DENSICAT® NEW GENERATION

Dense loading of fixed bed catalytic reactors is a technique which has been used for a few decades, and has proven
to be very useful for debottlenecking reactors and other vessels filled with particulate materials. It ensures the
increase of the catalyst loaded and the improvement of bed homogeneity generating improved performances of
the reactor. Today, PETROVAL has launched its new dense loading technology dedicated to large reactors: the
Densicat® New Generation (DNG). It was developed keeping in mind three key points: safety, rapidity and quality.

CHARACTERISTICS
OF THE DENSICAT® NEW GENERATION

The DNG machine consists of a stationary cylindrical body, supported as needed inside the reactor. The body
serves to receive the catalyst from the top hopper via a sock, and to do the initial rough distribution of the catalyst.
This initial partition is done via windows on the side of the machine body, and several openings at the bottom. The
dimensions of these openings control the catalyst flow rate.

The machine body also houses the air-driven motor that is used to rotate the strip assembly, which is the main
distribution device. This strip assembly is attached to the bottom of the motor, and turns the catalyst that is
flowing out of the machine openings into a dispersed "rain" of particles.

The strip assembly consists for four layers of flat rubber flaps, attached to a central core. Each of the top three
layers contains eight long strips and the bottom one only four short strips.
Six radar probes are installed on two arms and one in the centre to check, every time, the bed levelness. All datas
are collected by the central control station where PETROVAL's engineer adjusts continuously the control
parameters.

The DNG also has a vacuum system through the hollow shaft, to extract dust during the dense loading.
BENEFITS
FOR CUSTOMERS OF THE DENSICAT® NEW GENERATION
In accordance with PETROVAL's safety objective of zero accident, the DENSICAT® NEW GENERATION reduced
drastically risks of accident. Thanks to the radars and the remote controller, nobody is inside the reactor during the
catalyst dense loading. Also, the vacuum system eliminates catalysts dusts to protect workers around the reactor
and improves the quality of the dense loading.

Radars permit to have a continuous overview of the bed profile during the dense loading. The operator outside the
reactor can adjust in real time the DNG to correct the flatness of the bed. The quality of the loading is improved
and the intermediary checks are avoided. The DNG was created with a potential loading flow rate up to 40
tons/hour, which allows a significant saving of time.
THE PRINCIPLE OF THE UNIDENSE® TECHNOLOGY
The UNIDENSE® technology is a catalyst loading method for primary reformer tubes which is less complex and
faster then the traditional "sock" loading method. Catalyst is slowly filled into the tube through a specially
designed funnel and the loading rope is gradually pulled out of the tube as the catalyst layer builds up. The brushes
with flexible springs reduce the speed of the catalyst particles so that breakage is avoided. With the
UNIDENSE® technology the catalyst particles will have a free fall from the lowest brush to the catalyst surface. This
gives a "low intensity" filling and the particles will come to rest before being interlocked by other particles. Hence,
there will not be any risk for bridging, and vibration of the tubes is not necessary. The UNIDENSE® technology
ensures a filling without extra voids and a high uniform density along the full length of the tubes is obtained. The
catalyst is charged from buckets and the time consuming and expensive socking of the catalyst is avoided.
Weighing of catalyst loaded in each tube is not necessary.
Several layers of catalyst
When more than one type of catalyst is to be loaded in the tubes with the UNIDENSE® technology the level for
each type is easily adjusted by marks on the loading rope, and frequent measurement of loaded outage is
therefore not necessary. Experience from an emergency loading with 5 different types (shapes and sizes), including
used and screened catalyst, concluded that the final pressure drop variation was less than ± 5 %. All common
catalyst types and sizes have successively been loaded.
Pressure drop variation
The guaranty for the variation in pressure drop measurement of the loading is that the final result shall be within ±
5% of the average. However, a variation of ± 3% or less is a realistic target when a careful loading has been made.
The pressure drop is normally measured with the plant's own equipment and personnel as a quality control, and is
normally taken during night in order to minimize variations in temperature and barometric pressure.
High uniform density - Less settling of catalyst during operation
With the UNIDENSE® technology it is often experienced that more catalyst (3 to 7%) is loaded than with the "sock"
method and normal vibration. This is due to the uniform packing of the catalyst. The increase in density does not
result in increased pressure drop in the reformer as normally should be expected. The explanation to this is that
"sock" loading and vibration results in spots with locally very compact and high density, causing increased pressure
drop. The Unidense® loaded density is uniform all through the tube and high enough to avoid settling of the
catalyst during operation. Experience from one plant with many starts and stops, is that the settling of the catalyst
was even and only a few inches in all the tubes.
ABOUT THE "SOCK" LOADING METHOD
The traditional "sock" loading method results in a loose filling. When the catalyst flushes out of the sock this will be
a "high intensity" filling and the catalyst particles may (will) interlock and form bridges. Vibration will remove some
of the bridges and increase the density. After the plant is started, the tubes will expand and some bridges may
break and cause settling of the catalyst and possibly new bridges and hot spots. When vibration is used on the top
of the tube it is obvious that the effect of the vibration in the lower/bottom part of the tube will be less. The
experience is that settling of the catalyst after a "sock" loading has been to such an extent, that the catalyst level
has been inside the heated zone and resulted in overheating of the top part of the tubes.
 Benefits with the UNIDENSE® technology:
Socking of catalyst and weighing of the socks prior to loading is time consuming and is avoided with the
UNIDENSE® technology. However, the catalyst has to be brought to the tubes, and there is a good experience with
transfer of the catalyst in bags with up to approx. 30kg. Bagging of the catalyst is much faster than filling a large
number of socks and only a few bags need to be weighed. Also there is very good experience by using hoppers and
charging the catalyst directly in buckets which is carried to the tubes.
The UNIDENSE® technology is a fast loading method. The actual time for loading a tube with UNIDENSE® vary,
depending on the tube dimensions and is for a 4" i.d. tube approx. 10 minutes (one of catalyst type) including the
final outage measurement. A reformer with 300 to 400 tubes is normally completed in 3 to 4 shifts of 12 hours.
The time it takes to complete a reformer loading with the UNIDENSE® technology is often less than half of the time
for sock loading. Often the time to replace the primary reformer catalyst is the critical item in a maintenance plant
stop and reducing the down time is the owner's main goal. Even using less man-hour for catalyst replacements is a
great benefit.
Pressure drop of the tubes has proved to be within a narrow range with the majority within ± 2,5% variation
around the average pressure drop. Rarely tubes have pressure drop outside of ± 5%, and most of the reformers
have been completed without reloading of tubes. Since reloading of tubes is avoided, less (no) expensive catalyst is
wasted.
Often when a "sock" loading is made problems like loosing a part, or a full sock into the tube happens. Sometimes
the sock opens during lowering into the tube and catalyst have free fall causing catalyst breakage. The way the
vibration is made varies from team to team leading to large variations in loaded density and pressure drop.
Adjustment of the loading by vibration and reloading of tubes is time consuming and may delay start up of the
plant. Such or similar problems are avoided by the UNIDENSE® technology, and very seldom tubes need to be
emptied and reloaded. We see only positive effects and no negative risks of using the UNIDENSE® technology
compared with the "sock" loading method.
The even and stable pressure drop results in even tube wall temperatures and the high uniform loaded density will
ensure a long life of the reformer tubes and allow for improved conversion and increased throughput. Using the
UNIDENSE® technology contributes to extend operating periods.
In summary the main benefits with the UNIDENSE® technology are:
1. No need for socking/weighing of catalyst - time and manpower saving prior to loading,
2. Catalyst delivered in drums / bags - lower costs (no socking costs),
3. No need for vibration or hammering - no damage to tubes, insulation and structure,
4. Less risk for refilling of tubes - less problems during the loading and less waste of catalyst,
5. Uniform high loaded density and uniform pressure drop - prolonged tube life and potential for increased
production,
6. No bridging or extra voids - less settling and less tendency to hot spots,
7. The loading can be completed in less time - reduced down time and labour cost
Different internal tube diameters
Some tubes have less internal diameter in the top part to give room for the top flanges. This tube design may be
difficult to load with "socks" because the sock diameter must fit the smallest top section. In the part of the tube
with larger internal diameter the sock may easily open and catalyst will have free fall resulting in breakage. By
applying a special design of the loading ropes we have successfully loaded a number of plants with such tube
design by the UNIDENSE™ technology and obtained excellent results.

 PMENT
Add to bookmarks

The UNIDENSE® loading equipment consists of the following basic components:

1. Loading funnel,
2. Brushes,
3. Loading rope.
 The loading equipment must be prepared to fit the tube to be loaded.
Funnels
The part of the funnel where the catalyst is made with an angel so that catalyst is flowing into the tube. In the neck
of the funnel where the catalyst enters the tube slits are made in order to remove some of the catalyst dust during
the loading. A rubber sheet where catalyst is charged will reduce catalyst dust formation and reduce the noise
level during the loading.

Brushes
The brushes consist of a body with springs through the centre. The springs are equally distributed to cover the
cross-section of the tube and are fixed in the body. The number of springs is selected according to the diameter of
the tube and the size of the catalyst particles to be loaded.Thickness of the steel springs varies with length and
stiffness. The springs shall reduce the speed of the falling catalyst particles, but not stop them, so that the catalyst
is loaded without the particles being crushed.

Loading rope
The loading rope is made up with a weight in the bottom connected directly to the first brush. The 3 brushes at the
end make up the first part of the rope, an the distance between remaining brushes are approx. 1m. When 2 or
more layers of catalyst are to be loaded, the outage from the top of the funnel to each layer is calculated and
"flags" of thin steel plate are fixed to the rope in order to let the rope act as a measuring tape.
In 2009, UNIDENSE® Technology GmbH introduces a new loading system which automates the conventional
UNIDENSE® method. The UNILOADER® with its innovative features including automatic rope winch, catalyst
conveyor belt and both being synchronized to achieve desired density. It has also built-in active dust removal
mechanism. In summary, the UNILOADER® is a machine to automatically load reformer tubes with catalyst using
the UNIDENSE® principle.

The UNILOADER® brings new benefits to the UNIDENSE® technology. The possibility for human error is eliminated
as all tubes are loaded consistently, resulting in higher uniformity and reducing the pressure drop variation to + /-
3% (For new reformers, = +/- 2% is possible). Attached vacuum cleaner and carefully designed air flow ensures
dust-free loading.

EXTRA BENEFITS UNILOADER®:

 Human failure eliminated
 Improved uniform pressure drop variation +/- 3%
 Faster reformer loading (up to 20% faster as manuell)
 Highly uniform loading
 Dust-free loading

COMPARISON - CONVENTIONAL UNIDENSE VS. UNILOADER:

UNIDENSE® UNILOADER®

Two technicians required to operate Only one Supervisor can operate two

the rope and loading funnel UNILOADER

dP Garantie +/- 5% dP Garantie +/- 3%

Batch loading as the activity pauses when
changing buckets Continuous catalyst loading

Dust removal passively Active de-dusting capability

High human error possibility Eliminates human error