C Reactors are used in processing facilities to contain catalysts that promote chemical transformation of feeds or as agents to remove unrequired materials from feeds, Reactors are generally vertical steel hollow vessels and often operate under very high tempera- tures and pressures, One of the principal layout fe tures of the reactor is the requirement for cat loading and unloading. The use of catalystcharged vessels are essential t0 modern processes and have found widespread application in the production of chemical and refinery products. This chapter highlights the general requirements for reactor plant yout design. It provides instructions on how to locate nozzles, instruments, piping, and controls to provide convenient and safe platforms for ‘operator and maintenance access PROCESS OPERATION ‘There are many catalyst-charged vessels within the cat egory of reactors, mainly because their characteristics and layout requirements are similar, Examples .of these are desulfurizers, methanators, and guard cham- bers. The desulfurizer, which usually operates with a twin vessel, is responsible for the removal of sulfur from feedstock by absorbing the sulfur on the inter nally loaded catalyst. When the catalyst becomes satu- rated with sulfur, regeneration takes place and the spent catalyst becomes refurbished. Exhibit 9-1 shows a typical desulfurizer process arrangement. The reactor used in a typical hydrotreater unit is more versatile, in the hydrotreating process, the treated stream is mixed with hydrogen and heated to between 500° and 800° F (260° to 427° C). The hydro- gen-oil mixture is then charged to a reactor filled with a pelleted catalyst, and the following reactions take place: * The hydrogen combines with sulfur to form hydro: gen sulfide. CHAPTER Reactors + Some of the nitrogen is converted to ammoni * Any metals entrained in the oi are deposited on the catalyst Some of the olefins, aromatics, and naphthenes be- come hydrogen saturated and some cracking takes place, causing the formation of butanes, propane, and lighter gases. Exhibit 9-2 shows a typical hydro- treater process arrangement. Caralysts: promote a reaction but do not reaét in any way themselves. The catalyst used inside reactors is generally ball or pellet shaped and, depending on the type of service, can be made from a variety of mate rials, including alumina, zine oxide, or even such an expensive metal as platinum, DESIGN CONSIDERATIONS FOR REACTORS Although some reactors (eg, those used in methanol and catalytic reforming units) are spherical, most are vertically mounted vessels with elliptical heads. There are fewer connections for the plant layout designe to be concerned with than there are with the distillation tower. Generally, connections are limited to inlet and outlet, maintenance access, unloading, simple, and temperature, Internally, reactors are furnished with bed supports, screens, inlet baffles, outlet collectors, catalysts, and inert materials. Exhibit 9-3 depicts a typi- cal reactor and its principal components Nozzle requirements and overall dimensions ofthe reactor are highlighted on the process vessel sketch furnished by process engineering and are included in the process release package. If the reactor operates in a high-pressure service, it is recommended, for clear- ance purposes, that the plant layout designer obtain the shell thickness of the vessel before proceeding with layout arrangements. Exhibit 9-4 shows a typical reactor process vessel sketch, and Exhibit 9.5 shows high-pressure reactor. 203204 i Kock OUT Daun EXHIBIT 9-1 Desulfurizer Process caroutey Cesutruermers EXHIBIT 9-2 Hydrotreater Process euneae Fb FEED EXCHANGERS LOCATION OF REACTORS Reactors are located within a process unit adjacent 10 related equipment and in a suitable position for oper- ation and catalyst loading and unloading, A reactor ‘operates in sequence and close to a furnace because ‘expensive high-temperature piping runs must be mia- imized. Exhibit 9-6 illustrates a partial plot plan of a bydrotreater unit. SUPPORT AND ELEVATION ‘There are four principal methods of support for rex: tors: a skirt from a concrete foundation, lugs from eS ->> ‘Process Plant Layout and Piping Design Reroemer EXHIBIT 9-3. Typical Reactor twee Manresa zie Recess Teweeestuee wee ouper perett hezaLe MauDue, concrete piers, a ring girder from a concrete table top, and a skirt from a concrete table top. Exhibit 9-7 de picts these four arrangements, Reactor elevation is dictated by the catalyst’s un- loading nozzle or clearance for the outlet piping, whichever results in the lower tangent line elevation ‘The tangent line elevation, however, could be much higher to suit specific client unloading requirements205 EXHIBIT 9-4 Process Vessel Sketch NOZZLE SOMA NMpol size [SERVICE (a Booster INLET a B¥boo% eF | OUTLET $ SMeoot er | SAMPLE T Méo0% BT renrecetsnel [uc fiteocter |exranysr ROP ouT| IMAnTENsACE] MA |24*Gooter MZCevs EXHIBIT 9-5 High-Pressure Reactor EXHIBIT 9.6 Partial Plot Plan for a Hydrotreater Unit - a sueae iM cunewe 5 uence | 1 ! ouece : Pumps Hopi t 1 lo'-12"/ 260 -2ot Waemes ober wall THigeness PPE phcxe eederoe, | PT ems. 1 a UatoabIng as AeEA |206. pene Rt A EXHIBIT 9-7 Methods for Reactor Support Rexcteoe “Tar a. Skirt Supported (Foundation) i Resctes a Lp ene cmnee eesctoe phytase cenceere Bisse b. Lug Supported eens P< SH | | conesere ce TOT c. Ring Girder Supported a “Process Plant Layout and Piping Design d. Skirt Supported (Table Top)207 Las}e eg, truck unloading). Exhibit 9-8 depicts minimum Jevation requirements, and Exhibit 9-9 shows direct inloading into a truck. To set the elevation of reactors, he plant layout designer requires the following infor- nation: Reactor dimensions. ‘Type of heads Support details Bottom outlet size. Unloading nozzle size. Client preference for catalyst handling. NOZZLE LOCATIONS AND ELEVATIONS Nozzles are located to suit process operation and haintenance requirements and to facilitate an eco- EXHIBIT 9.8 Minimum Reactor Blevation Requirements Minium To Sut PPE supeoet , 0% low-Fomit DEA EXHIBIT 9-9 Direct Unloading from a Reactor to a Truck208 EXHIBIT 9-10 ‘Top-Head Nozzle Arrangements ER 10, Towers) ELeyATION: WWLET NozZL MAINTENANCE Recess ELEVATION La nomic and orderly interconnection of piping between the reactor and related equipment, The following in- formation is required to locate and elevate reactor novzles Process vessel sketch. Instrument vessel sketch, Piping and instrumentation Piping line Ti + Nozzle summary. Plant layout specification. + Insulation requirements, The process inlet i located at the top head of the reactor along with maintenance access, which is used for catalyst loading, On small-diameter reactors whose space is limited, the inlet nozzle can be integral with maintenance access, Exhibit 9-10 shows typical top: head arrangements ‘The process outlet and the catalyst unloading, no: ‘Process Plant Layout and Piping Design ze are located on the botom head of the reactor, If the reactor is skirt supported, the outlet is arranged like a tower bottoms outlet, If supported by lugs or by ring girder, the nozzle is vertical on the centerline of the vessel that terminates at the nozdle flange. The catalyst unloading nozzle is angled from the bottom head to clear the skirt and is positioned beoween the piers on lug-supported reactors and below the table top on ring girder-supported reactors. Exhibit 9-11 depicts (ypical bottom-head arrangements, In certain cases, especially with stacked reactors, catalyst unload- ing nozdes are located in the side shell of the reactor, as shown in Exhibit 9-12. : Temperature instruments are usually required at reactors; they are used to measure the temperature at different levels of the catalyst bed. These instruments can be individual nozles located at various levels on the shell of the reactor or, to minimize multiple con- nections, immersed in a well from the top of the reac- tor, either on an individual nozele or through the maintenance access. Instrument requirements for re-EXHIBIT 9.11 CATALYST. Bottom-ead Nozzle ONE NOZZLE UNLOADING Arrangements DIAMETER Nozzle Mini \ ~ ouTLeT Kaun Rois TANGENT Pow OUTSIDE 230 pete us Rains “TASS ELEVATION PLAN SkizT SuPPoRTED By eaTbLy ST UNoADING Neowzce ELEVaTION PLAN LEG Suppoereo sually highlighted on a vessel instrument ich that is furnished by the instrument engineer. it 9-13 illustrates side shell-mounted tempera- sre instruments, and Exhibit 9-14 shows the top-head, srtical arrangement. Sample probe connections, which are sometimes vecified, are usually located on the side shell of the sssel as shown in Exhibit 9-15, LATFORM ARRANGEMENTS atforms are required at reactors for access to valves, struments, blinds, maintenance accesses, and cata- st loading as well as at stacked reactors for catalyst unloading, Platform elevations are determined by the items that require operation and maintenance; on tall reactors, platform elevations are set accommodate a maximum ladder run length of 30 f (9150 mm). Exhibit 9-16 shows platform and ladder elevation re- quirements, Reactors taller than 30 ft (9,150 mm) should be treated much like towers (see Chapter 10) for plat- form requirements except that, for reactors, interme- diate platforms and ladders are required only for ac» cess to temperature instruments, sample probes, catalyst unloading nozzles at stacked vessels, and max. imum ladder runs, Because of the economics of plat- form bracket welding or client preference, however, reactors must sometimes be surrounded by steel Reactors210 EXHIBIT 9-12 Side Shell~Mounted Catalyst Unloading Nozzles ANGLED HeeiZon ToL Nozze wozale veeaue ‘Ey se camnerer Surpoet ese EXHIBIT 9-13 Side Shell-Mounted Temperature Connections WITHOZAWAL er structures with stairs for operator and maintenance access. On reactors shorter than 30 ft (9,150 mm), only a top-head platform is needed. Exhibits 9-17 through 9-21 show typical reactor platform arrangements, PIPING ARRANGEMENTS Reactor piping must be arranged for ease of support and positioned to suit interconnection with related Process Plant Layout and Piping Design enone ene sentra RRR EXHIBIT 9-14 Vertically Mounted Temperature Connection WITRDZAWAL, SPACE eet EESTI EXHIBIT 9-15 Sample Probe Connection WITH eAWAL race,201 Jor WeAD PLATFORM EXHIBIT 9-16 VALE, VET, Tewpegaruee Reactor Platform and Nt Romeo oe ler Elevation INSTROMEWT ¢ CATALYST Requirements Leap imiG ey he nee T 280 A EMPERA TARE J WFTRIMENIT Kecess ye by Lanner of PATRORM SAMPLE connection A" heceoe BY pi PLATFORM ny CATALYST UNLOADING Acceos Feo GRADE 2 PLATFORM steemeoire _/ “as Te Sor sexinmuim LApDES day212 a EXHIBIT 9-17 Vessel-Supported Plavform Arrangement TEMP RZATURE In! (emer IyTeeMepUTe, PATROEM Level aa eee ST RRBET7 , 7 Tv r CTA T ye APo7 Toso ie J wens ahol/one Leelee (yrcat Tues $i9Es) Jee HEAD PtATRoeM LeveL EXHIBIT 9. Single Platform Arrangement H- 4 ELEVATION! ——— — ————————T “Process Plant Layout! and Piping Design EXHIBIT 9-19. Structure-Supported Platform Net eoMensTe Tr ki caranys Tease NozeLe Tee Heap PiAtroam LeveL213 EXHIBIT 9-20 Top Platform Arrangements weemowenG@) ‘Teeical. ree } fuciLiaay ZEONNEETIONS CONNECTION eS it214 apa a EXHIBIT 9-21 Mukipte-Reactor ™, Lok Arrangement i 7 ‘EXHIBIT 9.22 Single Reactor Piping ‘Arrangement eee i Process Plant Layout and Piping Desig215 EXQUBIT 9.23 Reactors in Series: Manually Operated Vaive Manifold ELEVATION: tuipment, Because reactors often operate at very gh temperatures, piping must be arranged with suffi- ant flexibility to absorb excessive stress under usual verating conditions. Piping at reactors or other similar catalyst operating uuipment can be relatively simple in configuration, shown in the process flow diagram in Exhibit 9-2, or are sophisticated, as shown in the flow diagram in hibit 9-1. In the single-reactor arrangement, which Sno controls to influence the design, the piping can EOBIT 9.24 Reactors in Series: ' Remotely Operated Valve Manifold BLSvaTion: be routed directly between related equipment to suit economics, flexibility, and supports, as shown in Ex- hibit 9-22. Ifthe facility operates in a series, the piping system is designed to accommodate regeneration of a catalyst in one reactor while the other is still on stream, as shown in Exhibit 9-23. To do this, the sys- tem is furnished with controls and crossover bypasses. For ease of operation, the valve manifolds for regener- ation should be located at grade. If these valves are controlled remotely, however, the overhead manifold ——— Reacior:216. EXHIBIT 9.25 Davit Arrangement ReUEr valves \ + HET Tv wae RE, Saigon Se NOaELE Loapinics acs UNLOAD NG BREA can be located at the top-head platform, as shown in Exhibit 9-24 Relief valves are usually furnished as part of the reactor piping system and should be located in accor- dance with the arrangements shown in Chapters 5 (Drums) and 10 (Towers). MAINTENANCE Handling such removable items as relief valves and valve drives for offsite repair and catalyst loading can be achieved by fixed handling devices or by mobile equipment, Fixed handling devices can be davits os, for structure-mounted reactors, trolley beams. Exhibit 9-25 depicts a typical davit arrangement, and Exhibit 9-26 shows a trolley beam arrangement. Catalysts are loaded through the top-head mainte- nance access of the reactor afier removal of the inlet nozdle if integral to the maintenance access cover flange. If the catalyst is not supported on a fixed gra: ing and screen assembly, which would be fabricated Process Plant Layout and Piping Destan 2 sseceeentcnenoscnaetsranrSSESENNNANREA EXHIBIT 9.26 Trolley Beam Arrangement REEF VALvES hoapmig, Nozze LOADING AnD HNLeACING AGEm with the vessel, the first step isto load the botiom head and unload the nozzle with inert material. The inert material could be silica pellets or alumina balls, which are usually larger than the catalyst and support the catalyst bed. The inert material is then covered with the bottom floating screen, The catalyst is first sieved through a mesh screen to remove the finer particles. It is then loaded into a bucket or sock and lowered through the maintenance access, where it is manually distributed in layers until the reactor is filled to the required capacity. The top and bottom layers of cata lyst are usually a larger mesh than the main bed. The top floating screen is then installed and covered with an acklitional layer of inert material that is used to hold down the screen assembly during regeneration and eliminates inlet gas turbulence during operation. The catalyst is removed infrequently. Removal is accomplished during shutdowns after cool-down by allowing the catalyst to exit through the bottom un- loading nozzle. After removal of the flange cover on217 Whe T ‘EXHIBIT 9-27 No2z2._e Spherical Reactor MAIN TENANCE INLET ACL ESS Barr FLOATING ScREEN 7 eas eaTeLyeT TEMPERATURE Reo WEUWS ~ ~ FIXED caTALy eT GRATING PRor our 4 SczeeN NozzLe outlet — -. ouTler Nozzle SulecTog i Skeet EXHIBIT 9-28 TYPICAL) he unloading nozzle, the catalyst can be allowed co cee fall to a temporary containment area or be re- soved using an industrial vacuum, or a temporary alve may be used to control the unloading rates. Ex- ‘bits 9-27 through 9-30 are examples of less common eactor arrangements, ‘The dimensions, clearances, and guidelines high- Horizontal Reactor t OuTLeT_ Unlesomé Sozzue oeere suet wet heey NozzLe CPEmMG eaTALyeT ' LObDIm Ge v MozZ2te ee Process Plant Layout and Piping Design et REESE EXHIBIT 9.30 Multibed Reactor caranyet wer Teapmie NOBELE rfp _Noune caTayeT Ben Crxpleat) INLET NOZ2Les NozZLes ourter Nozzle