured interface reaches 100%. i. Once the calibration of the continuous interface detector for the closed hopper buffer is completed, enter the total number of points and store the calibration curve. j. Before continuing to load the catalyst, close the inspection hole of the lockhopper buffer. ③ Calibration of the lock hopper area of the lock hopper. The lock hopper area of the lock hopper must be calibrated in order to determine its load capacity – that is, the amount of catalyst transported by the lock hopper per cycle. It is important to accurately measure the load capacity of the lock hopper, as it serves as the basis for setting the desired catalyst circulation rate. Using this calibration method, it is possible to adjust the position of the level gauge LY1003 so that the load capacity of the lock hopper is set at 45 to 46 kilograms. The calibration of the lock hopper area will be carried out after the catalyst circulation system is established. The specific calibration steps are described in the regeneration startup procedure. VI. Resetting 1. Reactor manholes (1) All the open sections of the removable covers on each reactor shall be restored to their original state, and it must be ensured that all locking pins and stainless steel wires are properly installed. (2) The cover plates were all vacuumed to remove all catalyst dust, and after thorough cleaning, the fan-shaped tube covers were removed. (3) Close the manhole and use new gaskets. 2. Reduction section: (1) Remove the charging hopper, scaffolding, and other charging tools. (2) Reinstall the two catalyst lift line flanges and thermowell sleeves, as well as the No. 1 reduction gas pipeline. 3. Regeneration section (1) Close the flange at the top of the separation hopper D-303, using a new gasket. (2) Close the two inspection ports of lock hopper D-308 and use new gaskets. 4. Shut down all remaining points in the reactor and regeneration sections. (1) The blind flanges on the reactor nozzles should remain installed until the reforming unit is put into operation. At that time, remove the blind flange, tighten the flanges, and use new gaskets. (2) Stop the instrument air purge for drying and disconnect it. (3) Maintain positive pressure in the reactor and regeneration section until startup is ready.