TYPES OF CONVERTERS

The converter serves the following functions:

 Provides single or multiple beds in which the catalyst is placed

 Provides for the distribution of gas across the catalyst bed.
 Provides for the collection of gas to exit the converter

The design of converters has evolved over time as plants have increased in size and materials of
construction have changed.

Conventional Converter

The conventional converter consists of a carbon steel shell with

cast iron support grids and division plates, cast iron posts,
insulating brick lining of Bed 1 and metallizing of carbon steel. The
disadvantages of the conventional post and beam converter design
are:

a) Poor gas distribution

Acceptable gas distribution with side inlet nozzle requires gas inlet
velocities substantially lower than designers are willing to use -
either for cost or mechanical strength considerations. Also, high
velocity inlet gas at one point can blow catalyst around (digging holes in bed) worsening gas
distribution. The net result is a higher catalyst loading to achieve the same conversion.

b) Poor access to beds

The first bed which is screened the most often is usually located on
the top due to poor strength of carbon steel shell at high
temperatures. Posts in the beds make access difficult for catalyst
loading and screening.

c) Bypassing of gas

Asbestos rope is jammed between grids and shell to give a tight

seal. Poor installation or differential expansion between the shell and
the grids can cause gaps to open up and provide a path for gas down
the shell.

d) Bed collapse

Bed collapse can occur due to either creep of the shell causing
bulging, creep of the catalyst support grids, failure of the metallized
lining or corrosion of angle iron welded to shell.

e) Leaks at gas nozzle

Rectangular nozzles are often used to minimize the height of the converter. This results in high stress
corners and less resistance to stresses imposed by ducting leading to failures and gas leaks.
Stainless Steel Converter

Many of the disadvantages of the conventional converter have been eliminated by employing stainless
steel as a material of construction. The advantages of the stainless steel converter are:

 all stainless steel construction (304 SS)

 radial symmetry.
 all welded construction
 core tube for gas distribution and internal heat exchanger(s)
 all ducts connected to converter via circular nozzles
 flexibility in design to position catalyst beds in any order to
ensure optimum ducting arrangements and access to Bed 1
which is screened the most often.

The design of the stainless steel converter is generally not governed by ASME Code due to the low
operating pressure (< 15 psig). The advantages of all stainless steel construction are apparent from the
following graph which shows the allowable stresses versus design temperature. Allowable stresses for
516/70 carbon steel are only quoted to a temperature 570°C (1058°F) whereas the operating temperature
in Bed 1 can exceed 610°C (1130°F). The sudden drop in stress values for carbon steel at approximately
400°C (752°F) is the cause of bulging of conventional converter shells. Type 304 stainless steel is the
'ideal' material of construction having acceptable stress values at the normal operating temperatures of
the converter.

Single Bed Converters

Single bed converters are typically installed as part

or an acid plant retrofit. A single bed converter can
be a new first pass where the plant is handling a
higher gas strength and the existing converter is
not suitable for the higher operating
temperatures. Single bed converters can also be
used as the final pass in a single to double
absorption retrofit. The existing converter passes
become the passes before the intermediate
absorption tower. After passing through the
intermediate absorption tower, the gas is heated
back up prior to entering the single bed converter holding the final pass.

Single pass converters have been constructed in the traditional carbon steel/cast iron design as well as
the newer stainless steel design. The first pass single bed converters are usually stainless steel since
these operate at higher gas strengths and temperatures.