Hydrocarbon Processing - December 2022 - 15

Special Focus Catalysts
E. MAAS, Shell Catalysts & Technologies, Houston, Texas;
J. SIGAUD, Shell Catalysts & Technologies, Amsterdam,
the Netherlands; and G. POUSSIN and T. CALDAS,
CREALYST-Oil, Paris, France
Solving maldistribution: Catalyst loading
and why it matters
Are your reactor yields lower than
forecast? Does your fixed-bed catalytic
reactor suffer from hotspots? Are your
cycle lengths shorter than planned? If you
answered " yes " to any of these, then your
reactor could be suffering from liquid/gas
maldistribution-one of the most common
causes of poor reactor performance.
The impact of maldistribution can be
severe and long-lasting, yet its root cause is
often misunderstood. Although faulty or
poorly installed reactor internals are often
to blame, maldistribution can be frequently
traced back to poor catalyst loading.
The authors' companies collaborated
to share insights into the impacts of maldistribution
and the critical role that catalyst
loading plays in reactor performance, as
well as the important steps that plant personnel
can take to ensure optimal performance
of expensive catalyst and hardware.
Maldistribution: How is it affecting
production? Maldistribution is described
as the preferential flow and the uneven
distribution of liquids and/or gases
within a catalyst bed, which can have the
following consequences:
* Off-spec products due to
the suboptimal use of the
loaded catalyst volume
* Shorter-than-expected cycle length
due to end-of-run (EOR) conditions
reached sooner than expected
* Hotspot formations and the
resulting threat to the mechanical
integrity of the reactor.
Performance impacts: Poor use of
catalysts. Ideally, the weight hourly space
velocity (WHSV) should be uniform
within the entire catalyst bed volume;
however, if a reactor is suffering from
FIG. 1. The presence of hotspots (A) that can reduce distillate (diesel) yield. Localized hotspots
(B) can lead to over-cracking and the conversion of desired products (e.g., distillates) into
undesirable light ends.
Hydrocarbon Processing | DECEMBER 2022 15
maldistribution, then portions of expensive
catalyst are being underused (with a
lower-than-average WHSV), resulting in
lower-than-expected yields and off-spec
products. Consequently, the reactor must
run under more severe conditions to meet
the targeted product properties or yields.
Time impacts: Shorter run/cycle
times and increased downtime. In
the most severe cases, maldistribution
can lead to the early termination of the
reactor cycle. This is caused by the development
of hotspots-sections of the
catalyst bed where the liquid/gas flow is
impeded, causing high temperatures-
that result in EOR temperatures being
reached sooner than scheduled. Should
a cycle be cut short, valuable run time is
replaced with the costly and time-consuming
process of replacing exhausted
catalysts. In the most extreme cases, the
hotspot temperature can be high enough
to threaten the mechanical integrity of
the reactor and cause severe safety incidents
[e.g., reactor rupture, fire, explosion
or hydrogen sulfide (H2
S) release].
For example, imagine that plant personnel
have targeted a 1,000-d unit cycle
length, but the development of maldistribution
forces the cycle to terminate after
only 730 d, thereby reducing cycle run
time by 27%. Stopping the unit earlier than
scheduled and taking up to 3 wk to load a
fresh batch of catalyst can impact the bottom
line by as much as $18 MM (the cycle
scenario assumes a planned yield quota of
$500,000/d, a total planned cycle revenue
of $500 MM, and replacement catalyst
and downtime costs of $18 MM).
Cost impacts: Lost revenue and
poor return on investment. Maldistribution
results in lower yields, shorter
cycles and more downtime, which, together,
have a significant impact on unit
economics by increasing the total cost of
ownership (TCO) of each reactor (FIG. 1).
Moreover, each cycle requires an investment
in catalyst, hardware, feed and labor,
which is calculated based on the forecast
yield. If the yield is down and downtime
is up, then return on investment (ROI)
will be lower. The impacts of maldistribution
are unpredictable, and unpredictability
is difficult to budget.
Spotting maldistribution: It is all in
the temperature. The key to identifying

Hydrocarbon Processing - December 2022

Table of Contents for the Digital Edition of Hydrocarbon Processing - December 2022

Hydrocarbon Processing - December 2022 - 1
Hydrocarbon Processing - December 2022 - 2
Hydrocarbon Processing - December 2022 - 3
Hydrocarbon Processing - December 2022 - 4
Hydrocarbon Processing - December 2022 - 5
Hydrocarbon Processing - December 2022 - 6
Hydrocarbon Processing - December 2022 - 7
Hydrocarbon Processing - December 2022 - 8
Hydrocarbon Processing - December 2022 - 9
Hydrocarbon Processing - December 2022 - 10
Hydrocarbon Processing - December 2022 - 10A
Hydrocarbon Processing - December 2022 - 10B
Hydrocarbon Processing - December 2022 - 11
Hydrocarbon Processing - December 2022 - 12
Hydrocarbon Processing - December 2022 - 13
Hydrocarbon Processing - December 2022 - 14
Hydrocarbon Processing - December 2022 - 15
Hydrocarbon Processing - December 2022 - 16
Hydrocarbon Processing - December 2022 - 17
Hydrocarbon Processing - December 2022 - 18
Hydrocarbon Processing - December 2022 - 19
Hydrocarbon Processing - December 2022 - 20
Hydrocarbon Processing - December 2022 - 21
Hydrocarbon Processing - December 2022 - 22
Hydrocarbon Processing - December 2022 - 23
Hydrocarbon Processing - December 2022 - 24
Hydrocarbon Processing - December 2022 - 25
Hydrocarbon Processing - December 2022 - 26
Hydrocarbon Processing - December 2022 - 27
Hydrocarbon Processing - December 2022 - 28
Hydrocarbon Processing - December 2022 - 29
Hydrocarbon Processing - December 2022 - 30
Hydrocarbon Processing - December 2022 - 31
Hydrocarbon Processing - December 2022 - 32
Hydrocarbon Processing - December 2022 - 33
Hydrocarbon Processing - December 2022 - 34
Hydrocarbon Processing - December 2022 - 35
Hydrocarbon Processing - December 2022 - 36
Hydrocarbon Processing - December 2022 - 37
Hydrocarbon Processing - December 2022 - 38
Hydrocarbon Processing - December 2022 - 39
Hydrocarbon Processing - December 2022 - 40
Hydrocarbon Processing - December 2022 - 41
Hydrocarbon Processing - December 2022 - 42
Hydrocarbon Processing - December 2022 - 43
Hydrocarbon Processing - December 2022 - 44
Hydrocarbon Processing - December 2022 - 45
Hydrocarbon Processing - December 2022 - 46
Hydrocarbon Processing - December 2022 - 47
Hydrocarbon Processing - December 2022 - 48
Hydrocarbon Processing - December 2022 - 49
Hydrocarbon Processing - December 2022 - 50
Hydrocarbon Processing - December 2022 - 51
Hydrocarbon Processing - December 2022 - 52
Hydrocarbon Processing - December 2022 - 53
Hydrocarbon Processing - December 2022 - 54
Hydrocarbon Processing - December 2022 - 55
Hydrocarbon Processing - December 2022 - 56
Hydrocarbon Processing - December 2022 - 57
Hydrocarbon Processing - December 2022 - 58
Hydrocarbon Processing - December 2022 - 59
Hydrocarbon Processing - December 2022 - 60
Hydrocarbon Processing - December 2022 - 61
Hydrocarbon Processing - December 2022 - 62
Hydrocarbon Processing - December 2022 - 63
Hydrocarbon Processing - December 2022 - 64
Hydrocarbon Processing - December 2022 - 65
Hydrocarbon Processing - December 2022 - 66
Hydrocarbon Processing - December 2022 - 67
Hydrocarbon Processing - December 2022 - 68
https://www.nxtbook.com/gulfenergyinfo/gulfpub/HPI-Market-Data-2023-v3
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2024-v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2024
https://www.nxtbook.com/gulfenergyinfo/gulfpub/gas-processes-handbook-2022_v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/gas-processes-handbook-2022
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hp_202212
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2023-v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2023
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hp_202211
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202210
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202209
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202208
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202207_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202207
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202206_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202206
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202205_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202205
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202204_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202204
https://www.nxtbook.com/nxtbooks/gulfpub/hp_032022
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202203
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202202
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202201
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202112
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202111
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202110
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2022_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2022
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202109
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202108
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_processes_handbook_2021_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_processes_handbook_2021
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202107
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202106
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202105
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202104
https://www.nxtbook.com/nxtbooks/gulfpub/hp_ebooks
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202103
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202102
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202101
https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202012
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202011
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202010
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2021
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202009
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202008
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202007
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202006
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202005
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202004
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202003
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202002
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202001
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201912
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201911
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201910
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201909
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201908
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201907
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201906
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201905
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201904
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201903
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201902
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201901
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201812
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201811
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201810
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201809
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201808
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201807
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201806
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201805
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201804
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201803
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201802
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201801
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201712
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201711
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201710
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201709
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201708
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201707
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201706
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201705
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201704
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201703
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201702
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201701
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2017mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201612
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201611
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201610
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201609
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201608
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201607
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201606
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201605
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201604
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201603
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201602
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201601
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201512
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201511
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201510
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2016mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201509
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201508
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201507
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2015tmsd
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201506
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201505
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201504
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201503
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201502
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201501
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201412
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201411
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2015mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201410
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201409
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201408
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201407
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2014petrochemicalprocesses_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2014petrochemicalprocesses
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201406
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201405
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201404
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201403
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2014calendar
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201402
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201401
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201312
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2014mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201311
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201310
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201309
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201308
https://www.nxtbook.com/nxtbooks/gulfpub/hp_srsguide2013
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201307
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201306
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201305
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201304
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201303
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201302
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201301
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201212
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201211
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201210
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201209
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201208
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201207
https://www.nxtbook.com/nxtbooks/gulfpub/hp_srsguide2012
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201206
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201205
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201204
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201203
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201202
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201201
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201112
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201111
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201110
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201109
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201108
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201107_srsguide
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201107
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201106
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201105
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201104
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201103
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201102
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201101
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201012
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201011
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201010
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201009
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201008
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201007
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201006
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201005
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201004
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201003
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201002
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201001
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200912
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200911
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200910
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200909
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200908
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200907
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200906
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200905
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200904
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200903
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200902
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200901
https://www.nxtbookmedia.com