Chemical Engineering August 2021 - 50

today involves loading systems that
drop bulk catalyst charges from a
hopper by tube volume into cartridges
loaded onto ten-tube vibratory
loaders. Tracking of progress
and status of each tube as it is
loaded is essential to avoid mistakes
when so many tubes are involved.
In order to accurately track loading
progress, color-coded caps
cover each tube. The availability of
four or five different cap colors is
typically required, so if a reactor contains
10,000 tubes, up to 50,000 or
60,000 tube caps are required per
reactor. The installation, removal and
re-installation of these caps can be a
very time-consuming, but necessary,
step in the loading process. The requirement
for accurate tube counts
between shifts and other times is
also very time consuming. For each
loader inside the vessel and on the
tube-sheet, a dedicated operator is
required, along with a runner who
delivers the filled cartridges to the
loader operator.
This system also requires two or
three additional
personnel at the
charging hopper in addition to hole
watchers, ground and other support
personnel. With most reactor inner
diameters at 20 in. or less, the space
accommodates anywhere from four
to six ten-tube loaders, requiring a
crew of 12 to 16 people.
Once installed, the wheeled, individual
loaders are moved relatively
easily via a system of tracks. These
systems are electrically driven with
built-in dust collection that is fairly
adequate. Load results are typically
good, with an average of 50 tubes at
a time filled.
Next-generation loaders capable
of loading 120 tubes at once, and
tube-sheet cover plates that replace
the need for individual tube caps,
have recently become available.
They include a de-dusting hopper
and two stages of built-in dust collection.
The pneumatically driven
units have several features to prevent
double loading of tubes. Tube-sheet
cover plates can be custom made
for each reactor, based upon reactor
and tube-sheet inner diameter, tube
inner diameter and pitch.
Every catalyst manufacturer will
likely have recommended best practices
on how to load their product
into a reactor. Reputable catalyst
handling companies can contribute
valuble experience and special
equipment to accompish the loading
safely and correctly.
■
Edited by Scott Jenkins
Author
John Deajon is the vice president
of catalysts for the U.S. at
Maviro Inc. (1102 Howard Drive,
Deer Park, TX 77536; Phone:
+1-833-462-8476; Email:
jdeajon@maviro.com).
Deajon
has worked in the catalyst business
since 1995, and his career
has touched on all aspects of
the industry. Deajon was a field
employee, an equipment manager, a corporate life
support manager, an operations manager and a general
manager before becoming vice president of
Maviro's U.S. catalyst operations in 2020. He is
based on the U.S. Gulf Coast.
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Chemical Engineering August 2021

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