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1.The dense loading process

Reminder of the sock loading process

During loading

- Loading is not homogeneous- High void space in the catalyst bed- Reactor capacity not at maximum- Loading rate about 6 to 8 t/h- High risk of catalyst attrition

- Risk of breakage if the technician walks on thebed during loading

During operation

- Preferential channels can form> Higher temperatures> Preferential coking/plugging> Shorter cycle

- Compaction of the catalyst bed- Increased maintenance budget- Non optimised operation of the loaded catalyst.

The advantages

of Densicat/Catapac technologies

Better dense loading

During loading

- More homogenous loading- Lower void space in the catalyst bed

- 10 to 20% more catalyst can be loaded- Loading rate up to 25 t/h

During operation

- Maximum catalyst activity- Homogeneous distribution of the flow in the

reactor- Reactor at maximum capacity.

The (PETROVAL) Dense Loading process

A certified, experienced technician- Trained in the specific characteristics of the reactors- Certification renewed every year

A certified machine- The latest available technology : Densicat and/or

Catapac- Full maintenance before each job

Technical procedure in accordance with

standards- Catalyst density guaranteed before loading- Machine installed in accordance with PETROVAL

standards- Inspection and checking of the catalyst bed profile- Fully documented report

Densicat and/or Catapac :Horizontal orientation of catalyst particles

Sock loading :Random catalyst particles orientation

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2.Densicat and Catapac

Petroval know-how More than 50 reactors / year / PETROVAL technician Each technician is trained for all types of dense loading Density guaranteed

Flat profile of bed

Very flexible technologies

Size and type of reactor- Diameter from 0,4 to 7,5 m.- Reactor types : axial, radial, spherical, multi-bed,

reactor with excentric manholes ...

- The only procedures capable of loading very largereactors

Catalyst flow- From 0,6 to 25 t/h- The only procedures capable of achieving very

high catalyst flows without causing attrition

Maximum load volume- These technologies permit loading up to 40cm

below the distribution tray (depending on reactor

diameter)

For efficient dense loading, the PETROVAL

solution : Densicat, Catapac

Best possible distribution of catalyst particles

Efficient for all types of catalyst :

- Cylindrical extrudes- Trilobe extrudes- Quadrilobe extrudes

- Spherical- Tablets

Reduces attrition and dust

Fast and safe

Maximum density and levelness of the

catalyst bed- Better activity and stability of the catalyst bed- Eliminates preferential paths

Horizontal orientation of the particles

- Better contact between reactive phases

High loading rate- High level of activity and better availability of

the unit

Densicat

Catapac

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3.The technical advantages

Evolution and product research : Densicat,

a procedure in constant evolution

Densicat (a)- Limitation of loading flow below 10 t/h- Densicat loading was limited to reactors with a

diametre of less than 1,8 m

Evolution 1 (b)- Optimisation of catalyst distribution by improvement

of the loading flow- Flow limited to about 15 t/h- Problems observed :Too much catalyst flow in the centre of the reactor,hemispherical distribution not well managed

Evolution 2 (c)- Modification of the strip layout for more reliable

permeability during loading.

- Better distribution. Flat distribution profile with alarge catalyst flow, up to 25 t/h

Evolution 3In R&D phase.

Objective 1: load density

Advantages of dense loading linked todensity- Load density is near to maximum density- The increase in density depends on the type and

size of the material to be loaded:

a

b

c

Type Density gained

Cylindrical extrudes 14 % to 20 %Trilobe extrudes 17 % to 20 %Quadrilobe extrudes 17 % to 21 %Spherical 8 % to 12 %Tablets 12 % to 17 %

For an existing reactor or for a new reactor, thisincrease in density allows:

- Either to increase the conversion rate while main-taining the same operating conditions

- Or to vary the operating conditions to your advan-tage while maintaining the same performance.

- Technical analysis and preparation of the worksite

- Choice of technology : Densicat or Catapac

- Permanent on-site interface with the customer

- Approval of the customers load targets (density,loading plan, organisation, etc.)

- Pre-loading report

- Technical report approved by thePETROVAL technical manager

Ojective 2 : optimum loading organisation

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Objective 3: loading homogeneity

Correct dense loading- The orientation of the particles does not affectthe flow- Orientation of catalyst pellets

> Horizontal> Perpendicular to the flow

Concavedense load

Convexdense load

Dense load badlydistributed

PETROVAL : The dense loading specialist Refineries and petrochemical sites

More than 3 500 projects carried out since the 1990s and more than 1 200 reactors loaded Long term agreements and partnerships with

> ExxonMobil, Shell, Total, BP> Loading performed in more than 50 countries around the world, on all six continents.

Examples of poor dense loading

=37

=10

=6 Zone 3

Zone 2

Densicat ZoneDensicat Zone Yes Yes

Zone 2 No Yes

Zone 3 No No

Maximum

density

Horizontal

orientation ofthe pellets

Correct dense loading

Petroval loading

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4. Examples of industrial applications

>PETROVAL quality charter + PETROVAL technology + PETROVAL reactiveness= optimization of maintenance shutdown and catalyst reliability

ZoneUnit

Reactor

Team mobilisedNo. of loading shiftsQuantity loadedLoad heightReactor diametreSame type of loading

EuropeDGO

1 bed

1160 t8,5 m3,5 m125/year

EuropePowerformer

Sphrical

1136 t4,7 m6,3 m10/year

ZoneUnit

Reactor


EuropeReforming

Radial

1125 t10 m2,8 m15/year

ZoneUnit

ReactorTeam mobilisedNo. of loading shiftsQuantity loadedLoad heightReactor diametreSame type of loading

AsiaAmmonia Co

S2001135 t14 m1,2 m15/year

ZoneUnitReactor


EuropeAnilinTubular(11800 tubes 1)1115 t3 m3,5 m5/year

ZoneUnit

ReactorTeam mobilisedNo. of loading shiftsQuantity loadedLoad heightReactor diametreSame type of loading

AsiaHDT

3 beds2 (J/N)6*500 t25 m5,7 m137/year

ZoneUnitReactor


USAHDS6 beds

2 (J/N)10*450 t35 m4,5 m45/year

ZoneUnit

Reactor 8 reactors


AsiaARDS

double beds

4 (J/N)25*800 t20 m4,8 m25/year

* Internal assembling stations included

ZoneUnit

Reactor


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PETROVAL SA

PETROVAL SA - Parc Econormandie - BP 66 - 76430 Saint Romain de Colbosc - France

Tl. : +33 (0)2 35 31 00 00 - Fax : +33 (0)2 35 31 35 35 - E-Mail : [email protected]

PETROVAL LP - PO BOX 56625 - Houston, Texas 77256-6625 - United States

Phone: +1 713 527 9575 - Fax: +1 713 529 7573 - E-mail: [email protected]

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