SlideShare une entreprise Scribd logo
1  sur  19
Télécharger pour lire hors ligne
GBH Enterprises, Ltd.

Process Engineering Guide:
GBHE-PEG-RXT-807

Reactor and Catalyst Design

Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the information
for its own particular purpose. GBHE gives no warranty as to the fitness of this
information for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability resulting from reliance on this
information. Freedom under Patent, Copyright and Designs cannot be assumed.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Process Engineering Guide:

Reactor and Catalyst Design

CONTENTS

SECTION

0

INTRODUCTION/PURPOSE

2

1

SCOPE

2

2

FIELD OF APPLICATION

2

3

DEFINITIONS

2

4

CATALYST DESIGN

2

4.1
4.2
4.3

Equivalent Pellet Diameter
Voidage
Pellet Density

3
6
8

5

REACTOR DESIGN

8

6

CATALYST SUPPORT

10

6.1

Choice of Support

10

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
TABLES

1

CATALYST SUPPORT SHAPES

12

2

SECONDARY REFORMER SPREADSHEET

13

FIGURES
1

GRAPH OF EFFECTIVENESS v THIELE MODULUS

4

2

VARIATION OF COSTS WITH CATALYST SIZE

6

3

VARIATION OF COSTS WITH CATALYST BED VOIDAGE

8

4

VARIATION OF COSTS WITH VESSEL DIAMETER

9

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
0

INTRODUCTION/PURPOSE

When the catalyst chemistry of a new fixed feed chemical reaction has been
developed, decisions need to be made about the catalyst design. The issues that
need to be decided are:
(a)

The catalyst particle size.

(b)

The catalyst shape to give a reasonable optimum pressure drop in the
catalyst bed.

(c)

The catalyst particle density to make the catalyst particles reasonably
effective.

These issues are closely related to the reactor shape and the cost of pressure
drop.
This Process Engineering Guide provides some explanation of these issues and
equations by which the key parameters can be determined.

1

SCOPE

This Process Engineering Guide deals with the design of the catalyst, particularly
its size and shape, and the reactor geometry as well as catalyst support types. It
does not cover the chemical selection of the catalyst.

2

FIELD OF APPLICATION

This Guide applies to process engineers and technologists in GBH Enterprises
worldwide, who may be involved in the design of reactors and catalysts.

3

DEFINITIONS

For the purposes of this Guide no specific definitions apply.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
4

CATALYST DESIGN

The design of catalyst particles can be characterized by three independent
variables:
(a)

Equivalent pellet diameter

de

(b)

Voidage

e

(c)

Density

ρ

These can all be optimized.

4.1

Equivalent Pellet Diameter

Larger catalyst size leads to:
(a) Lower pressure drop in reactor:
(1)

Lower compression power.

(b) Lower catalyst effectiveness:
(1)
(2)
(3)

Larger catalyst volume
Higher vessel cost
Higher catalyst cost.
Thiele modulus F = b x de

.......................................... (1)

where:
b

is assumed to be a constant (probably related to the pore structure)

de

is the equivalent sphere diameter of the particle.
de = 6 x particle volume / particle surface area

.......................... (2)

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
For a spherical catalyst particle:
Effectiveness E = 3/F x (1/tanh(F) - 1/F))

................. (3)

The constant b may be calculated from measurements of the effective catalyst
activity at two different particle sizes.
The intrinsic activity is defined as:
Intrinsic Activity = Apparent Activity / Effectiveness ....... (4)

4.1.1

Example: Calculation of Intrinsic Activity

Results from pellet testing give:
Test

Pellet size

1
2

2
4

Apparent Activity
4.2
3

Figure 1 shows a graph of Effectiveness v Thiele Modulus based on Equation 3.
FIGURE 1 GRAPH OF EFFECTIVENESS v THIELE MODULUS

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
What are the Thiele Moduli for the different pellet sizes and the intrinsic activity?
Using Figure 1, it can be seen that to get an apparent activity increase of 40% for
a halving of the pellet diameter, the only points that will fit are:
F = 2,

E = 0.8

F = 4,

E = 0.57

Thus, from Equation 4, the Intrinsic activity is 4.2 / 0.8 = 5.25.
4.1.2 Pressure Drop
For turbulent flow:
Pressure drop ΔP = 2 x Velocity head x 1.75 x (1 - e) x L / (e3 x de) (5)
where:
e
L

is the bed voidage
is vessel length or height.

For axial flow:
Capitalized cost = Cp x V / (de x D6)

.............................. (6)

where:
Cp
V
D

is a constant for fixed voidage
is the catalyst volume
is the catalyst bed diameter.

4.1.3 Catalyst Volume
Catalyst volume (V):
V = V0 / E

................................................................ (7)

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
where:
V0 is the catalyst volume for unit effectiveness.
Vessel cost:
Capital cost = Cv x (V + D3)

....................................... (8)

where:
Cv is a constant.
Catalyst cost:
Capitalized cost = Ccat x V

............................................ (9)

where:
Ccat is a constant that depends on catalyst cost and catalyst change frequency.
Calculate the parameter (q):
q = 1.89 / (Cv + Ccat) x (Cv / V0)0.67 x (Cp x b)0.33 .............................(10)
For axial flow in an adiabatic pressure vessel optimum pellet size is given by:
q = (b x de)0.375 x (0.4 + 0.022 x (b x de)2) .................................... (11)
If q < 20, calculate:
de = (2.5 x q)0.375 / b

................................................. (12)

If q > 20, calculate:
d e = (q / 0.022)3/14 / b

................................................. (13)

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
If optimum pellet diameter is greater than 3mm
If optimum diameter is less than 3mm

- use pellets or rings.

- examine other supports (see later).

The necessary data to determine the Thiele Modulus and hence the optimum
pellet diameter of most of the catalysts that GBHE uses is not available.
Typical optimum particle sizes:
Ammonia plant:
HT Shift
Methanator
Secondary Reformer
Methanol synthesis

3.8 mm
1.8 mm
0.1 mm
4.7 mm

Figure 2 shows the variation of capitalized costs (pressure drop cost, vessel cost,
catalyst cost and total cost) and effectiveness with catalyst size.
FIGURE 2

VARIATION OF COSTS WITH CATALYST SIZE

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
4.2

Voidage
Higher voidage leads to:
(a)

Lower pressure drop.

(b)

Larger catalyst vessel.

It is possible to increase voidage by moving to more eccentric particles, i.e.
length / diameter L / D ratio greater than 1.3, or by using rings instead of pellets.
4.2.1 Pressure Drop Cost
Pressure drop cost:
Capitalized cost = Cp1 x Vs / D6 / e3

................. (14)

where:
Cp1 is a constant for constant particle diameter, etc.
Vs is the solid volume of catalyst
D is the vessel diameter
e is the bed voidage.

Vs = V x (1 - e)

............................................................... (15)

where:
V is the catalyst volume of catalyst.

4.2.2 Vessel Cost
Vessel cost:
Capital cost = Cv x (V + D3) ............................................. (16)
where:
Cv is a constant
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Calculate the parameter (w):
w = 1.89 x (Cp1 / Cv / Vs 2 )0.33

...................................... (17)

For axial flow in an adiabatic pressure vessel:
Optimum voidage = w0.5 / (1 + w 0.5)
If optimum voidage is less than 0.4
If optimum voidage is greater than 0.4
Typical optimum voidages:

........................... (18)

- use pellets or beads.
- use rings or maybe eccentric

Ammonia plant secondary reformer
Ammonia plant methanator
Methanol plant converter

0.5
0.36
0.5

The catalyst needs to be strong to maintain a voidage above 0.4, so GBHE still
uses pellets for methanol synthesis catalyst.
Figure 3 shows the variation of costs (pressure drop cost, vessel cost and total
cost) with catalyst bed voidage.

FIGURE 3

VARIATION OF COSTS WITH CATALYST BED VOIDAGE

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
4.3

Pellet Density

Higher density gives:
(a)
(b)

More active catalyst component.
Lower pore volume:
(1)
Lower effectiveness
(2)
Possibly lower selectivity.

There appear to be no established relationships to determine optimum pellet
density.
5

REACTOR DESIGN

Optimum length to diameter ratio of the reactor may be determined as follows:
Pressure drop cost:
Capitalized cost = Cp x V / (de x D6) ................................ (6)
where:
Cp is a constant for fixed voidage
V is the catalyst volume
de is the equivalent sphere diameter
D is the catalyst bed diameter.

Vessel cost:
Capital cost = Cv x (V + D3) ............................................ (8)
where:
Cv is a constant.
Optimum diameter D = ( 2 x Cp x V / (Cv x de))1/9 ...... (19)
If optimum L / D ratio is greater than 1
If optimum L / D ratio is between 0.2 and 1
If optimum L / D ratio is less than 0.2

- use axial flow in vertical vessel.
- consider horizontal vessel.
- consider radial flow vessel.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Typical optimum L / D ratios:
Ammonia plant secondary reformer
Ammonia plant desulfurizer
Ammonia plant LT shift

0.8
2.8
1.1

Figure 4 shows the variation of costs (vessel cost, pressure drop cost and total
cost) with vessel diameter).
FIGURE 4

6

VARIATION OF COSTS WITH VESSEL DIAMETER

CATALYST SUPPORT TYPES
The following catalyst support types are available:
(a)
(b)
(c)
(d)

(e)
(f)

Pellets, beads, extrudates
Rings.
Monoliths (honeycombs).
Ceramic foams (macroporous catalyst):
(1)
Sheet
(2)
Pellets.
Knitted wire mesh.
Multi-holed extrudates

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
6.1

Choice Of Support

6.1.1 General Guidance
(a)

Use pellets, rings or extrudates when optimum particle diameter is
greater than 2 mm.

(b)

Use rings if optimum voidage is greater than 0.4.

(c)

Use monoliths if optimum particle diameter is less than 2 mm and
cost of pressure drop is high.

(d)

Use ceramic foams or knitted wire mesh if optimum particle
diameter is less than 1 mm.

(e)

Use multi-holed extrudates when optimum particle diameter is less
than 2 mm and using a tubular reactor.

Other factors that come into play are:
(1)

Length / diameter limitations.

(2)

Fouling.

(3)

Heat transfer limit in tubular reactors.

(4)

Vessel length / particle diameter ratio.

(5)

Degree of conversion required.

(6)

Want to be film diffusion limited.

6.1.2 Quantitative Evaluation
The best method to evaluate alternative catalysts is on a spreadsheet model. In
order to do this the supports need to be characterized.
Since most novel supports are only generally used when the catalyst is severely
pore diffusion limited (in order to get high surface areas), they can be
characterized most easily on the basis of their geometric surface area.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
The types of support can be characterized by:

Total bed voidage e = 1 - (1- eb ) x (1- ep) ................................ (20)
where:
eb
ep

is the Interparticle voidage
is the Intraparticle voidage.

Specific geometric surface area per unit volume of bed (As):
As = 6 x (1- e) / de ........................................... (21)
where:
de

is the equivalent sphere diameter.

Specific pressure drop (Ps) is the pressure drop as velocity heads per unit
geometric surface area.
For turbulent flow through pellets, spheres, rings, gauze or ceramic foams:
Ps = 0.58 / eb3

…………………................................ (22)

For multi-holed extrudates of typical dimensions (particle size / de = 4):
Ps = 0.18 / eb3 ............................................................. (23)
For monoliths with turbulent flow:
Ps = 0.015 / ep3 ......................................................... (24)

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
For monoliths with laminar flow (Re < 3500 ):
Reynolds number Re = actual velocity x hole diameter / viscosity.. (25)
Hole diameter = 2/3 x de x ep / (1 – ep)

................................. (26)

Ps = 16 / Re / ep3 ……………...................................................... (27)
Pressure drop:
Pressure drop = Ps x surface area x superficial velocity head ... (28)
6.1.3 Cost of Catalyst
For some types of support it is most appropriate to measure the cost of the
catalyst per unit volume, whereas for others, it is appropriate to measure it per
unit geometric surface area.
The vessel cost can be determined as before.
Table 1 details typical manufacturing costs for each catalyst support shape.
TABLE 1

CATALYST SUPPORT SHAPES

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
6.1.4 Example: Secondary Reformer
What is the optimum support and surface area / unit volume for the following
example:
Surface area required A

=

6000 m2

Cost of vessel Cd

=

3600 (V + D3)

Capitalized pressure drop cost Cp

=

£2 / pascal

Mass flow M

=

38 kg / s

Density

=

5 kg / m3

Catalyst life

=

2 yrs

Viscosity * 1000

=

0.4

Factor for optimum diameter b

=

1990

The optimum support and surface area / unit volume can be determined from
Table 2.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
TABLE 2

SECONDARY REFORMER SPREADSHEET

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

Contenu connexe

Tendances

(LTS) Low Temperature Shift Catalyst - Comprehensive Overview
(LTS) Low Temperature Shift Catalyst - Comprehensive Overview(LTS) Low Temperature Shift Catalyst - Comprehensive Overview
(LTS) Low Temperature Shift Catalyst - Comprehensive OverviewGerard B. Hawkins
 
SMR PRE-REFORMER DESIGN: Case Study
SMR PRE-REFORMER DESIGN: Case StudySMR PRE-REFORMER DESIGN: Case Study
SMR PRE-REFORMER DESIGN: Case StudyGerard B. Hawkins
 
Catalytic Reforming: Catalyst, Process Technology and Operations Overview
Catalytic Reforming:  Catalyst, Process Technology and Operations OverviewCatalytic Reforming:  Catalyst, Process Technology and Operations Overview
Catalytic Reforming: Catalyst, Process Technology and Operations OverviewGerard B. Hawkins
 
Selection of Reboilers for Distillation Columns
Selection of Reboilers for Distillation ColumnsSelection of Reboilers for Distillation Columns
Selection of Reboilers for Distillation ColumnsGerard B. Hawkins
 
A presentation on reformer new
A presentation on reformer newA presentation on reformer new
A presentation on reformer newGowri Shankar
 
Line Sizing presentation on Types and governing Equations.
Line Sizing presentation on Types and governing Equations.Line Sizing presentation on Types and governing Equations.
Line Sizing presentation on Types and governing Equations.Hassan ElBanhawi
 
Calculation of Caloric Value and other Characteristic Data of Fuel Gas
Calculation of Caloric Value and other Characteristic Data of Fuel GasCalculation of Caloric Value and other Characteristic Data of Fuel Gas
Calculation of Caloric Value and other Characteristic Data of Fuel GasGerard B. Hawkins
 
Water Gas Shift Reactor Design
Water Gas Shift Reactor DesignWater Gas Shift Reactor Design
Water Gas Shift Reactor Designl16cn
 
Ammonia synthesis converter
Ammonia synthesis converterAmmonia synthesis converter
Ammonia synthesis converterPrem Baboo
 
PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)
PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)
PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)Aree Salah
 
Selection of Internals for Distillation Columns
Selection of Internals for Distillation ColumnsSelection of Internals for Distillation Columns
Selection of Internals for Distillation ColumnsGerard B. Hawkins
 
Critical Variables in Catalytic Reforming and Unit Monitoring Best Practices
Critical Variables in Catalytic Reforming and Unit Monitoring Best PracticesCritical Variables in Catalytic Reforming and Unit Monitoring Best Practices
Critical Variables in Catalytic Reforming and Unit Monitoring Best PracticesGerard B. Hawkins
 
101 Things That Can Go Wrong on a Primary Reformer - Best Practices Guide
101 Things That Can Go Wrong on a Primary Reformer -  Best Practices Guide101 Things That Can Go Wrong on a Primary Reformer -  Best Practices Guide
101 Things That Can Go Wrong on a Primary Reformer - Best Practices GuideGerard B. Hawkins
 
Methane Steam Reformer Re-tube Studies
Methane Steam Reformer Re-tube StudiesMethane Steam Reformer Re-tube Studies
Methane Steam Reformer Re-tube StudiesGerard B. Hawkins
 
Tube Wall Temperature Measurement On Steam Reformers - Best Practices
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesTube Wall Temperature Measurement On Steam Reformers - Best Practices
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesGerard B. Hawkins
 
Shift Conversion Catalysts - Operating Manual
Shift Conversion Catalysts - Operating ManualShift Conversion Catalysts - Operating Manual
Shift Conversion Catalysts - Operating ManualGerard B. Hawkins
 
Steam reforming - The Basics of Reforming
Steam reforming  - The Basics of ReformingSteam reforming  - The Basics of Reforming
Steam reforming - The Basics of ReformingGerard B. Hawkins
 
Heating and Cooling of Batch Processes
Heating and Cooling of Batch ProcessesHeating and Cooling of Batch Processes
Heating and Cooling of Batch ProcessesGerard B. Hawkins
 

Tendances (20)

(LTS) Low Temperature Shift Catalyst - Comprehensive Overview
(LTS) Low Temperature Shift Catalyst - Comprehensive Overview(LTS) Low Temperature Shift Catalyst - Comprehensive Overview
(LTS) Low Temperature Shift Catalyst - Comprehensive Overview
 
SMR PRE-REFORMER DESIGN: Case Study
SMR PRE-REFORMER DESIGN: Case StudySMR PRE-REFORMER DESIGN: Case Study
SMR PRE-REFORMER DESIGN: Case Study
 
Catalytic Reforming: Catalyst, Process Technology and Operations Overview
Catalytic Reforming:  Catalyst, Process Technology and Operations OverviewCatalytic Reforming:  Catalyst, Process Technology and Operations Overview
Catalytic Reforming: Catalyst, Process Technology and Operations Overview
 
Selection of Reboilers for Distillation Columns
Selection of Reboilers for Distillation ColumnsSelection of Reboilers for Distillation Columns
Selection of Reboilers for Distillation Columns
 
A presentation on reformer new
A presentation on reformer newA presentation on reformer new
A presentation on reformer new
 
Line Sizing presentation on Types and governing Equations.
Line Sizing presentation on Types and governing Equations.Line Sizing presentation on Types and governing Equations.
Line Sizing presentation on Types and governing Equations.
 
DESIGN PROJECT 2013
DESIGN PROJECT 2013DESIGN PROJECT 2013
DESIGN PROJECT 2013
 
Calculation of Caloric Value and other Characteristic Data of Fuel Gas
Calculation of Caloric Value and other Characteristic Data of Fuel GasCalculation of Caloric Value and other Characteristic Data of Fuel Gas
Calculation of Caloric Value and other Characteristic Data of Fuel Gas
 
Water Gas Shift Reactor Design
Water Gas Shift Reactor DesignWater Gas Shift Reactor Design
Water Gas Shift Reactor Design
 
Ammonia synthesis converter
Ammonia synthesis converterAmmonia synthesis converter
Ammonia synthesis converter
 
PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)
PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)
PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)
 
Ammonia plant flowsheets
Ammonia plant flowsheetsAmmonia plant flowsheets
Ammonia plant flowsheets
 
Selection of Internals for Distillation Columns
Selection of Internals for Distillation ColumnsSelection of Internals for Distillation Columns
Selection of Internals for Distillation Columns
 
Critical Variables in Catalytic Reforming and Unit Monitoring Best Practices
Critical Variables in Catalytic Reforming and Unit Monitoring Best PracticesCritical Variables in Catalytic Reforming and Unit Monitoring Best Practices
Critical Variables in Catalytic Reforming and Unit Monitoring Best Practices
 
101 Things That Can Go Wrong on a Primary Reformer - Best Practices Guide
101 Things That Can Go Wrong on a Primary Reformer -  Best Practices Guide101 Things That Can Go Wrong on a Primary Reformer -  Best Practices Guide
101 Things That Can Go Wrong on a Primary Reformer - Best Practices Guide
 
Methane Steam Reformer Re-tube Studies
Methane Steam Reformer Re-tube StudiesMethane Steam Reformer Re-tube Studies
Methane Steam Reformer Re-tube Studies
 
Tube Wall Temperature Measurement On Steam Reformers - Best Practices
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesTube Wall Temperature Measurement On Steam Reformers - Best Practices
Tube Wall Temperature Measurement On Steam Reformers - Best Practices
 
Shift Conversion Catalysts - Operating Manual
Shift Conversion Catalysts - Operating ManualShift Conversion Catalysts - Operating Manual
Shift Conversion Catalysts - Operating Manual
 
Steam reforming - The Basics of Reforming
Steam reforming  - The Basics of ReformingSteam reforming  - The Basics of Reforming
Steam reforming - The Basics of Reforming
 
Heating and Cooling of Batch Processes
Heating and Cooling of Batch ProcessesHeating and Cooling of Batch Processes
Heating and Cooling of Batch Processes
 

En vedette

How to use the GBHE Reactor Technology Guides
How to use the GBHE Reactor Technology GuidesHow to use the GBHE Reactor Technology Guides
How to use the GBHE Reactor Technology GuidesGerard B. Hawkins
 
Solid Catalyzed Gas Phase Reactor Selection
Solid Catalyzed Gas Phase Reactor SelectionSolid Catalyzed Gas Phase Reactor Selection
Solid Catalyzed Gas Phase Reactor SelectionGerard B. Hawkins
 
Reactor Modeling Tools - An Overview
Reactor Modeling Tools - An OverviewReactor Modeling Tools - An Overview
Reactor Modeling Tools - An OverviewGerard B. Hawkins
 
Fixed Bed Reactor Scale-up Checklist
Fixed Bed Reactor Scale-up ChecklistFixed Bed Reactor Scale-up Checklist
Fixed Bed Reactor Scale-up ChecklistGerard B. Hawkins
 
Residence Time Distribution Data
Residence Time Distribution DataResidence Time Distribution Data
Residence Time Distribution DataGerard B. Hawkins
 
Orifice Restrictors - Design Guidelines
Orifice Restrictors - Design GuidelinesOrifice Restrictors - Design Guidelines
Orifice Restrictors - Design GuidelinesGerard B. Hawkins
 
Physical properties and thermochemistry for reactor technology
Physical properties and thermochemistry for reactor technologyPhysical properties and thermochemistry for reactor technology
Physical properties and thermochemistry for reactor technologyGerard B. Hawkins
 
Integration of Special Purpose Centrifugal Fans into a Process
Integration of Special Purpose Centrifugal Fans into a ProcessIntegration of Special Purpose Centrifugal Fans into a Process
Integration of Special Purpose Centrifugal Fans into a ProcessGerard B. Hawkins
 
Estimation of Pressure Drop in Pipe Systems
Estimation of Pressure Drop in Pipe SystemsEstimation of Pressure Drop in Pipe Systems
Estimation of Pressure Drop in Pipe SystemsGerard B. Hawkins
 
Reciprocating Compressors - Protection against Crank Case Explosions
Reciprocating Compressors - Protection against Crank Case ExplosionsReciprocating Compressors - Protection against Crank Case Explosions
Reciprocating Compressors - Protection against Crank Case ExplosionsGerard B. Hawkins
 
The Preliminary Choice of Fan or Compressor
The Preliminary Choice of Fan or Compressor The Preliminary Choice of Fan or Compressor
The Preliminary Choice of Fan or Compressor Gerard B. Hawkins
 
Naphtha Steam Reforming Catalyst Reduction by NH3 Cracking
Naphtha Steam Reforming Catalyst Reduction by NH3 CrackingNaphtha Steam Reforming Catalyst Reduction by NH3 Cracking
Naphtha Steam Reforming Catalyst Reduction by NH3 CrackingGerard B. Hawkins
 
Examination of Critical Centrifugal Fans and Blowers
Examination of Critical Centrifugal Fans and BlowersExamination of Critical Centrifugal Fans and Blowers
Examination of Critical Centrifugal Fans and BlowersGerard B. Hawkins
 

En vedette (20)

How to use the GBHE Reactor Technology Guides
How to use the GBHE Reactor Technology GuidesHow to use the GBHE Reactor Technology Guides
How to use the GBHE Reactor Technology Guides
 
Centrifugal Compressors
Centrifugal CompressorsCentrifugal Compressors
Centrifugal Compressors
 
Solid Catalyzed Reactions
Solid Catalyzed Reactions Solid Catalyzed Reactions
Solid Catalyzed Reactions
 
Gas - Liquid Reactors
Gas - Liquid ReactorsGas - Liquid Reactors
Gas - Liquid Reactors
 
Solid Catalyzed Gas Phase Reactor Selection
Solid Catalyzed Gas Phase Reactor SelectionSolid Catalyzed Gas Phase Reactor Selection
Solid Catalyzed Gas Phase Reactor Selection
 
Novel Reactor Technology
Novel Reactor TechnologyNovel Reactor Technology
Novel Reactor Technology
 
Homogeneous Reactors
Homogeneous ReactorsHomogeneous Reactors
Homogeneous Reactors
 
Chemical Process Conception
Chemical Process ConceptionChemical Process Conception
Chemical Process Conception
 
Reactor Modeling Tools - An Overview
Reactor Modeling Tools - An OverviewReactor Modeling Tools - An Overview
Reactor Modeling Tools - An Overview
 
Fixed Bed Reactor Scale-up Checklist
Fixed Bed Reactor Scale-up ChecklistFixed Bed Reactor Scale-up Checklist
Fixed Bed Reactor Scale-up Checklist
 
Residence Time Distribution Data
Residence Time Distribution DataResidence Time Distribution Data
Residence Time Distribution Data
 
Orifice Restrictors - Design Guidelines
Orifice Restrictors - Design GuidelinesOrifice Restrictors - Design Guidelines
Orifice Restrictors - Design Guidelines
 
Physical properties and thermochemistry for reactor technology
Physical properties and thermochemistry for reactor technologyPhysical properties and thermochemistry for reactor technology
Physical properties and thermochemistry for reactor technology
 
Integration of Special Purpose Centrifugal Fans into a Process
Integration of Special Purpose Centrifugal Fans into a ProcessIntegration of Special Purpose Centrifugal Fans into a Process
Integration of Special Purpose Centrifugal Fans into a Process
 
Estimation of Pressure Drop in Pipe Systems
Estimation of Pressure Drop in Pipe SystemsEstimation of Pressure Drop in Pipe Systems
Estimation of Pressure Drop in Pipe Systems
 
Reciprocating Compressors - Protection against Crank Case Explosions
Reciprocating Compressors - Protection against Crank Case ExplosionsReciprocating Compressors - Protection against Crank Case Explosions
Reciprocating Compressors - Protection against Crank Case Explosions
 
The Preliminary Choice of Fan or Compressor
The Preliminary Choice of Fan or Compressor The Preliminary Choice of Fan or Compressor
The Preliminary Choice of Fan or Compressor
 
Process Synthesis
Process SynthesisProcess Synthesis
Process Synthesis
 
Naphtha Steam Reforming Catalyst Reduction by NH3 Cracking
Naphtha Steam Reforming Catalyst Reduction by NH3 CrackingNaphtha Steam Reforming Catalyst Reduction by NH3 Cracking
Naphtha Steam Reforming Catalyst Reduction by NH3 Cracking
 
Examination of Critical Centrifugal Fans and Blowers
Examination of Critical Centrifugal Fans and BlowersExamination of Critical Centrifugal Fans and Blowers
Examination of Critical Centrifugal Fans and Blowers
 

Similaire à Reactor and Catalyst Design

Data Sources For Calculating Chemical Reaction Equilibria
Data Sources For Calculating Chemical Reaction EquilibriaData Sources For Calculating Chemical Reaction Equilibria
Data Sources For Calculating Chemical Reaction EquilibriaGerard B. Hawkins
 
Reactor Modeling Tools – Multiple Regressions
Reactor Modeling Tools – Multiple Regressions Reactor Modeling Tools – Multiple Regressions
Reactor Modeling Tools – Multiple Regressions Gerard B. Hawkins
 
Distillation Sequences, Complex Columns and Heat Integration
Distillation Sequences, Complex Columns and Heat IntegrationDistillation Sequences, Complex Columns and Heat Integration
Distillation Sequences, Complex Columns and Heat IntegrationGerard B. Hawkins
 
How to Use the GBHE Mixing Guides
How to Use the GBHE Mixing GuidesHow to Use the GBHE Mixing Guides
How to Use the GBHE Mixing GuidesGerard B. Hawkins
 
Cost Estimating: Turbo Blowers
Cost Estimating: Turbo BlowersCost Estimating: Turbo Blowers
Cost Estimating: Turbo BlowersGerard B. Hawkins
 
Turbulent Heat Transfer to Non Newtonian Fluids in Circular Tubes
Turbulent Heat Transfer to Non Newtonian Fluids in Circular TubesTurbulent Heat Transfer to Non Newtonian Fluids in Circular Tubes
Turbulent Heat Transfer to Non Newtonian Fluids in Circular TubesGerard B. Hawkins
 
Integration of Special Purpose Reciprocating Compressors into a Process
Integration of Special Purpose Reciprocating Compressors into a ProcessIntegration of Special Purpose Reciprocating Compressors into a Process
Integration of Special Purpose Reciprocating Compressors into a ProcessGerard B. Hawkins
 
Integration of Special Purpose Centrifugal Pumps into a Process
Integration of Special  Purpose Centrifugal Pumps into a ProcessIntegration of Special  Purpose Centrifugal Pumps into a Process
Integration of Special Purpose Centrifugal Pumps into a ProcessGerard B. Hawkins
 
H - Acid Caustic Fusion Stage
H - Acid Caustic Fusion StageH - Acid Caustic Fusion Stage
H - Acid Caustic Fusion StageGerard B. Hawkins
 
Mixing of Gas Liquid Systems
Mixing of Gas Liquid SystemsMixing of Gas Liquid Systems
Mixing of Gas Liquid SystemsGerard B. Hawkins
 
Selection of Heat Exchanger Types
Selection of Heat Exchanger TypesSelection of Heat Exchanger Types
Selection of Heat Exchanger TypesGerard B. Hawkins
 
Troubleshooting in Distillation Columns
Troubleshooting in Distillation ColumnsTroubleshooting in Distillation Columns
Troubleshooting in Distillation ColumnsGerard B. Hawkins
 

Similaire à Reactor and Catalyst Design (20)

Batch Distillation
Batch DistillationBatch Distillation
Batch Distillation
 
Data Sources For Calculating Chemical Reaction Equilibria
Data Sources For Calculating Chemical Reaction EquilibriaData Sources For Calculating Chemical Reaction Equilibria
Data Sources For Calculating Chemical Reaction Equilibria
 
Centrifugation
CentrifugationCentrifugation
Centrifugation
 
Gas Mixing
Gas MixingGas Mixing
Gas Mixing
 
Sedimentation
SedimentationSedimentation
Sedimentation
 
Reactor Modeling Tools – Multiple Regressions
Reactor Modeling Tools – Multiple Regressions Reactor Modeling Tools – Multiple Regressions
Reactor Modeling Tools – Multiple Regressions
 
Distillation Sequences, Complex Columns and Heat Integration
Distillation Sequences, Complex Columns and Heat IntegrationDistillation Sequences, Complex Columns and Heat Integration
Distillation Sequences, Complex Columns and Heat Integration
 
How to Use the GBHE Mixing Guides
How to Use the GBHE Mixing GuidesHow to Use the GBHE Mixing Guides
How to Use the GBHE Mixing Guides
 
Cost Estimating: Turbo Blowers
Cost Estimating: Turbo BlowersCost Estimating: Turbo Blowers
Cost Estimating: Turbo Blowers
 
Turbulent Heat Transfer to Non Newtonian Fluids in Circular Tubes
Turbulent Heat Transfer to Non Newtonian Fluids in Circular TubesTurbulent Heat Transfer to Non Newtonian Fluids in Circular Tubes
Turbulent Heat Transfer to Non Newtonian Fluids in Circular Tubes
 
Large Water Pumps
Large Water PumpsLarge Water Pumps
Large Water Pumps
 
Filtration
FiltrationFiltration
Filtration
 
Integration of Special Purpose Reciprocating Compressors into a Process
Integration of Special Purpose Reciprocating Compressors into a ProcessIntegration of Special Purpose Reciprocating Compressors into a Process
Integration of Special Purpose Reciprocating Compressors into a Process
 
Pressure Systems
Pressure SystemsPressure Systems
Pressure Systems
 
Integration of Special Purpose Centrifugal Pumps into a Process
Integration of Special  Purpose Centrifugal Pumps into a ProcessIntegration of Special  Purpose Centrifugal Pumps into a Process
Integration of Special Purpose Centrifugal Pumps into a Process
 
H - Acid Caustic Fusion Stage
H - Acid Caustic Fusion StageH - Acid Caustic Fusion Stage
H - Acid Caustic Fusion Stage
 
Mixing of Gas Liquid Systems
Mixing of Gas Liquid SystemsMixing of Gas Liquid Systems
Mixing of Gas Liquid Systems
 
Selection of Heat Exchanger Types
Selection of Heat Exchanger TypesSelection of Heat Exchanger Types
Selection of Heat Exchanger Types
 
Spray Drying
Spray DryingSpray Drying
Spray Drying
 
Troubleshooting in Distillation Columns
Troubleshooting in Distillation ColumnsTroubleshooting in Distillation Columns
Troubleshooting in Distillation Columns
 

Plus de Gerard B. Hawkins

Pressure Relief Systems Vol 2
Pressure Relief Systems   Vol 2Pressure Relief Systems   Vol 2
Pressure Relief Systems Vol 2Gerard B. Hawkins
 
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
GAS DISPERSION -  A Definitive Guide to Accidental Releases of Heavy GasesGAS DISPERSION -  A Definitive Guide to Accidental Releases of Heavy Gases
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy GasesGerard B. Hawkins
 
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...Gerard B. Hawkins
 
Theory of Carbon Formation in Steam Reforming
Theory of Carbon Formation in Steam Reforming Theory of Carbon Formation in Steam Reforming
Theory of Carbon Formation in Steam Reforming Gerard B. Hawkins
 
Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...
Adiabatic Reactor Analysis for Methanol Synthesis   Plant Note Book Series: P...Adiabatic Reactor Analysis for Methanol Synthesis   Plant Note Book Series: P...
Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...Gerard B. Hawkins
 
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTSSTEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTSGerard B. Hawkins
 
Calculation of an Ammonia Plant Energy Consumption:
Calculation of an Ammonia Plant Energy Consumption:  Calculation of an Ammonia Plant Energy Consumption:
Calculation of an Ammonia Plant Energy Consumption: Gerard B. Hawkins
 
Piping and Vessels Flushing and Cleaning Procedure
Piping and Vessels Flushing and Cleaning ProcedurePiping and Vessels Flushing and Cleaning Procedure
Piping and Vessels Flushing and Cleaning ProcedureGerard B. Hawkins
 
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS Gerard B. Hawkins
 
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...Gerard B. Hawkins
 
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...Gerard B. Hawkins
 
Getting the Most Out of Your Refinery Hydrogen Plant
Getting the Most Out of Your Refinery Hydrogen PlantGetting the Most Out of Your Refinery Hydrogen Plant
Getting the Most Out of Your Refinery Hydrogen PlantGerard B. Hawkins
 
EMERGENCY ISOLATION OF CHEMICAL PLANTS
EMERGENCY ISOLATION OF CHEMICAL PLANTS EMERGENCY ISOLATION OF CHEMICAL PLANTS
EMERGENCY ISOLATION OF CHEMICAL PLANTS Gerard B. Hawkins
 
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND PRELIMINARY ENGINEER...
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND  PRELIMINARY ENGINEER...PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND  PRELIMINARY ENGINEER...
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND PRELIMINARY ENGINEER...Gerard B. Hawkins
 
Purificación – Mecanismos de Reacción
Purificación – Mecanismos de Reacción Purificación – Mecanismos de Reacción
Purificación – Mecanismos de Reacción Gerard B. Hawkins
 
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide
Amine Gas Treating Unit  - Best Practices - Troubleshooting Guide Amine Gas Treating Unit  - Best Practices - Troubleshooting Guide
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
 
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...Gerard B. Hawkins
 
GBHE Over View jan_13_español
GBHE Over View jan_13_españolGBHE Over View jan_13_español
GBHE Over View jan_13_españolGerard B. Hawkins
 

Plus de Gerard B. Hawkins (20)

Pressure Relief Systems Vol 2
Pressure Relief Systems   Vol 2Pressure Relief Systems   Vol 2
Pressure Relief Systems Vol 2
 
Pressure Relief Systems
Pressure Relief Systems Pressure Relief Systems
Pressure Relief Systems
 
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
GAS DISPERSION -  A Definitive Guide to Accidental Releases of Heavy GasesGAS DISPERSION -  A Definitive Guide to Accidental Releases of Heavy Gases
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
 
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...
 
Theory of Carbon Formation in Steam Reforming
Theory of Carbon Formation in Steam Reforming Theory of Carbon Formation in Steam Reforming
Theory of Carbon Formation in Steam Reforming
 
Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...
Adiabatic Reactor Analysis for Methanol Synthesis   Plant Note Book Series: P...Adiabatic Reactor Analysis for Methanol Synthesis   Plant Note Book Series: P...
Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...
 
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTSSTEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS
 
Calculation of an Ammonia Plant Energy Consumption:
Calculation of an Ammonia Plant Energy Consumption:  Calculation of an Ammonia Plant Energy Consumption:
Calculation of an Ammonia Plant Energy Consumption:
 
Pickling & Passivation
Pickling & PassivationPickling & Passivation
Pickling & Passivation
 
Piping and Vessels Flushing and Cleaning Procedure
Piping and Vessels Flushing and Cleaning ProcedurePiping and Vessels Flushing and Cleaning Procedure
Piping and Vessels Flushing and Cleaning Procedure
 
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
 
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...
 
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...
 
Getting the Most Out of Your Refinery Hydrogen Plant
Getting the Most Out of Your Refinery Hydrogen PlantGetting the Most Out of Your Refinery Hydrogen Plant
Getting the Most Out of Your Refinery Hydrogen Plant
 
EMERGENCY ISOLATION OF CHEMICAL PLANTS
EMERGENCY ISOLATION OF CHEMICAL PLANTS EMERGENCY ISOLATION OF CHEMICAL PLANTS
EMERGENCY ISOLATION OF CHEMICAL PLANTS
 
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND PRELIMINARY ENGINEER...
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND  PRELIMINARY ENGINEER...PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND  PRELIMINARY ENGINEER...
PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND PRELIMINARY ENGINEER...
 
Purificación – Mecanismos de Reacción
Purificación – Mecanismos de Reacción Purificación – Mecanismos de Reacción
Purificación – Mecanismos de Reacción
 
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide
Amine Gas Treating Unit  - Best Practices - Troubleshooting Guide Amine Gas Treating Unit  - Best Practices - Troubleshooting Guide
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide
 
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...
 
GBHE Over View jan_13_español
GBHE Over View jan_13_españolGBHE Over View jan_13_español
GBHE Over View jan_13_español
 

Dernier

Nanopower In Semiconductor Industry.pdf
Nanopower  In Semiconductor Industry.pdfNanopower  In Semiconductor Industry.pdf
Nanopower In Semiconductor Industry.pdfPedro Manuel
 
Cybersecurity Workshop #1.pptx
Cybersecurity Workshop #1.pptxCybersecurity Workshop #1.pptx
Cybersecurity Workshop #1.pptxGDSC PJATK
 
UiPath Studio Web workshop series - Day 7
UiPath Studio Web workshop series - Day 7UiPath Studio Web workshop series - Day 7
UiPath Studio Web workshop series - Day 7DianaGray10
 
COMPUTER 10 Lesson 8 - Building a Website
COMPUTER 10 Lesson 8 - Building a WebsiteCOMPUTER 10 Lesson 8 - Building a Website
COMPUTER 10 Lesson 8 - Building a Websitedgelyza
 
9 Steps For Building Winning Founding Team
9 Steps For Building Winning Founding Team9 Steps For Building Winning Founding Team
9 Steps For Building Winning Founding TeamAdam Moalla
 
Things you didn't know you can use in your Salesforce
Things you didn't know you can use in your SalesforceThings you didn't know you can use in your Salesforce
Things you didn't know you can use in your SalesforceMartin Humpolec
 
How to Effectively Monitor SD-WAN and SASE Environments with ThousandEyes
How to Effectively Monitor SD-WAN and SASE Environments with ThousandEyesHow to Effectively Monitor SD-WAN and SASE Environments with ThousandEyes
How to Effectively Monitor SD-WAN and SASE Environments with ThousandEyesThousandEyes
 
Salesforce Miami User Group Event - 1st Quarter 2024
Salesforce Miami User Group Event - 1st Quarter 2024Salesforce Miami User Group Event - 1st Quarter 2024
Salesforce Miami User Group Event - 1st Quarter 2024SkyPlanner
 
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdfIaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdfDaniel Santiago Silva Capera
 
RAG Patterns and Vector Search in Generative AI
RAG Patterns and Vector Search in Generative AIRAG Patterns and Vector Search in Generative AI
RAG Patterns and Vector Search in Generative AIUdaiappa Ramachandran
 
UWB Technology for Enhanced Indoor and Outdoor Positioning in Physiological M...
UWB Technology for Enhanced Indoor and Outdoor Positioning in Physiological M...UWB Technology for Enhanced Indoor and Outdoor Positioning in Physiological M...
UWB Technology for Enhanced Indoor and Outdoor Positioning in Physiological M...UbiTrack UK
 
Introduction to Quantum Computing
Introduction to Quantum ComputingIntroduction to Quantum Computing
Introduction to Quantum ComputingGDSC PJATK
 
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdfUiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdfDianaGray10
 
Introduction to Matsuo Laboratory (ENG).pptx
Introduction to Matsuo Laboratory (ENG).pptxIntroduction to Matsuo Laboratory (ENG).pptx
Introduction to Matsuo Laboratory (ENG).pptxMatsuo Lab
 
UiPath Studio Web workshop series - Day 6
UiPath Studio Web workshop series - Day 6UiPath Studio Web workshop series - Day 6
UiPath Studio Web workshop series - Day 6DianaGray10
 
Artificial Intelligence & SEO Trends for 2024
Artificial Intelligence & SEO Trends for 2024Artificial Intelligence & SEO Trends for 2024
Artificial Intelligence & SEO Trends for 2024D Cloud Solutions
 
Apres-Cyber - The Data Dilemma: Bridging Offensive Operations and Machine Lea...
Apres-Cyber - The Data Dilemma: Bridging Offensive Operations and Machine Lea...Apres-Cyber - The Data Dilemma: Bridging Offensive Operations and Machine Lea...
Apres-Cyber - The Data Dilemma: Bridging Offensive Operations and Machine Lea...Will Schroeder
 
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPAAnypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPAshyamraj55
 
GenAI and AI GCC State of AI_Object Automation Inc
GenAI and AI GCC State of AI_Object Automation IncGenAI and AI GCC State of AI_Object Automation Inc
GenAI and AI GCC State of AI_Object Automation IncObject Automation
 
Babel Compiler - Transforming JavaScript for All Browsers.pptx
Babel Compiler - Transforming JavaScript for All Browsers.pptxBabel Compiler - Transforming JavaScript for All Browsers.pptx
Babel Compiler - Transforming JavaScript for All Browsers.pptxYounusS2
 

Dernier (20)

Nanopower In Semiconductor Industry.pdf
Nanopower  In Semiconductor Industry.pdfNanopower  In Semiconductor Industry.pdf
Nanopower In Semiconductor Industry.pdf
 
Cybersecurity Workshop #1.pptx
Cybersecurity Workshop #1.pptxCybersecurity Workshop #1.pptx
Cybersecurity Workshop #1.pptx
 
UiPath Studio Web workshop series - Day 7
UiPath Studio Web workshop series - Day 7UiPath Studio Web workshop series - Day 7
UiPath Studio Web workshop series - Day 7
 
COMPUTER 10 Lesson 8 - Building a Website
COMPUTER 10 Lesson 8 - Building a WebsiteCOMPUTER 10 Lesson 8 - Building a Website
COMPUTER 10 Lesson 8 - Building a Website
 
9 Steps For Building Winning Founding Team
9 Steps For Building Winning Founding Team9 Steps For Building Winning Founding Team
9 Steps For Building Winning Founding Team
 
Things you didn't know you can use in your Salesforce
Things you didn't know you can use in your SalesforceThings you didn't know you can use in your Salesforce
Things you didn't know you can use in your Salesforce
 
How to Effectively Monitor SD-WAN and SASE Environments with ThousandEyes
How to Effectively Monitor SD-WAN and SASE Environments with ThousandEyesHow to Effectively Monitor SD-WAN and SASE Environments with ThousandEyes
How to Effectively Monitor SD-WAN and SASE Environments with ThousandEyes
 
Salesforce Miami User Group Event - 1st Quarter 2024
Salesforce Miami User Group Event - 1st Quarter 2024Salesforce Miami User Group Event - 1st Quarter 2024
Salesforce Miami User Group Event - 1st Quarter 2024
 
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdfIaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
IaC & GitOps in a Nutshell - a FridayInANuthshell Episode.pdf
 
RAG Patterns and Vector Search in Generative AI
RAG Patterns and Vector Search in Generative AIRAG Patterns and Vector Search in Generative AI
RAG Patterns and Vector Search in Generative AI
 
UWB Technology for Enhanced Indoor and Outdoor Positioning in Physiological M...
UWB Technology for Enhanced Indoor and Outdoor Positioning in Physiological M...UWB Technology for Enhanced Indoor and Outdoor Positioning in Physiological M...
UWB Technology for Enhanced Indoor and Outdoor Positioning in Physiological M...
 
Introduction to Quantum Computing
Introduction to Quantum ComputingIntroduction to Quantum Computing
Introduction to Quantum Computing
 
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdfUiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
 
Introduction to Matsuo Laboratory (ENG).pptx
Introduction to Matsuo Laboratory (ENG).pptxIntroduction to Matsuo Laboratory (ENG).pptx
Introduction to Matsuo Laboratory (ENG).pptx
 
UiPath Studio Web workshop series - Day 6
UiPath Studio Web workshop series - Day 6UiPath Studio Web workshop series - Day 6
UiPath Studio Web workshop series - Day 6
 
Artificial Intelligence & SEO Trends for 2024
Artificial Intelligence & SEO Trends for 2024Artificial Intelligence & SEO Trends for 2024
Artificial Intelligence & SEO Trends for 2024
 
Apres-Cyber - The Data Dilemma: Bridging Offensive Operations and Machine Lea...
Apres-Cyber - The Data Dilemma: Bridging Offensive Operations and Machine Lea...Apres-Cyber - The Data Dilemma: Bridging Offensive Operations and Machine Lea...
Apres-Cyber - The Data Dilemma: Bridging Offensive Operations and Machine Lea...
 
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPAAnypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPA
 
GenAI and AI GCC State of AI_Object Automation Inc
GenAI and AI GCC State of AI_Object Automation IncGenAI and AI GCC State of AI_Object Automation Inc
GenAI and AI GCC State of AI_Object Automation Inc
 
Babel Compiler - Transforming JavaScript for All Browsers.pptx
Babel Compiler - Transforming JavaScript for All Browsers.pptxBabel Compiler - Transforming JavaScript for All Browsers.pptx
Babel Compiler - Transforming JavaScript for All Browsers.pptx
 

Reactor and Catalyst Design

  • 1. GBH Enterprises, Ltd. Process Engineering Guide: GBHE-PEG-RXT-807 Reactor and Catalyst Design Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the information for its own particular purpose. GBHE gives no warranty as to the fitness of this information for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 2. Process Engineering Guide: Reactor and Catalyst Design CONTENTS SECTION 0 INTRODUCTION/PURPOSE 2 1 SCOPE 2 2 FIELD OF APPLICATION 2 3 DEFINITIONS 2 4 CATALYST DESIGN 2 4.1 4.2 4.3 Equivalent Pellet Diameter Voidage Pellet Density 3 6 8 5 REACTOR DESIGN 8 6 CATALYST SUPPORT 10 6.1 Choice of Support 10 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 3. TABLES 1 CATALYST SUPPORT SHAPES 12 2 SECONDARY REFORMER SPREADSHEET 13 FIGURES 1 GRAPH OF EFFECTIVENESS v THIELE MODULUS 4 2 VARIATION OF COSTS WITH CATALYST SIZE 6 3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE 8 4 VARIATION OF COSTS WITH VESSEL DIAMETER 9 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 4. 0 INTRODUCTION/PURPOSE When the catalyst chemistry of a new fixed feed chemical reaction has been developed, decisions need to be made about the catalyst design. The issues that need to be decided are: (a) The catalyst particle size. (b) The catalyst shape to give a reasonable optimum pressure drop in the catalyst bed. (c) The catalyst particle density to make the catalyst particles reasonably effective. These issues are closely related to the reactor shape and the cost of pressure drop. This Process Engineering Guide provides some explanation of these issues and equations by which the key parameters can be determined. 1 SCOPE This Process Engineering Guide deals with the design of the catalyst, particularly its size and shape, and the reactor geometry as well as catalyst support types. It does not cover the chemical selection of the catalyst. 2 FIELD OF APPLICATION This Guide applies to process engineers and technologists in GBH Enterprises worldwide, who may be involved in the design of reactors and catalysts. 3 DEFINITIONS For the purposes of this Guide no specific definitions apply. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 5. 4 CATALYST DESIGN The design of catalyst particles can be characterized by three independent variables: (a) Equivalent pellet diameter de (b) Voidage e (c) Density ρ These can all be optimized. 4.1 Equivalent Pellet Diameter Larger catalyst size leads to: (a) Lower pressure drop in reactor: (1) Lower compression power. (b) Lower catalyst effectiveness: (1) (2) (3) Larger catalyst volume Higher vessel cost Higher catalyst cost. Thiele modulus F = b x de .......................................... (1) where: b is assumed to be a constant (probably related to the pore structure) de is the equivalent sphere diameter of the particle. de = 6 x particle volume / particle surface area .......................... (2) Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 6. For a spherical catalyst particle: Effectiveness E = 3/F x (1/tanh(F) - 1/F)) ................. (3) The constant b may be calculated from measurements of the effective catalyst activity at two different particle sizes. The intrinsic activity is defined as: Intrinsic Activity = Apparent Activity / Effectiveness ....... (4) 4.1.1 Example: Calculation of Intrinsic Activity Results from pellet testing give: Test Pellet size 1 2 2 4 Apparent Activity 4.2 3 Figure 1 shows a graph of Effectiveness v Thiele Modulus based on Equation 3. FIGURE 1 GRAPH OF EFFECTIVENESS v THIELE MODULUS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 7. What are the Thiele Moduli for the different pellet sizes and the intrinsic activity? Using Figure 1, it can be seen that to get an apparent activity increase of 40% for a halving of the pellet diameter, the only points that will fit are: F = 2, E = 0.8 F = 4, E = 0.57 Thus, from Equation 4, the Intrinsic activity is 4.2 / 0.8 = 5.25. 4.1.2 Pressure Drop For turbulent flow: Pressure drop ΔP = 2 x Velocity head x 1.75 x (1 - e) x L / (e3 x de) (5) where: e L is the bed voidage is vessel length or height. For axial flow: Capitalized cost = Cp x V / (de x D6) .............................. (6) where: Cp V D is a constant for fixed voidage is the catalyst volume is the catalyst bed diameter. 4.1.3 Catalyst Volume Catalyst volume (V): V = V0 / E ................................................................ (7) Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 8. where: V0 is the catalyst volume for unit effectiveness. Vessel cost: Capital cost = Cv x (V + D3) ....................................... (8) where: Cv is a constant. Catalyst cost: Capitalized cost = Ccat x V ............................................ (9) where: Ccat is a constant that depends on catalyst cost and catalyst change frequency. Calculate the parameter (q): q = 1.89 / (Cv + Ccat) x (Cv / V0)0.67 x (Cp x b)0.33 .............................(10) For axial flow in an adiabatic pressure vessel optimum pellet size is given by: q = (b x de)0.375 x (0.4 + 0.022 x (b x de)2) .................................... (11) If q < 20, calculate: de = (2.5 x q)0.375 / b ................................................. (12) If q > 20, calculate: d e = (q / 0.022)3/14 / b ................................................. (13) Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 9. If optimum pellet diameter is greater than 3mm If optimum diameter is less than 3mm - use pellets or rings. - examine other supports (see later). The necessary data to determine the Thiele Modulus and hence the optimum pellet diameter of most of the catalysts that GBHE uses is not available. Typical optimum particle sizes: Ammonia plant: HT Shift Methanator Secondary Reformer Methanol synthesis 3.8 mm 1.8 mm 0.1 mm 4.7 mm Figure 2 shows the variation of capitalized costs (pressure drop cost, vessel cost, catalyst cost and total cost) and effectiveness with catalyst size. FIGURE 2 VARIATION OF COSTS WITH CATALYST SIZE Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 10. 4.2 Voidage Higher voidage leads to: (a) Lower pressure drop. (b) Larger catalyst vessel. It is possible to increase voidage by moving to more eccentric particles, i.e. length / diameter L / D ratio greater than 1.3, or by using rings instead of pellets. 4.2.1 Pressure Drop Cost Pressure drop cost: Capitalized cost = Cp1 x Vs / D6 / e3 ................. (14) where: Cp1 is a constant for constant particle diameter, etc. Vs is the solid volume of catalyst D is the vessel diameter e is the bed voidage. Vs = V x (1 - e) ............................................................... (15) where: V is the catalyst volume of catalyst. 4.2.2 Vessel Cost Vessel cost: Capital cost = Cv x (V + D3) ............................................. (16) where: Cv is a constant Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 11. Calculate the parameter (w): w = 1.89 x (Cp1 / Cv / Vs 2 )0.33 ...................................... (17) For axial flow in an adiabatic pressure vessel: Optimum voidage = w0.5 / (1 + w 0.5) If optimum voidage is less than 0.4 If optimum voidage is greater than 0.4 Typical optimum voidages: ........................... (18) - use pellets or beads. - use rings or maybe eccentric Ammonia plant secondary reformer Ammonia plant methanator Methanol plant converter 0.5 0.36 0.5 The catalyst needs to be strong to maintain a voidage above 0.4, so GBHE still uses pellets for methanol synthesis catalyst. Figure 3 shows the variation of costs (pressure drop cost, vessel cost and total cost) with catalyst bed voidage. FIGURE 3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 12. 4.3 Pellet Density Higher density gives: (a) (b) More active catalyst component. Lower pore volume: (1) Lower effectiveness (2) Possibly lower selectivity. There appear to be no established relationships to determine optimum pellet density. 5 REACTOR DESIGN Optimum length to diameter ratio of the reactor may be determined as follows: Pressure drop cost: Capitalized cost = Cp x V / (de x D6) ................................ (6) where: Cp is a constant for fixed voidage V is the catalyst volume de is the equivalent sphere diameter D is the catalyst bed diameter. Vessel cost: Capital cost = Cv x (V + D3) ............................................ (8) where: Cv is a constant. Optimum diameter D = ( 2 x Cp x V / (Cv x de))1/9 ...... (19) If optimum L / D ratio is greater than 1 If optimum L / D ratio is between 0.2 and 1 If optimum L / D ratio is less than 0.2 - use axial flow in vertical vessel. - consider horizontal vessel. - consider radial flow vessel. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 13. Typical optimum L / D ratios: Ammonia plant secondary reformer Ammonia plant desulfurizer Ammonia plant LT shift 0.8 2.8 1.1 Figure 4 shows the variation of costs (vessel cost, pressure drop cost and total cost) with vessel diameter). FIGURE 4 6 VARIATION OF COSTS WITH VESSEL DIAMETER CATALYST SUPPORT TYPES The following catalyst support types are available: (a) (b) (c) (d) (e) (f) Pellets, beads, extrudates Rings. Monoliths (honeycombs). Ceramic foams (macroporous catalyst): (1) Sheet (2) Pellets. Knitted wire mesh. Multi-holed extrudates Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 14. 6.1 Choice Of Support 6.1.1 General Guidance (a) Use pellets, rings or extrudates when optimum particle diameter is greater than 2 mm. (b) Use rings if optimum voidage is greater than 0.4. (c) Use monoliths if optimum particle diameter is less than 2 mm and cost of pressure drop is high. (d) Use ceramic foams or knitted wire mesh if optimum particle diameter is less than 1 mm. (e) Use multi-holed extrudates when optimum particle diameter is less than 2 mm and using a tubular reactor. Other factors that come into play are: (1) Length / diameter limitations. (2) Fouling. (3) Heat transfer limit in tubular reactors. (4) Vessel length / particle diameter ratio. (5) Degree of conversion required. (6) Want to be film diffusion limited. 6.1.2 Quantitative Evaluation The best method to evaluate alternative catalysts is on a spreadsheet model. In order to do this the supports need to be characterized. Since most novel supports are only generally used when the catalyst is severely pore diffusion limited (in order to get high surface areas), they can be characterized most easily on the basis of their geometric surface area. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 15. The types of support can be characterized by: Total bed voidage e = 1 - (1- eb ) x (1- ep) ................................ (20) where: eb ep is the Interparticle voidage is the Intraparticle voidage. Specific geometric surface area per unit volume of bed (As): As = 6 x (1- e) / de ........................................... (21) where: de is the equivalent sphere diameter. Specific pressure drop (Ps) is the pressure drop as velocity heads per unit geometric surface area. For turbulent flow through pellets, spheres, rings, gauze or ceramic foams: Ps = 0.58 / eb3 …………………................................ (22) For multi-holed extrudates of typical dimensions (particle size / de = 4): Ps = 0.18 / eb3 ............................................................. (23) For monoliths with turbulent flow: Ps = 0.015 / ep3 ......................................................... (24) Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 16. For monoliths with laminar flow (Re < 3500 ): Reynolds number Re = actual velocity x hole diameter / viscosity.. (25) Hole diameter = 2/3 x de x ep / (1 – ep) ................................. (26) Ps = 16 / Re / ep3 ……………...................................................... (27) Pressure drop: Pressure drop = Ps x surface area x superficial velocity head ... (28) 6.1.3 Cost of Catalyst For some types of support it is most appropriate to measure the cost of the catalyst per unit volume, whereas for others, it is appropriate to measure it per unit geometric surface area. The vessel cost can be determined as before. Table 1 details typical manufacturing costs for each catalyst support shape. TABLE 1 CATALYST SUPPORT SHAPES Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 17. 6.1.4 Example: Secondary Reformer What is the optimum support and surface area / unit volume for the following example: Surface area required A = 6000 m2 Cost of vessel Cd = 3600 (V + D3) Capitalized pressure drop cost Cp = £2 / pascal Mass flow M = 38 kg / s Density = 5 kg / m3 Catalyst life = 2 yrs Viscosity * 1000 = 0.4 Factor for optimum diameter b = 1990 The optimum support and surface area / unit volume can be determined from Table 2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 18. TABLE 2 SECONDARY REFORMER SPREADSHEET Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 19. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com