steam reforming - catalyst loading
DESCRIPTION
OBJECTIVES Best practices Sock Loading Unidense Pressure Drop Measurement Common ProblemsTRANSCRIPT
![Page 1: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/1.jpg)
Gerard B. Hawkins Managing Director
![Page 2: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/2.jpg)
The aim of this presentation is to • Give an understanding of ◦ Best practices ◦ Sock Loading ◦ Unidense ◦ Pressure Drop Measurement ◦ Common Problems
![Page 3: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/3.jpg)
Use approved drum handling techniques Do not roll drums Do not lift on forks of fork lift truck Do not stack more than 4 high - even on
pallets Protect from rain and standing water Keep lids on Do not expose to temperature extremes
![Page 4: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/4.jpg)
Before loading • Inspect vessel for stress damage • Check conditions of thermocouples
– Document their location with respect to inlet flange or tangent line
• Check support balls for breakage or extraneous materials
• Check support grids for condition (e.g., damaged clips; grid binding)
![Page 5: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/5.jpg)
• During charging – Use appropriate personnel protection Dust masks Gloves Full body coverage Fresh air in vessels
• Support workers in reactors with boards • Snow shoes
![Page 6: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/6.jpg)
During charging – Use hopper or supersack with attached sock
– Ensure uniform distribution by moving sock
– Maximum catalyst freefall 3ft (1m)
– Minimum catalyst freefall 1ft (.3m)
– Helps ensure dense loading
![Page 7: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/7.jpg)
Aim is to achieve • Same flow through each tube ◦ No hot tubes
• No bridging ◦ No hot spots
• Ultimately ◦ Minimize methane slip ◦ Extends tube life
![Page 8: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/8.jpg)
Inspection • Check tubes for defects using LOTISTM or eddy
current etc
• Internal surfaces - Look smooth
• Catalyst support grids are in place
• Inlet and exit pigtails are not blocked
![Page 9: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/9.jpg)
• Procedure is ◦ Only have one type of catalyst on
the steam reformer at any one time ◦ Ensure sock “rope” is longer than
catalyst tube ◦ Anchor free and of rope, or fit object
• to prevent rope falling into tube ◦ One end sealed for attachment of
lowering rope ◦ Other end folded over - 10cm (4”)
flap ◦ Calculate weight per sock to give
whole number of socks per tube
![Page 10: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/10.jpg)
• Sock OD should be 20mm (3/4”) smaller than tube ID
• Filled sock length should be around 150cm (5’)
• Socks material is canvas, polythene or similar
• Fill socks with same known weight
• Label socks for different types of catalyst
![Page 11: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/11.jpg)
Filling Tubes Folding Over Attaching Rope
![Page 12: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/12.jpg)
Jerking Rope Topping Up Checking Outage
![Page 13: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/13.jpg)
Compressed air
Inletpressure
Handvalve
Orificeplate
Catalystpressuredrop
Cam and leverto expand bung
Cam and leverto expand bung
Guidering
Catalysttube
![Page 14: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/14.jpg)
Developed by Hydro Agri of Norway Proprietary technique available through a select number of
licensees Widely practiced - more than 260 steam reformer charges
have been loaded using this technique Leads to “denser” packing
– less pd variation more uniform gas flows
– easier procedure shorter loading time (70%)
– slightly higher pd effect on throughput - marginal
![Page 15: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/15.jpg)
Outlet pigtail
Brushes
Catalyst tube
Catalyst drum
Charging hopper
Inlet pigtail
Move rope upwards
![Page 16: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/16.jpg)
![Page 17: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/17.jpg)
![Page 18: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/18.jpg)
Aim to pack catalyst to uniform voidage Measure pd
– Not outage in tube at any one time – Not weight per tube – Not catalyst density – After 50% – After full loading
Use defined and consistent procedure throughout
![Page 19: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/19.jpg)
Fixed flow of air (choked flow through orifice)
Mass flowrate through orifice function of ◦ upstream pressure ◦ orifice diameter (known) ◦ temperature (known)
Downstream pressure is measure of pd
![Page 20: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/20.jpg)
• For air, the critical value of P2 is around 50% of P1
• If flow is sonic, then mass flow is constant • Resistance to flow downstream (pd) can be
read now as P2 value
P1 P2
Orifice
![Page 21: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/21.jpg)
Flow must be sonic to obtain meaningful results ◦ requires a minimum upstream/downstream
pressure ratio ◦ check upstream pressure adequate
If using a shared air supply, monitor pressure carefully - other users can lead to a drop in supply pressure.
![Page 22: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/22.jpg)
PD rig
Inlet pigtail
Exit pigtail
4a. Exit pigtail
Empty tube
PD rig
4b. Catalyst
catalyst
PD rig
4c. Inlet pigtail
catalyst
![Page 23: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/23.jpg)
If too high then – suck out catalyst and recharge
If too low then – Vibrate tube – Use a soft faced hammer – Top up if outage too great
![Page 24: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/24.jpg)
![Page 25: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/25.jpg)
Voids Stacking
![Page 26: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/26.jpg)
Voids
Broken Pellet
Voids Voids
![Page 27: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/27.jpg)
-20 -15 -10 -5 0 5 10 15 20-15
-10
-5
0
5
10
15
-40-30-20-10010203040
Pressure Drop Variation (%)
Flow
Var
iatio
n (%
)
Tube
Tem
pera
ture
Var
iatio
n (°
C)
![Page 28: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/28.jpg)
• If loading is poor • variety of flows in tubes
• Each tube has different exit temperature ◦ Each tube has a close approach ◦ Mixture of all tubes far from equilibrium ◦ Methane slip not linear with temperature ◦ Methane slip higher than it should be ◦ Tube temperature distribution ◦ Some tubes will be hot
• Therefore fail sooner ◦ Operational costs - High Slip ◦ Maintenance costs - Failed tubes
![Page 29: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/29.jpg)
Mixed Gas Exit
Reformer
872 1602
9 16
3.9
Process Gas Exit (°C) Temp (°F)
Methane/Steam (°C) Approach (°F)
Methane Slip (% dry) Max twt (°C) (°F)
Well Balance
870 1598
2 3
3.6
891 1636
Poorly Balance
834 - 992 1533 - 1692
1 - 3 1 - 5
1.6 - 6.5
860 - 930 1580 - 1706
![Page 30: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/30.jpg)
Charging tube
high pressure drop
Support Grid Catalyst Support
More larger particles low pressure drop
![Page 31: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/31.jpg)
• This means that there is ◦ A high voidage at the walls ◦ A low voidage in the center
• This will cause flow mal-distribution ◦ More flow at walls ◦ Less in the centre
• Will cause a shortened life
![Page 32: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/32.jpg)
Giraffe Necking
Tiger Tailing
“Bridging”
![Page 33: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/33.jpg)
Settling
Not enough catalyst, or overcompaction and breakage
![Page 34: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/34.jpg)
Outage (Pressure Drop)
Amount of vibration or hammering
Overcompacted
Correctly Settled
![Page 35: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/35.jpg)
Two methods: – Vacuum from top Most desirable form informational standpoint Costly Difficult if catalyst pyrophoric
– Bottom dump Faster Cheaper
Nickel containing catalyst – Potential for nickel carbonyl – Formed by CO reacting with Ni – Stable below 200oC (390oF)
![Page 36: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/36.jpg)
Use a device as illustrated below
15cms Clip
Mesh
Hose
Vacuum System
![Page 37: Steam Reforming - Catalyst Loading](https://reader038.vdocuments.mx/reader038/viewer/2022102408/55621f8ad8b42ac6588b48ac/html5/thumbnails/37.jpg)