• INTRODUCTION

  • Catalyst Loading in Reactors:
  • Catalyst loading of reactors is a very important process in refineries. The catalyst used in reactors is expensive and it is essential to ensure proper loading of the catalyst.
  • Proper loading of catalyst gives:
  • More catalyst for the same volume
  • Homogenous bed
  • Higher catalyst activity
  • Lesser coke formation
  • Better pressure drop across the bed
  • DENSICAT dense loading system for catalyst loading:

  • Conventional loading methods using a sock often result in loosely packed beds with poor catalyst orientation. Hence dense bed loading is used to overcome these deficiencies.
  • Dense bed loading applies the principles of individual particle movement in free fall in a static air column
  • KEY ADVANTAGES OF DENSICAT

  • Increased bulk density:
    • Catalyst loading by dense bed loading results in a more dense bed than is obtained by conventional loading.
    • More catalyst can be loaded into a given reactor and throughput can be increased.
  • Improved catalyst utilization:
    In two phase (liquid and gas) systems, the liquid catalyst contacting is improved by dense bed loading and increased efficiency is obtained in very high conversion reactions. Uniform void spaces and tendency towards horizontal particle orientation enhance efficiency.
  • Reduced bed setting:
  • Since a near maximum density is achieved with dense bed loading at the start of the cycle bed setting and shifting is greatly reduced. This helps eliminate damage to reactor internals which is common to conventional techniques.
  • The DENSICAT dense bed loading method is a controlled rate loading procedure that achieves uniform high density catalyst beds using a loading device designed to distribute the catalyst over the entire surface.
  • DENSICAT (patented by TOTAL) and CATAPAK (patented by AXENS) are used by Petroval for the loading of all fixed bed reactors (HDS/HDT, Hydrocrackers, Molecular sleves, dryers, PSA adsorbers, sulphur traps etc.).
  • BENEFITS OF DENSICAT

  • Increased density compared to sock loading upto 20% higher
  • Improved bed homogeneity and
  • Loading rate upto 25 tons/hour