Read BIC Magazine online at www.bicalliance.com March 2012 67

M icrochannel reactors hold the prom-ise of improved productivity and

cost effectiveness at scales far smaller than what is possible with conventional tech-nology. However, before they are widely accepted many operational issues need to be addressed, including commercial methods for loading and unloading catalyst. This challenge was accepted by Mourik, a world-wide leader in catalyst handling, that worked closely with Velocys Inc. to develop equip-ment and methods that were used to success-fully load a commercial scale microchannel Fischer-Tropsch (FT) reactor. On the surface conventional tubular reac-tors, such as the 1,200-ton FT reactors in Shell’s Pearl plant in Qatar, may seem to have little in common with microchannel reactors developed by Velocys, a member of Oxford Catalysts Group. But what the two have in common is that both are essentially fixed bed systems — one with thousands of 30-feet-long (10 meters), one-inch tubes and the other

with thousands of passages with far smaller dimensions and lengths (2 feet or 60 centime-ters). Mourik possesses deep experience with loading catalyst in tubular reactors — and this explains why Shell, Velocys and many others turned to it for catalyst handling solutions. In order to achieve maximum produc-tivity, catalyst must be loaded uniformly throughout a reactor. The aim is to achieve the same pressure drop — a measure of packing density — in each tube or bank of microchannels. Although in practice it is not possible to achieve perfect uniformity, Mourik’s technology and experience has allowed it to achieve loadings close to this ideal specification in reactors containing up to 30,000 tubes, but could it be done in tens of thousands of microchannels? Loading catalyst into microchannel reac-tors poses new challenges. While catalyst particles used in tubular reactors are pellets, with diameters about one-eighth to one-quar-ter inches (3 to 6 millimeters), the catalyst for microchannels is a powder, with 200-500 micron grain sizes. Loading powdered catalyst into thousands of microchannels in each reactor and ensuring each is filled to the same volume required a novel solution. To accomplish this, Mourik modified commer-cially available equipment and with Velocys developed an innovative catalyst loading pro-cedure. The resulting approach included a novel apparatus, with a built-in source of vibra-tion. A mechanism feeds catalyst into all

the microchannels at once, then the reac-tor is vibrated to ensure as much catalyst as possible is packed into each channel. Afterward, relatively standard methods were used to measure catalyst volumes and pressure drops to verify that the reactor is uniformly loaded. At the end of life, a simi-

lar method is used to remove the catalyst. “We are very pleased with the equip-ment and methods developed by Mourik as well as the catalyst loading they achieved,” said Dave Kilanowski, senior project leader of Velocys. “As is the case with any new procedure, there are still improvements to be

made, but we are confident that we are work-ing with the right partner to figure these out.” For more information about Mourik LP, visit www.mourik-usa.com or call (281) 479-4449. For more information about Velocys Inc., visit www.velocys.com or call (614) 733-3300. •

Commercial catalyst loading for microchannel reactors validatedMourik LP/Velocys Inc.

BUSINESS UPDATE

Mourik LP specializes in catalyst handling services for industrial applications, utilizing its innovative technology and proven expertise to secure contracts with some of the largest oil companies in the world.

Why Mourik?Mourik is an innovative family business that combines traditional human values with modern entrepreneurship, sophisticated technologies, inspiring leadership and a proactive attitude.

Catalyst Services• Catalyst change-outs• Unloading & reloading of tubular reactors• Dense loading activities• Inspections, repairs & reactor revamps• Mechanical work• Reactor cleaning• Video inspections• Hole watch / Fire watch

www.mourik.com

2230 Pansy Street • Pasadena, TX 77503Phone: 1-281-479-4449Fax: 1-281-479-4443E-mail: sales@mourik-usa.comwww.mourik-usa.com

Mourik possesses deep experience with loading catalyst in tubular reactors.