BACKGROUND

This application claims priority from U. S. Provisional Application S/N

61/347,483 filed May 24, 2010, which is hereby incorporated herein by reference.

The present invention relates to a device for loading catalyst into the vertical reactor tubes of a chemical reactor.

Many chemical reactors are essentially a large shell and tube heat exchanger vessel, with the reaction occurring inside the tubes and a coolant circulating in the vessel outside the tubes. A chemical reactor vessel also can be a simple tank with a single volume of catalyst inside it, or it may be a single large tube. Some chemical reactions occur in furnace or reformer tubes, which may be a part of a system with 10 to 500 or more such tubes. In any of these reactor vessels, catalyst, typically in the form of pellets (and other types of pellets that are not catalyst), may be loaded into the reactor to facilitate the reaction. The pellets are replaced periodically.

The reactor tubes may be quite long, housed in a structure several stories tall, and the pellets may be transported up several stories to an elevation above the top of the tubes so they may then flow by gravity into the tubes. The pellets typically are supplied in 2,000 pound (or larger) "super sacks", 55 gallon drums, mini drums, metal bins or plastic bags loaded in pallet-mounted cardboard boxes.

The pellets are then carefully loaded into each reactor tube (there may be several thousand tubes in a single reactor) to try to uniformly fill each tube. It is desirable to prevent bridging of the pellets in the reactor tube, because bridging can create voids or areas within a tube in which there are no pellets. Mechanical devices may be used to aid in the loading of the pellets.

In some cases, in a shell and tube reactor in which vertical reactor tubes are supported by upper and lower tube sheets, a template is placed over a portion of the upper tube sheet. The template has openings aligned with the tops of the reactor tubes, with the openings in the templates having a smaller diameter than the inside diameter of the cylindrical reactor tubes in order to restrict the flow of pellets into the reactor tubes to prevent bridging in the tubes. Pellets are dumped on top of the template, and operators then use their gloved hands, paddles, brooms, or rakes to spread the pellets back and forth across the template so that pellets fall through the holes in the template and into the respective reactor tubes. Moving the pellets back and forth breaks up any bridging of the pellets above the template, allowing the pellets to flow through the holes in the template and into the reactor tubes.

In other instances, loading sleeves are inserted into each reactor tube, with each loading sleeve having a top opening that is smaller than the inside diameter of the cylindrical reactor tube in order to limit the flow of pellets to prevent bridging inside the reactor tubes. Again, the pellets are dumped on top of the loading sleeves, and the operators push the pellets back and forth across the loading sleeves so that the pellets fall through the holes in the loading sleeves and into the respective reactor tubes.

Various other loading techniques also are known, such as the method taught in U.S. Patent 3,223,490 "Sacken", in which a tray with a plurality of downwardly extending loading sleeves is placed directly above the tube sheet, with the loading sleeves extending into respective reactor tubes. The catalyst is poured onto the tray, and then the tray is vibrated up and down vertically, shaking the pellets to break up any bridges and allow the pellets to fall through the sleeves in the tray and into the reactor tubes. The vibration of the pellets causes them to rub against and impact against each other. Catalyst is a friable material and thus is brittle and readily crumbled. It is desirable to minimize the opportunity for the particles to rub against or impact against each other or otherwise to be abraded or crushed, because such abrasion and crushing damages the pellets and creates dust. Raking the pellets back and forth across the template or loading sleeves creates substantial abrading of the catalyst pellets, creating dust particles which may not only fall into the reactor tubes creating higher pressure drops than desirable, but which also may become airborne, creating a health hazard for personnel inside the reactor vessel. Vibrating a tray full of catalyst as in the Sacken arrangement also causes the pellets to be jostled and to rub against and impact against each other, which also produces similar results. Summary

The present invention relates to loading devices for loading pellets into reactor tubes which break up any bridging of the pellets by using a subtle, localized motion that imparts a direct mechanical force to at least one of the pellets adjacent to the opening that is different from the force being applied to the surrounding pellets.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic, section view of a shell and tube type of chemical reactor vessel;

Figure 2 is a plan view of the upper tube sheet of the reactor of Figure 1 ; Figure 3 is a broken away, schematic section view of a single reactor tube, tube sheet, and catalyst pellets, showing the pellets bridging across the top opening of the reactor tube;

Figure 4 is a broken away, schematic section view, similar to Figure 3, but showing a much larger number of catalyst pellets bridging across the top opening of the reactor tube, and illustrates catalyst bridging inside a reactor tube;

Figure 5 is a broken away schematic section view, similar to Figure 4, but with the addition of a template to aid in the loading of the catalyst pellets into the reactor tube;

Figure 5A is a broken away schematic section view, similar to Figure 5, but using a loading sleeve instead of a template to aid in the loading of the catalyst pellets into the reactor tube;

Figure 6A is a broken away, schematic plan view of a device for loading catalyst mounted over a portion of the template;

Figure 6B is the same view as 6A, but with the device shifted to a second position;

Figure 6C is the same view as 6B, but with the device shifted to a third position;

Figure 6D is a broken away, plan view of a portion of the catalyst loading device of Figure 6A, showing an alternate configuration for the openings in the loading tray;

Figure 7 is a broken away schematic section view, similar to that of Figure 5, but including the loading device of Figure 6A in the position shown in Figure 6A, with catalyst pellets bridging above the top of the reactor tube;

Figure 8 is the same view as 7, but showing the loading device in the second position, shown in Figure 6B so as to break the bridging of the catalyst pellets above the top of the reactor tube;

Figure 9 is the same view as Figure 8, but showing the loading device in a third position;

Figure 10 is a schematic view of a pneumatic control arrangement for the loading device of Figures 6A-9;

Figure 1 1 is a schematic section view of the loading tray, taken along line 1 1 - 1 1 of Figure 10;

Figures 12A-12H are schematic plan views of some of the possible motions which may be made by the loading device of Figure 10;

Figure 13 is a broken away, section view of another embodiment of a loading device for loading catalyst, mounted on an upper tube sheet;

Figure 14 is a plan view of the loading device of Figure 13, with the tube sheet omitted for clarity:

Figure 15 is a broken away view, partially in section, of another embodiment of a device for loading catalyst;

Figure 16 is a view taken along line 16-16 of Figure 15;

Figure 17 is a view taken along line 17-17 of Figure 16;

Figure 18 is a broken away section view of another embodiment of a loading device;

Figure 19 is a view taken along line 19-19 of Figure 18;

Figure 20 is view similar to Figure 19, but for another embodiment of a loading device;

Figure 21 is the same view of a loading tray as in Figure 1 1 but showing an alternate arrangement mounted on a tube sheet and including a spacer between the loading device and the tube sheet;

Figure 22 is a broken away section view of the tube sheet, similar to Figure 3, except showing three tubes, each having a different height relative to the tube sheet;

Figure 23 is a side view of loading device like that of Figures 1 1 or 21 , but including a spacer to accommodate the varying tube heights of Figure 22;

Figure 24 is a side view of an alternate embodiment of a catalyst loading device, shown in a first, lowered position;

Figure 25 is a side view of the loading device of Figure 24, shown in a second, raised position;

Figure 26 is a side view of another alternate embodiment of a catalyst loading device, shown in a first position;

Figure 27 is a side view of the catalyst loading device of Figure 27, shown in a second position;

Figure 28 is a plan view of an alternate embodiment of a catalyst loading device, similar to that of Figure 26, but having two bridge breaking wires;

Figure 29 is a plan view an alternate embodiment of a catalyst loading device, similar to that of Figure 26, but for handling multiple tubes simultaneously;

Figure 30 is a side view of the catalyst loading device of Figure 29;

Figure 31 is a side view of another embodiment of a catalyst loading device;

Figure 32 side view of a bin transport device for the catalyst loading device of Figure 31 ;

Figure 33 is a plan view of one the bins of Figure 31 ;

Figure 34 is a side view of the bin of Figure 33;

Figure 35A is a side view of the bins of Figure 31 and the bin transport device of Figure 32, in preparation for transferring catalyst into the bins;

Figure 35B is a side view, similar to Figure 35A, but with the bin transport device starting to empty the catalyst into the bins;

Figure 35C is a side view, similar to Figure 35, but with the catalyst in the bin transport device emptied into the bins;

Figure 36 is a side view of another embodiment of a catalyst loading device;

Figure 37 is a view along line 37-37 of Figure 36;

Figure 38 is a broken away, side view, along line 38-38 of Figure 36;

Figure 39A is a section view along line 39A-39A of Figure 38;

Figure 39B is a section view along line 39B-39B of Figure 38; and

Figure 40 is a side view, similar to that of Figure 38, but with the bridge breaking device in the raised position. DESCRIPTION

Figure 1 depicts a typical chemical reactor vessel 10, which is a shell and tube heat exchanger, having an upper tube sheet 12 and a lower tube sheet 14 with a plurality of vertical tubes 16 welded or expanded to the tube sheets 12, 14 to form a tightly packed tube bundle. There may be from one to many hundreds or even thousands of cylindrical tubes 16 extending between the tube sheets 12, 14. Each tube 16 has a top end adjacent the upper tube sheet 12 and a bottom end adjacent the lower tube sheet 14, and the tubes 16 are open at both ends, except that there may be a clip at the bottom end to retain catalyst pellets inside the tube. The upper and lower tube sheets 12, 14 have openings that are the size of the outside diameter of the tubes 16, with each tube 16 located in its respective openings in the tube sheets 12, 14.

The vessel 10 includes a top dome (or top head) 13 and a bottom dome (or bottom head) 15, as well as manways 17 for access to the tube sheets 12, 14 inside the vessel 10. The manways are closed during operation of the reactor but are opened for access, such as during catalyst handling. In this instance, the tubes 16 are filled with catalyst pellets, which facilitate the chemical reaction. (It may be noted that similarly-shaped shell and tube heat exchangers may be used for other purposes, such as for a boiler or other heat exchanger.)

This particular reactor vessel 10 is fairly typical. Its tubes may range in length from 5 feet to 65 feet, and it is surrounded by a structural steel skid or framework (not shown), which includes stairways or elevators for access to the tube sheet levels of the reactor vessel 10 as well as access to intermediate levels and to a topmost level which may be located at or near the level of the top opening of the reactor vessel 10. On a regular basis, which can be every 2 to 48 months or longer, as the catalyst becomes less efficient, less productive, or "poisoned", it is changed out, with the old catalyst being removed and a new charge of catalyst being installed in the tubes 16 of the reactor vessel 10. Catalyst handling also may have to be done on an emergency basis, on an unplanned and usually undesirable schedule.

A catalyst change operation involves a complete shutdown of the reactor, resulting in considerable cost due to lost production. (The loading devices shown and described herein may be used both for the initial loading of a new reactor and for catalyst change operations.) It is desirable to minimize the amount of time required for the catalyst change operation in order to minimize the lost production and accompanying cost caused by the reactor shutdown.

Figure 2 is a schematic plan view of the upper tube sheet 12 of Figure 1 , including a plurality of reactor tubes 16 (and is identical to the lower tube sheet 14). As shown in Figure 3, catalyst pellets 18 may bridge over the open top end of the reactor tube 16 when trying to load catalyst into the reactor tube 16, which prevents the pellets from entering into the reactor tube 16. Figure 4 shows that the bridging situation is exacerbated as more catalyst pellets 18 are dumped on top of the tube sheet 12. Furthermore, if two or more pellets 18 fall into the top opening of the reactor tube at approximately the same time, the conditions are favorable for forming a bridge inside the reactor tube 16, as shown in Figure 4, which creates a void or space below the bridged catalyst inside the tube 16, preventing the catalyst from completely filling the reactor tube 16 and resulting in a non-uniform and undesirable catalyst loading of the reactor tube 16.

To prevent bridging of catalyst pellets 18 inside the reactor tube 16, prior art devices have relied on templates 20 (as shown in Figure 5) or loading sleeves 22 (as shown in Figure 5A) which have smaller openings 34 (in Fig. 5) and 23 (in Fig. 5A) than the reactor tubes 16 and thereby restrict the flow of pellets 18 into the reactor tubes 16 so as to prevent bridging inside the tube 16. (i.e., if the pellets flow through the tube 16 in "single file" or few enough at a time that they cannot span the full diameter of the tube at any one time, bridging will not occur.) However, the catalyst pellets 18 still form natural bridges atop the template 20 or atop the loading sleeve 22. Operators sweep the mound of catalyst pellets 18, as depicted by the arrow 25 in Figures 5 and 5A, using gloved hands, paddles, brooms, rakes, and other such devices to break the bridging so that additional catalyst pellets 18 fall through the openings 34 in the template 20 (or through the openings 23 in the flanges 21 of the loading sleeves 22) and drop into the reactor tubes 16. This sweeping action is applied to substantially the entire mass of catalyst pellets 18 resting atop the template 20 or loading sleeves 22, causing many of the brittle catalyst pellets 18 to fracture and break into smaller particles and forming dust.

Figures 6A-D and 7-10 show an arrangement including a first embodiment of a catalyst loading device 24 for loading catalyst into reactor tubes. The loading device 24 rests on top of a template 20, which rests on top of the upper tube sheet 12 of the reactor 10. On the right side of Figure 6A are shown some of the openings 34 in the template 20, and, behind them in phantom are the open-top reactor tubes 16. While the drawing shows only some of those openings 34 and tubes 16, it is understood that the openings 34 and tubes 16 are distributed evenly throughout the template 20 and the upper tube sheet 12, respectively. (This may be better understood by looking at Figure 1 1 , which is a section view through the tray 26 only.) It should be noted that the openings 34 in the template 20 have a smaller diameter than the inside diameter of the reactor tubes 16 and are axially aligned with the tubes 16. The template 20 is a relatively thin body having horizontal, planar top and bottom surfaces and defining a plurality of holes extending from the top surface to the bottom surface. The bottom surface of the template 20 rests on top of the upper tube sheet 12 and may cover all or a portion of the upper tube sheet 12.

As best appreciated in Figure 6A, the catalyst loading device 24 includes a tray 26, which is operatively connected, via connecting rods 28 and pivots 30 (pivot locations are located on the rod end and cap end of their respective cylinders), to four linear-motion drives 32, which are fixed in position by means of pins 33, which extend into reactor tubes 16, as shown in Figures 7-9. (They could extend into other openings in the tube sheet 12 or in the template 20, or be secured in position by other means, if desired.) The double headed arrows 31 indicate the direction of motion of the linear-motion drives 32. The pivots 30 at either end of each connecting rod 28 allow for misalignment in the connection between the linear-motion drives 32 and the tray 26 to permit the desired motion of the tray 26. The tray 26 moves substantially horizontally, along a plane which is parallel to the plane of the template 20 on which the tray 26 rests. The tray 26 includes means for holding a plurality of pellets and has a plurality of openings 36 through which the pellets must pass in order to flow from the tray into the respective vertical reactor tubes 16. The pellets also must pass through the openings 34 in the template 20 located below the tray 26 in order to flow into the respective reactor tubes 16.

Again, while only some of the openings 36 are shown, it is understood that the openings 36 are evenly distributed over the entire tray 26. In an alternative arrangement, the catalyst loading device 24 may rest on top of the flanges 21 of a plurality of loading sleeves 22 (See Figure 5A) instead of resting on top of the template 20. In that case, then the pellets also would pass through the openings 23 in the loading sleeves in order to flow into the respective reactor tubes 16.

As shown in Figures 6A-D and 7-9, the tray 26 of the catalyst loading device 24 is resting on top of the template 20. The openings 36 through the tray 26 are a bit larger than the corresponding openings 34 in the template 20, which permits the tray 26 to shift horizontally relative to the stationary template 20 without closing off any portion of the openings 34 in the template 20.

As shown in Figures 6A and 7, the openings 36 of the tray 26 are axially aligned with the openings 34 in the template 20, which, in turn, are axially aligned with the respective longitudinal axes of the reactor tubes 16. The template 20 lies between the tray 26 and the tube sheet 12. Some of the pellets 18 that are forming a bridge are in contact with the top surface of the template 20.

As shown in Figures 6B and 8, the tray 26 has been shifted to the left, so the axes of the openings 36 in the tray 26 are to the left of the axes of their respective template openings 34 and reactor tubes 16. This position is achieved by the linear- motion drives 32 on the right hand side of the catalyst loading device 24 (as seen from the vantage point of Figures 6A-C) pushing the tray 26 to the left. This causes the vertical edge of the opening 36 in the tray 26 to contact the pellet 18A, which is resting on the top surface of the template 20 and push it to the left, into the opening 34 of the template 20, so that pellet 18A falls through the openings 36 and 34 and into the reactor tube 16. Since the pellet 18A was supporting the bridge adjacent to the opening 36, its movement relative to the other pellets 18 causes the bridge to fall and allows other pellets 18 to fall through the openings 36, 34 into the reactor tube 16 until another bridge is formed adjacent to the opening 36.

As the linear-motion drives 32 on the right hand side of the catalyst loading device 24 (as seen from the vantage point of Figures 6A-C) pull the tray 26 to the right while at the same time the linear-motion drives 32 on the bottom of the catalyst loading device 24 (as seen from the vantage point of Figures 6A-C) pull the tray 26 to the bottom, the larger through openings 36 of the catalyst loading device 24 are also shifted to the right and bottom, but are still in fluid communication with the respective top openings 38 of the reactor tubes 16 via the smaller through openings 34 of the template 20. This corresponds to Figures 6C and 9.

As was explained briefly above, it can be seen in Figure 7 that a bridge has been formed above the reactor tube 16, and some of the catalyst pellets 18 are resting on the template 20 inside the opening 36 of the tray 26. When the tray 26 is shifted to the left, the edge of the opening 36 of the tray contacts one or more of those pellets 18A, shifting it to the left as well, which breaks up the bridge and allows pellets 18 to fall through the opening 36 in the tray and through the opening 34 in the template 20 into the reactor tube 16 until another bridge forms adjacent to the opening 36 in the tray 26.

Shifting the tray 26 to the position of Figure 9 causes the edge of the opening 36 to contact another pellet 18B, again shifting that pellet 18B to break up the bridge that it is supporting and allowing the pellets 18 to fall through the openings 36, 34 in the tray 26 and template 20, respectively, and into the open top 38 of the reactor tube 16 until another bridge is formed.

This movement of the tray 26 relative to the template 20 continues to push the supporting pellets out from under the bridge of pellets that they are supporting, thereby breaking up the bridges and allowing the pellets to flow into the reactor tubes 16 without causing any more jarring or abrading of the pellets than is needed to break up the bridging and allow the pellets to flow through the tray 26 into the reactor tubes 16.

Figures 12A-12H schematically depict some of the different paths which may be traced out by the tray 26, ranging from a circular clockwise orbit (Figure 12A); a circular counter-clockwise orbit (Figure 12B); quarter circle turns (ninety degrees) alternating clockwise and counterclockwise (Figure 12C); shorter arcuate turns (such as 45 degrees) alternating clockwise and counterclockwise (Figure 12D); quarter oval-shaped turns alternating clockwise and counterclockwise (Figure 12E);

rectangular orbits (Figure 12F); star-shaped orbits (Figure 12G); and hexagonal- shaped orbits (Figure 12H). These different paths are just some of those which may be traced out by the tray 26, depending on the control scheme for the catalyst loading device 24. A possible control scheme is shown in Figure 10 and described below. Figure 6D depicts an alternate shape for the opening 36' in the tray 26' of the loading device 24', showing that these openings 36' need not be round (as shown in Figures 6A-6C) nor do they have to correspond on a one-to-one basis with the openings 34 in the template 20 (or in the loading sleeve 22). In this instance, the openings 36' are almost triangular in shape, with each opening 36' of the tray 26' opening into three openings 34 in the template 20.

The control system described in Figure 10 involves driving the loading device 24 pneumatically. It includes four linear-motion pneumatic drives 32, each one connected to the tray 26 via its corresponding connecting rod 28. A pivot 30 at each end of each connecting rod 28 ensures that the connection point at the tray 26 may be misaligned from the connection point at the linear-motion drive 32 so as to permit the desired motion of the tray 26.

A source 40 of pressurized gas (such as compressed air) is in fluid

communication, through piping 42, 44, with two multi-port solenoid valves 46, 48. Each solenoid valve 46, 48 is in turn in fluid communication with two linear-motion pneumatic drives 32 through a set of four flow control devices as described in more detail below.

The operation of the control scheme for the catalyst loading device 24 of Figure 10 is described below with respect to one linear-motion drive 32 only, on the upper left hand corner of Figure 10. It will be clear that the other drives 32 operate in essentially the same manner. The air source 40 provides compressed gas to the solenoid valve 46 via the line 42. The solenoid valve 46 sends the compressed air via the path 50 to the line 52 and through the flow control limiter 54 to the linear- motion drive 32 which pushes the connecting rod 28 outwardly (in the down direction as seen from the vantage point of Figure 10). The air is exhausted through the flow control limiter 56 and through the line 58 back to the solenoid valve 46 which exhausts the air through the path 60. A proximity switch 62 on the linear-motion drive 32 sends a signal to a controller (not shown) when the linear-motion drive 32 has reached the end of its run. The controller actuates the solenoid valve 46, causing it to shift to a second position (not shown), which reverses the flow of compressed air to retract the connecting rod 28 on the linear-motion drive 32. The proximity switch 62 on the linear-motion drive 32 again sends a signal to the controller when the linear-motion drive 32 has once again reached the end of its run. The controller actuates the solenoid valve 46 which shifts and again reverses the flow of compressed air, and the entire cycle is repeated.

While air-operated drives 32 are described here, it is understood that the drives could be electric motors or other known drive means instead, and the control means would be suitable to control the drive means.

Operation of the catalyst loading device

The catalyst loading device 24 is placed atop a template 20 wherein the through openings 34 on the template 20 are substantially axially aligned with the reactor tubes 16. Preferably the linear-motion drives 32 of the catalyst loading device 24 are secured to the template 20 or to the tube sheet 12 to prevent any relative movement between the linear-motion drives 32 and the template 20.

Catalyst pellets 18 are dumped into the tray area 26 of the catalyst loading device 24 which is then powered up to begin the catalyst loading process. The relative horizontal motion between the tray 26 and the template 20 breaks any bridges as they form, allowing the catalyst pellets 18 to fall through the respective opening 36 in the tray 26 and opening 34 in the template 20 and into the reactor tubes 16, as shown in Figures 6A-9.

It should be noted that during this process there is very little jostling and relative motion between the vast majority of the catalyst pellets 18 in the tray 26. When a local bridge is broken and a catalyst pellet 18 falls through the template 20 and into a reactor tube 16, any catalyst pellets 18 immediately above the collapsed bridge will collapse as well and flow into the tube 16 until a new bridge is formed. This new bridge is then broken by the relative motion between the tray 26 and the template 20, and the process is repeated continuously until the reactor tube 16 is fully loaded, or the tray 26 runs out of catalyst pellets 18, or the catalyst loading device 24 is powered off. Not only is there very little relative motion among the catalyst pellets 18 in the tray 26, which limits the erosion and breakage of the catalyst pellets 18 and the consequent dust generation, but the whole process is mechanized and needs very little operator attention. Of course, as explained earlier, the catalyst loading device 24 may rest on top of the flanges 21 of a plurality of loading sleeves 22 (see Figure 5A) instead of resting on top of the template 20, in which case the operation would be the same.

Note that it is the relative motion between the tray 24 and the underlying substrate (such as the surface of the template 20 or the surface of the flange of the loading sleeve 22) that imparts a direct mechanical force to at least one of the pellets 18 adjacent to the opening 36 that is different from the forces being applied to the other surrounding pellets 18 in order to break up the bridging adjacent to the opening 36, allowing catalyst pellets 18 to fall out of the tray 26, through the openings 36 and 34, and into the reactor tube 16. This process continues repeatedly, with successive bridge forming followed by bridge breaking to load the reactor tube 16 with catalyst pellets 18.

Additional embodiments of a catalyst loading device

Figures 13 and 14 show another embodiment of a catalyst loading device 70.

Comparing this catalyst loading device 70 in Figure 13 with the loading sleeve 22 of Figure 5A, it may be seen that they are quite similar. The most obvious difference is that the catalyst loading device 70 is mechanically driven by a drive 72 via a belt 74. The drive 72 may be a rotary or articulating drive, and the belt 74 is a means for transferring the motion of the drive 72 to the loading sleeve 76 of the catalyst loading device 70, as best seen in Figure 14. This means for transferring the motion of the drive 72 to the loading sleeve 76 may be accomplished by a variety of other means (not shown) such as a gear or a rod.

A less obvious difference is the presence of ridges 78 on the top surface of the flange 80 of the loading sleeve 76. This embodiment shows two ridges 78 (See Figure 14) which extend radially from the opening 77 to the outer edge of the flange 80 and which are diametrically opposed from each other. While the ridges 78 are preferred, the flange 80 may have a roughened surface or other high friction surface that will cause a pellet 18 that is resting on the top surface of the flange 80 to move along with the flange 80.

As may be seen in yet another embodiment of a catalyst loading device 70 ^* in Figure 16, the loading sleeve may have one or more such ridges 78, 78 ^* , as described in more detail later. The ridges 78, 78 ^* serve to enhance the frictional resistance between the flange 80 of the loading sleeve 76 and the catalyst pellets resting atop the flange 80 of the loading sleeve 76, such that the mechanical motion imparted by the drive 72 to the loading sleeve 76 is more readily transmitted to the catalyst pellets resting atop the flange 80 so as to promote the breaking of any catalyst bridge.

In this embodiment, the drive 72 imparts a rotary motion to the loading sleeve 76 of the catalyst loading device 70, causing the flange 80 of the loading sleeve 76 to rotate in a horizontal plane, parallel to the top of the tube sheet 12, rotating slowly about its longitudinal axis, which is a vertical axis, aligned with the vertical axis of the reactor tube 16. As it does so, the catalyst pellets 18 resting directly on top of the flange 80 travel with the flange 80, so the flange 80 imparts a direct mechanical force to the pellets 18 resting on top of it, causing them to move relative to the other surrounding pellets 18 above them, which breaks up any catalyst bridges that may form just above the reactor tube 16. In this case, the tube sheet 12 provides means for holding a plurality of pellets above the vertical reactor tube 16. The opening 77 in the flange 80 has a smaller diameter than the inside diameter of the reactor tube 16, and the pellets pass through the opening 77 to flow through from the holding means into the reactor tube 16.

Figures 15-17 depict yet another embodiment of a catalyst loading device 70 ^* .

This is similar to the catalyst loading device 70 of Figures 13 and 14, except that the drive 72 ^* is anchored and substantially enclosed by an adjacent reactor tube 16.

In Figure 15, only the tube sheet 12 is shown in section. The drive 72 ^* includes a battery 82 ^* , a motor 84 ^* , and a gearbox 86 ^* , all of which are suspended inside a reactor tube 16 by the flange 88 ^* which rests atop the tube sheet 12. A pulley 90 ^* is engaged by the belt 74 ^* which in turn engages and drives a similar pulley 92 ^* on the loading sleeve 76 ^* . In this embodiment of a catalyst loading device 70 ^* , the loading sleeve 76 ^* includes a bearing housing 94 ^* and a bearing 96 ^* to minimize frictional resistance to rotation of the loading sleeve 76 ^* in the reactor tube 16.

The flange 80 ^* on the loading sleeve 76 ^* defines a plurality of ridges 78 ^* (See also Figures 16 and 17). As the drive 72 ^* rotates the loading sleeve 76 ^* , the flange 80 ^* imparts a direct mechanical force to the pellets resting on it, causing those pellets to shift relative to the rest of the pellets in the bridge, and thereby breaking up any bridging of pellets adjacent to the opening 77 ^* in the flange 80 ^* so the pellets 18 can flow through the opening 77 ^* and into the reactor tube 16.

Figure 18 depicts yet another embodiment of a catalyst loading device 70 ^** .

In this embodiment, the catalyst loading device 70 ^** includes two loading sleeves 76 ^** (though one or more such loading sleeves 76 ^** may be present) which are similar to the loading sleeve 76 of Figures 13 and 14 in that they includes ridges 78 ^** . This catalyst loading device 70 ^** rests on top of an elevated stationary template or frame 98 ^** which has a top surface that lies on a plane which is parallel to the plane of the top surface of the tube sheet 12, but which provides some clearance between the frame 98 ^** and the tube sheet 12. The loading sleeve 76 ^** has its flange portion 80 ^** resting on top of the frame 98 ^** , while its tubular "leg" portion 100 ^** extends through the frame 98 ^** , through the space between the frame 98 ^** and the tube sheet 12, through the tube sheet 12, and into the reactor tube 16. The flange 80 ^** defines an opening 23 ^** that has a smaller diameter than the inside diameter of the reactor tube 16, again in order to regulate the flow of catalyst particles into the reactor tube 16 to prevent bridging within the tube 16.

Mounted to the leg portion 100 ^** of the loading sleeve 76 ^** , and in the space between the frame 98 ^** and the tube sheet 12, are blades 102 ^** (See also Figure 19), similar to the blades of a blower fan. A compressed air nozzle 104 ^** is mounted to the frame 98 ^** . As seen in Figure 19, as the compressed air from the air nozzle 104 ^** blows on the blades 102 ^** of the loading sleeve 76 ^** , it applies a force causing the loading sleeve 76 ^** to rotate in the direction of the arrow 106. The compressed air from the air nozzle 104 ^** may blow continuously or it may blow intermittently to cause the loading sleeve 76 ^** to spin about its longitudinal axis, and as it does so, it imparts a direct mechanical force to the pellets 18 resting on top of the flange 80 ^** of the loading sleeve 76 ^** which moves the catalyst pellets 18 resting directly atop the flange 80 ^** relative to other pellets 18 that may be forming a bridge adjacent to the opening 23 ^** in the flange 80 ^** to break up any catalyst bridges, allowing catalyst to fall through the opening 23 ^** in the loading sleeve 76 ^** .

Figure 18 also shows a funnel-like container 108 ^** directly above the loading sleeve 76 ^** , which provides means for holding a plurality of pellets 18. This container 108 ^** may include a mark 1 10 ^** corresponding to a preset volumetric loading of catalyst inside a reactor tube. In this embodiment, the funnel-like container 108 ^** does not rotate with the loading sleeve 76 ^** , but remains stationary, resting on the stationary frame 98 ^** . This embodiment may be particularly useful for partial loading of reactor tubes, such as when reactor tubes are loaded with different types of catalyst to different heights within the reactor tubes.

Figure 20 is a view similar to Figure 19, but for yet another embodiment of a catalyst loading device. This catalyst loading device is essentially identical to the catalyst loading device 70 ^** of Figure 18, except that it has a different mechanism for rotating the loading sleeve 76'. In this instance, the loading sleeve 76' is rotated by means of a drive (not shown) similar to the drive 72 of Figures 13 and 14, via a belt 74' and a pulley 75 '. Of course, other drive means, such as gears or rods, may be used instead of a belt.

Each loading sleeve 76 ^** in Figure 18 (or 76' in Figure 20) may be individually driven, or several may be tied together to a common drive. For instance, the belt 74' in Figure 20 may wind over a number of pulleys 75' of different loading sleeves 76'. Likewise, the air nozzle 104 ^** may be fed by a common compressed air line manifold which supplies air to a plurality of air nozzles which blow air on other catalyst loading devices 70 ^** .

It sometimes occurs that the top tube sheet 12 in a reactor vessel is not completely flat. Sometimes it is very slightly domed and often, as shown in Figure 22, the reactor tubes 16 project upwardly beyond the top tube sheet 12, with some tubes projecting upwardly more than other tubes. In Figure 22, the upper portion 16A projects upwardly more than the upper portion 16b. Some tubes may have a plug 1 14 secured to the top portion, as shown with the top portion 16c, which causes the tube to project even a greater distance above the tube sheet 12.

Figure 21 shows a solution to the problem of an uneven tube sheet 12, whether because the tube sheet 12 is slightly domed or because the tubes 16 project upwardly and unevenly from the tube sheet 12. In this instance, a spacer 1 12 is installed between the tube sheet 12 and the template 20 (or it could be between the tube sheet 12 and the loading sleeves 22 of Figure 5A). This spacer 1 12 is preferably made of a foam material which adapts its shape to conform to the dome shape of the tube sheet 12. The spacer 1 12 has through openings 1 16 which are aligned with the reactor tubes 16 in the tube sheet 12. These openings 1 16 are large enough to accommodate any tube projections above the tube sheet 12 such that the top surface 1 18 of the spacer 1 12 is substantially flat despite any

unevenness in the tube sheet 12 and its reactor tubes 16.

Figure 23 shows an alternate solution to the problem of an uneven tube sheet 12. In this instance, the template 20 is supported above the tube sheet 12 via a plurality of legs 120, with the openings 34 in the template 20 substantially vertically aligned with the top openings of the reactor tubes 16.

Figures 24 and 25 show another embodiment of a catalyst loading device 122. This catalyst loading device 122 is similar to a loading sleeve, such as the loading sleeve 22 of Figure 5A in that it includes tubular vertical leg 124, a portion of which slides into the top of a reactor tube 16. It also includes a flange 126 which supports the catalyst loading device 122 on the top surface of the tube sheet 12, and it has a through opening 128 at the top of the vertical leg 124 with a small enough diameter to restrict the flow of catalyst particles into the vertical leg 124 and into the reactor tube 16 so as to prevent possible bridging inside the vertical leg 124 and the reactor tube 16.

The catalyst loading device 122 includes a funnel shaped container 129 which provides means for holding a plurality of pellets above the reactor tube. This funnel 129 is attached to, and supported by, the vertical leg 124 of the loading sleeve by a plurality of arched stringers 130. This arrangement allows a narrow annular clearance 136 between the top edge 134 of the vertical leg 124 and the bottom opening 136 of the funnel 129, which is just wide enough for a movable sleeve 132 to fit between the vertical leg 124 and the funnel 129 and to shift up and down, as explained in more detail below.

The movable sleeve 132 has an inside diameter which is just slightly larger than the outside diameter of the vertical leg 124 of the loading sleeve and an outside diameter that is just slightly smaller than the inside diameter of the bottom edge 136 of the funnel 129. A lower stop band 138 is secured to the outside surface of the vertical leg 124 to provide a lower stop for the movable sleeve 132, as shown in Figure 24. An upper stop band 140 is secured to the outside surface of the movable sleeve 132 to provide an upper stop for the movable sleeve 132, as shown in Figure 25, wherein the upper stop band 140 impacts against the bottom of the funnel 129 to stop the movable sleeve 132 at its upper limit.

It may be appreciated that, when the movable sleeve 132 is in its lowest position, as shown in Figure 24, the top edge 131 of the movable sleeve 132 is substantially flush with the top edge 134 of the vertical leg 124. However, when the movable sleeve 132 is moved to its raised position as shown in Figure 25, the top edge 131 of the movable sleeve 132 projects above the top edge 134 of the vertical leg 124 and into the funnel area itself. This slight vertical movement of the movable sleeve 132 relative to the top edge 134 of the vertical leg 124 imparts a direct mechanical force to the pellets 18 adjacent to the opening 128 that is different from forces being applied to the surrounding pellets in order to break up any bridging that may occur within the funnel 129 adjacent to the opening 128.

To use the catalyst loading device 122, the leg 124 of the loading sleeve is inserted into a reactor tube 16 until the flange 126 is resting on top of the tube sheet 12. Note that the flange 126 may be adjusted vertically along the vertical leg 124, as desired by loosening the adjustment screw 127, shifting the flange 126 to the desired position, and then tightening the adjustment screw 127. Catalyst particles (not shown) are added to the funnel 129, and the movable sleeve 132 is moved up and down to continuously break any bridge forming adjacent to the opening 128 of the loading sleeve. The movable sleeve may be moved manually or by some type of automated mechanism as described with respect to the loading device 122 ^* of Figure 36. This process continues repeatedly, with successive bridges forming and then followed by bridge breaking to load the reactor tube 16 with catalyst pellets. As is explained below with respect to another embodiment of a catalyst loading device 122 ^* (See Figure 36), the vertical movement of the movable sleeve 132 may be mechanized to automate the loading of catalyst into the reactor tubes 16.

Figures 36-40 show another embodiment of catalyst loading device 122 ^* . It is similar to the catalyst loading device 122 of Figure 24 in that it has a funnel 129 ^* , a flange 126 ^* , a vertical leg 124 ^* , a stop 138 ^* , and a through opening 128 ^* (See Figure 37) at the top of the vertical leg 124 ^* which has a small enough diameter to ensure that the flow of catalyst particles is restricted enough to prevent bridging in the leg 124 ^* and in the reactor tube 16.

Referring to Figures 37, 38, 39A, and 39, the stop 138 ^* is actually a sleeve or collar which includes a ring 139 ^* with three upwardly and inwardly projecting prongs 142 ^* . The prongs 142 ^* are parallel to each other, have their top edges at the same elevation, their bottom edges at the same elevation, and are spaced apart at 120 degree intervals. The prongs 142 ^* ride in grooves 144 ^* (See Figure 38) in the vertical leg 124 ^* . These grooves 144 ^* extend from the top edge 146 ^* of the vertical leg 124 ^* downwardly to a distance substantially equal to the height of the prongs 142 ^* , as seen in Figure 38. The grooves 144 ^* lie inside the perimeter of the funnel 129 ^* , so, as the collar 138 ^* moves upwardly, the prongs 142 ^* move up into the interior of the funnel 129 ^* . The collar 138 ^* can move upwardly until its ring 139 ^* abuts the outer surface of the funnel 129 ^* , and it can move downwardly until the bottom surfaces 148 ^* of the prongs 142 ^* abut the surfaces 150 ^* at the bottom of the grooves 144 ^* (unless the drive mechanism prevents the collar 138 ^* from reaching its upper and lower limits).

When the sleeve 138 ^* is in its lowered position, as seen in Figures 38, 39A, and 39B, the bottom surface 148 ^* of the prong 142 ^* rests on top of the surface 150 ^* at the bottom of the groove 144 ^* (see Fig. 39B), and the top surface 152 ^* of each prong 142 ^* is flush with the top edge 146 ^* of the vertical leg 124 ^* (as shown in Figures 36, 37, and 38).

When the sleeve 138 ^* is raised, as seen in Figure 40, the top surface 152 ^* of each prong 142 ^* projects upwardly into the funnel area. This vertical movement of the prongs 142 ^* of the sleeve 13 ^* allows the prongs 142 ^* to impart a direct mechanical force to the pellets 18 adjacent to the opening 128 ^* that is different from the forces being applied to the surrounding pellets in order to break up any bridging that may occur within the funnel 129 ^* adjacent to the opening 128 ^* . Therefore, this catalyst loading device 122 ^* works in a very similar manner to the catalyst loading device 122 described earlier.

Figure 36 shows an actuator 152 that is fixed relative to the vertical leg 124 ^* and that is functionally connected to the collar 138 ^* via a connecting rod 154. The actuator 152 imparts a linear, up-and-down vertical motion to the connecting rod 154, which, in turn, imparts the same motion to the collar 138 ^* , as illustrated by the arrow 156, in order to automate the bridge breaking function of the catalyst loading device 122 ^* .

Figures 26 and 27 show yet another embodiment of a catalyst loading device 122 ^** . This catalyst loading device 122 ^* includes a vertical leg 124 ^** and a funnel 129 ^** which holds the pellets above the reactor tube. The top edge 134 ^** of the vertical leg 124 ^** defines a through opening 128 ^** with a smaller diameter than the rest of the leg 124 ^** and a smaller diameter than the inside diameter of the reactor tube 16 into which the leg 124 ^** is inserted to control the flow rate of pellets in order to prevent bridging in the leg 124 ^** and in the reactor tube 16. A short distance above the top edge 134 ^** of the vertical leg 124 ^** (that distance preferably being less than the smallest dimension of the pellets 18), a rod 156 ^** projects through the sides of the funnel 129 ^** and extends substantially across and over the opening 128 ^** . The rod 156 ^** may be a stiff rod or wire, or it may have some flexibility such as may be obtained by using a thin plastic strip. A small enlargement or bump 158 ^** is located midway along the length of the rod 156 ^** . As the rod 156 ^** reciprocates horizontally back and forth in the motion indicated by the arrow 160, the enlargement 158 ^** moves across the opening 128 ^** and imparts a direct mechanical force to at least one of the pellets adjacent to the opening 128 ^** that is different from forces being applied to the other surrounding pellets in order to break up any bridges formed by the catalyst pellets adjacent to the opening 128 ^** . This process continues repeatedly, with successive bridge forming followed by bridge breaking to load the reactor tube with catalyst pellets. The rod 156 ^** may be moved manually or through an automated, reciprocating mechanism such as a linear actuator that is fixed relative to the leg 124 ^** .

Figure 28 is a plan view of another embodiment of a catalyst loading device 122'. This catalyst loading device 122' is identical to the catalyst loading device 122 ^** described above, except that it has two rods 162', 164' extending through the funnel 129' instead of the single rod 156 ^** described earlier. It should be noted that neither of these two rods 162', 164' is located directly above the centerline of the through opening 128' through which the catalyst pellets fall into the reactor tube 16. The rod or rods should be located close enough to the opening 128' to impart a direct mechanical force to at least one of the pellets adjacent to the opening 128' that is different from the forces applied to the other surrounding pellets in order to break the bridges formed adjacent to the opening 128'.

It should also be noted that the bumps 158 ^** and 158' in the rods are not strictly necessary for proper operation of the catalyst loading devices. They provide enhanced contact between the rod and the catalyst pellets and in this manner improve the bridge breaking characteristics of the device. Other means for enhancing the contact with the pellets 18, such as roughening of the rod itself, may be used for the same end result.

Figure 28 further shows a reciprocating rotary actuator 166 used to automate the reciprocating motion of the rods 162', 164' in the direction of the arrow 160'.

Though not shown in this view, the actuator 166 may be used to reciprocate rods connected to a plurality of linearly-aligned catalyst loading devices 122'.

Figures 29 and 30 show another embodiment of a catalyst loading device 122". This catalyst loading device 122" may be described as a hybrid between the catalyst loading device 24 of Figure 6A and the catalyst loading device 122 ^** of Figure 26. The catalyst loading device 122" includes a tray 26" with a plurality of through openings 36", similar to the tray 26 (See Figure 1 1 ) of the catalyst loading device 24. The arrow 168 (See Figure 29) indicates the reciprocating motion of the tray 26" to break any catalyst bridges by the tray 26" imparting a direct mechanical force to pellets resting on the underlying substrate within the openings 36" of the tray 26". The underlying substrate is not shown in this view, but has been identified earlier with respect to the description of the catalyst loading device 24, as being either a template or a plurality of loading sleeves.

A comparison of the tray 26 of Figure 1 1 with the tray 26" of Figures 29 and

30 shows the addition of stationary rods 170 with resistance enhancing bumps 172 to the catalyst loading device 122", similar to the rod 156 ^** and bump 158 ^** of the catalyst loading device 122 ^** of Figure 26. The reciprocating motion of the tray 26" relative to the stationary rods 170 (as indicated by the arrow 168) causes the rods 170 to impart a direct mechanical force to the pellets adjacent to the openings 36" that is different from the forces applied to the surrounding pellets in order to break up catalyst bridges adjacent to the openings 36". Figures 31 -35 show yet another embodiment of a catalyst loading device 122 ^Λ . This catalyst loading device 122 ^Λ is similar to the catalyst loading device 24 of Figure 6A, but it has several separate bins mounted on the loading tray 12 ^Λ so a measured load of catalyst pellets 18 is delivered into each reactor tube 16.

Referring to Figure 31 , and comparing it with Figure 6A, the catalyst loading device 122 ^Λ includes a tray 26 ^Λ with a plurality of openings that are generally aligned with the openings in the top of the reactor tubes 16. It differs from the embodiment of Figure 6A in that there are several bins 176 mounted on the tray 26 ^Λ . The openings in the tray 26 ^Λ are the same size as and are aligned with the openings 190 in the bottoms of the bins 176, and the tray 26 ^Λ is thin enough that the openings in the tray are effectively the same as the openings 190 in the bottoms of the bins 176.

As with the embodiment of Figure 6A, this embodiment includes a plurality of linear motion drives 32 ^Λ that impart a reciprocating motion to the tray 26 ^Λ (and to the bins 176 that are fixed relative to the tray 26 ^Λ ).

Referring to Figures 33 and 34, each loading bin 176 is a container having a generally rectangular cross-section with an open top 178, four side walls 180, 182, 184, and 186, and a bottom with sloping ramps 188 that directs catalyst pellets to the through opening 190 (which corresponds to the opening 36 in the tray 26 of Figure 6A). Alternatively, each bin 176 may have an open bottom which matches up directly with its corresponding loading plate 174 which is part of the loading tray 26 ^Λ , and these loading plates 174 that have the sloping ramps 188 direct catalyst pellets to the through openings 190.

The cross-section of the loading bin 176 is large enough relative to the size of the catalyst pellets that the pellets will not bridge in the bin 176 until they reach the bottom of the bin 176 adjacent the opening 190. Any bridging in the bin 176 will occur at the very bottom of the bin 176, just above the opening 190. Just as with the embodiment of Figure 6A as described earlier, the reciprocating motion of the tray 26 ^Λ will impart a direct mechanical force to the pellets resting on the template below the tray 26 ^Λ that is different from the force being applied to surrounding pellets, thereby causing relative motion between the pellets forming a bridge so as to break up the bridges and allow the pellets to fall through the openings 190 and into the reactor tubes 16. This catalyst loading device 122 ^Λ has a yoke 192 that projects above the bins 176, as shown in Figures 31 and 34, which assists with loading the catalyst pellets into the bins 176, as will now be described.

With this embodiment, catalyst pellets are delivered in catalyst transport devices 196, which are open top containers that are adjustably mounted together on a transport bar 198 as shown in Figure 32 such that their positions along the length of the transport bar 198 may be adjusted to match the location and spacing of the loading bins 176. The transport bins 196 may be sized as needed. An exact, measured charge or load of catalyst pellets 18 (See Figures 35A-35C) is loaded into each transport bin 196 outside of or adjacent to the reactor prior to the loading operation. This charge may be measured by volume, by weight, or by some other desired means. In this particular embodiment, the transport bins 196 have marking lines 197 at various elevations, which indicate the various volume charges of pellets that would be loaded into the transport bin 196 if the pellets reached the particular marking line 197.

There are spools 200 mounted on the loading bar 198, and these spools rest on the yokes 192 of the loading bins 176. The spools 200 aid in the proper alignment of the transport bins 196 with the respective loading bins 176 and provide a bearing surface to support the transport bins 196 on the yokes 192. There also are handles 202 mounted on the transport bar 198 to assist the operators in pivoting the transport bins 196 to empty the catalyst pellets 18 into the respective loading bins 176, as shown in Figures 35B and 35C.

Initially, a measured charge of catalyst pellets 18 is loaded into each of the transport bins 196 (See Figure 35A). This preferably is done outside of the reactor 13 (See Figure 1 ). A plurality of these catalyst transport bins 196 may be used such that some of them are being loaded while others are being used to transport catalyst to the catalyst loading device 122 ^Λ , or the catalyst pellets may be delivered to the site pre-measured and pre-loaded into the transport bins 196.

The transport bins 196 may be picked up by the operators and transferred into the reactor vessel 13 through the manhole 17 for fixed head reactors or onto the reactor tube sheet area for removable head reactors either individually or in groups that are already mounted on a transport bar 198. Referring to Figure 35A, the catalyst transport bins 196, mounted on the transport bar 198, are moved in the direction of the arrow 204, and placed onto the catalyst loading device 122 ^Λ such that the spools 200 rest on the yokes 192, which automatically aligns the transport bins 196 with the loading bins 176, as shown in phantom. The operators then pivot the transport bar 198 in the direction shown by the arrows 206, 208 of Figure 35B until all the catalyst pellets 18 are emptied from the transport bins 196 into their respective loading bins 176, as shown in Figure 35C.

Once the catalyst is loaded into the loading bins 176, the transport bar 198 with attached transport bins 196 is removed and the motion drives 32 ^Λ are powered up to start the reciprocating motion of the tray 26 ^Λ and of the loading bins 176 that are fixed to the tray 26 ^Λ . Note that the catalyst loading device 122 ^Λ is mounted on a template 20, or on a plurality of loading sleeves 22, or may even be mounted directly on the tube sheet 12. If no template or loading sleeves are used, the openings 190 should be small enough to control the flow rate of pellets into the reactor tubes 16 to prevent bridging inside the reactor tubes 16.

The reciprocating motion of the catalyst loading device 122 ^Λ imparts a force to at least one of the pellets resting on the template 20 or loading sleeve 22 or tube sheet 12 that is different from the force being applied to the surrounding pellets in order to break up any bridging in the loading bins 176 adjacent to the openings 190 to keep the catalyst pellets 18 flowing into the respective reactor tubes 16. This process continues repeatedly, with successive bridge forming followed by bridge breaking to load the reactor tubes 16 with catalyst pellets 18.

It should be noted that the speed of the reciprocating motion of the catalyst loading device 122 ^Λ may be adjusted as desired to achieve the desired flow of pellets through the loading device 122 ^Λ and into the reactor tubes 16.

It will be obvious to those skilled in the art that modifications may be made to the embodiments described above without departing from the scope of the present invention.