Catalytic reactor charging system and method for operation thereof

Abstract

A catalyst loading system for utilizing catalyst from a bulk supply located adjacent but not on the upper tube sheet of a catalytic reactor and for mechanized measuring of multiple identical quantities of catalyst and for mechanized loading of catalyst pellets into the reaction tubes of the reactor to achieve even drop rate, compaction and outage of the reaction tubes. From the bulk supply, multi-compartment catalyst charging hoppers are individually filled in rapid and accurately measured fashion by mechanized filling equipment having a predetermined sequence of operation that ensures accuracy of volumetric catalyst measurement. The charging hoppers are used for delivery of measured volumes of catalyst of a reactor tube loading mechanism which may take the form of a mobile cart framework being selectively positionable relative to the upper tube sheet and reaction tubes of a catalytic reactor to be charged with catalyst pellets. A pair of electronic vibrators are mounted to the cart framework and provide for support and vibratory movement of a vibratory tray having a catalyst feed hopper adapted to feed catalyst pellets to a plurality of generally parallel catalyst transfer troughs along which catalyst pellets are moved by vibration of the vibratory tray to a plurality of drop tubes. A compartmented hopper is fixed to the vibratory tray and controllably feeds catalyst pellets into respective catalyst transfer troughs. A plurality of charging tubes are connected to respective drop tubes by a plurality of elongate flexible tubes and are maintained in fixed, spaced relation by a structural element so as to define a charging manifold for simultaneous, timed delivery of catalyst pellets into a plurality of reactor tubes. The charging manifold has locator pins which are inserted into selected reactor tubes for orienting the charging tubes of the charging manifold with respect to a selected group of reaction tubes. A system is also provided for raising and lowering the charging manifold for efficiency of reactor tube charging operations. An electronic control system is effective for controlling the vibrators to achieve even drop rate from each of the catalyst transfer troughs and to control the vibrators responsive to catalyst weight to achieve even catalyst drop rate during an entire catalyst charging cycle.

What is claimed is:  
     
         1 . A catalyst loading cart for mechanized loading of catalyst pellets into the reaction tubes of a catalytic reactor, comprising: 
 (a) a cart framework being selectively positionable relative to the upper tube sheet of a catalytic reactor to be charged with catalyst pellets;    (b) at least one electronic vibrator being fixed to said cart framework;    (c) a vibratory tray being connected for vibration thereof by said electronic vibrator and having a plurality of generally parallel catalyst transfer troughs through which catalyst pellets are moved by vibration of said vibratory tray and a plurality of drop tubes through which catalyst pellets drop from said catalyst transfer troughs of said vibratory tray;    (d) a loading cart hopper being fixed to said vibratory tray and having a plurality of catalyst compartments each being disposed to feed catalyst pellets into respective catalyst transfer troughs;    (e) a catalyst charging manifold having a plurality of charging tubes each being disposed in immovable spaced relation and being receivable within the reaction tubes of the reactor,    (f) a plurality of elongate flexible tubes having upper and lower ends and having the upper ends thereof connected to respective drop tubes and the lower ends thereof connected to respective charging tubes;    (g) charging manifold locator elements projecting from said charging manifold and being receivable within selected reactor tubes for location of said charging tubes within other selected reactor tubes for charging thereof with catalyst pellets; and    (h) electronic control means being in electrically controllable connection with said at least one electronic vibrator and being adjustable to achieve vibrator control for substantially identical discharge rate of catalyst pellets from each of said catalyst transfer troughs.    
     
     
         2 . The catalyst loading cart of    claim 1   , wherein said at least one electronic vibrator comprising: 
 (a) a pair of electronic vibrators each having electronic operational circuits and having vibratory connection with respective side portions of said vibratory tray;    (b) a pair of adjustable electronic trimmer circuits being electrically connected to respective electronic operational circuits of respective electronic vibrators for adjusting the amplitude of vibration thereof to achieve substantially identical rate of discharge of catalyst pellets from each catalyst transfer trough of said vibratory tray; and    (c) a master adjustable electronic vibrator control circuit being electronically connected to both of said adjustable electronic trimmer circuits and being adjustable to vary the rate of catalyst discharge from said vibratory tray.    
     
     
         3 . The catalyst loading cart of    claim 1   , wherein: 
 (a) weight responsive signal means generating electronic control signals responsive at least in part to the weight of catalyst pellets within said loading cart hopper; and    (b) control circuitry receiving said weight responsive signals and controlling the amplitude of vibration of said electronic vibrator responsive to said weight responsive signals to achieve a selected rate of catalyst pellet discharge from said vibratory tray regardless of the weight of catalyst pellets within said loading cart hopper.    
     
     
         4 . The catalyst loading cart of    claim 3   , wherein said weight responsive signal means comprising: 
 (a) an accelerometer being fixed to said vibratory tray for detecting the amplitude of vibratory motion thereof and providing an amplitude related electronic signal output responsive thereto:    (b) a signal conditioning circuit receiving and conditioning said amplitude related electronic signal output and providing conditioned weight related output signals; and    (c) said control circuitry receiving said conditioned weight related output signals and controlling operation of Said vibrator to maintain substantially constant vibratory amplitude of said vibratory tray as the weight of catalyst pellets within said loading cart hopper is depleted during a catalyst loading cycle.    
     
     
         5 . The catalyst loading cart of    claim 1   , wherein: 
 (a) wheel retraction means being moveably connected to said cart framework: and    (b) wheels being connected to said wheel retraction means and being selectively positionable by said wheel retraction means at an extended position for mobile support of said catalyst loading cart by said wheels and a retracted position for support of said catalyst loading cart by said cart framework.    
     
     
         6 . The catalyst loading cart of    claim 5   , wherein: 
 (a) a pair of wheel positioning elements each being pivotally connected to said cart framework;    (b) a pair of wheels being mounted to each of said wheel positioning elements; and    (c) an actuator assembly being supported by said cart framework and being operative to impart pivoting movement to said wheel positioning plates for selectively positioning said wheels at said extended and retracted positions thereof.    
     
     
         7 . The catalyst loading cart of    claim 1   , wherein: 
 (a) a vent hood being pivotally mounted to said vibratory tray for location above said plurality of catalyst transfer troughs; and    (b) a source of vacuum being in communication with said vent hood for removing dust released from catalyst pellets during transfer thereof along the length of said catalyst transfer troughs.    
     
     
         8 . The catalyst loading cart of    claim 1   , wherein: 
 (a) said catalyst transfer troughs each having perforate bottom wall sections through which catalyst tailings and dust descend for separation thereof from the catalyst pellets being transferred along said catalyst transfer troughs by vibratory action of said vibratory tray; and    (b) a catch pan being located immediately below said catalyst transfer troughs and in position for catching any catalyst tailings and dust that descend through said perforate bottom wall sections.    
     
     
         9 . The catalyst loading cart of    claim 8   , wherein: 
 a source of vacuum being in communication with said catch pan for removing catalyst tailings and dust released from catalyst pellets and descending through said perforate bottom wall sections during transfer of catalyst pellets along the length of said catalyst transfer troughs by said vibratory action of said vibratory tray.    
     
     
         10 . The catalyst loading cart of    claim 1   , wherein: 
 said catalyst charging manifold being vertically movable relative to said vibratory tray to permit efficiency of selective positioning of said charging tubes in charging relation with selected reactor tubes.    
     
     
         11 . The catalyst loading cart of    claim 1   , wherein: 
 (a) a plurality of adjustment tubes being disposed in telescoping vertically adjustable relation with respective drop tubes;    (b) a structural member securing said adjustment tubes in fixed relation with one another; and    (c) means for moving said structural member and thus said adjustment tubes upwardly and downwardly relative to said drop tubes; and    (d) said flexible tubes of said charging manifold being connected to respective adjustment tubes and, upon vertical movement thereof by said adjustment tubes, causing vertical movement of said charging manifold.    
     
     
         12 . The catalyst loading cart of    claim 1   , wherein: 
 (a) said loading cart hopper defining an upwardly facing opening and having a movable closure for said upwardly facing opening;    (b) a portable charging hopper having the same number of internal catalyst compartments as said loading cart hopper and having an open bottom section adapted to be received in charging assembly with said upwardly facing opening of said loading cart hopper; and    (c) a slide gate being positionable to close said open bottom of said portable charging hopper for securing catalyst pellets with said internal catalyst compartments of said portable charging hopper and being selectively movable to an open position for dumping catalyst pellets into respective catalyst compartments of said loading cart hopper.    
     
     
         13 . The catalyst loading cart of    claim 12   , wherein: 
 (a) said portable charging hopper defining an upwardly facing opening; and    (b) a closure being in movable relation with said portable charging hopper and being positionable for closing said upwardly facing opening thereof.    
     
     
         14 . The catalyst loading cart of    claim 12   , wherein: 
 (a) said portable charging hopper defining a gate opening and gate track;    (b) said slide gate being movable through said gate opening and along said gate track during opening and closing movement thereof.    
     
     
         15 . A method for charging the multiple reaction tubes of a catalytic reactor having a shell and an upper tube sheet to which the upper ends of a multiplicity of reaction tubes are connected and to charge the reaction tubes with measured charges of catalyst pellets, comprising: 
 (a) locating on the upper tube sheet and within the bounds of the reactor shell of the catalytic reactor a catalyst loading cart having a multiple compartment feed hopper and a multi trough vibratory tray operated by a pair of electrically energized vibrators and having a plurality of drop tubes for simultaneous dropping of catalyst pellets into a plurality of the reaction tubes of the reactor;    (b) controllably vibrating the vibratory tray of the catalyst loading cart for controlled transfer of catalyst pellets along said multiple troughs for dropping thereof through said drop tubes and into the reaction tubes at a predetermined drop rate;    (c) locating a catalyst charging hopper at a catalyst source outside the bounds of said upper tube sheet, said catalyst charging hopper having the same number of charging compartments as the number of compartments of said feed hopper;    (d) filling all of said measuring compartments of said charging hopper with catalyst pellets;    (e) closing said charging hopper;    (f) manually transporting the filled charging hopper to said catalyst loading cart and placing said charging hopper in charging assembly with said feed hopper, with the compartments of said charging hopper in charging registry with the compartments of the feed hopper;    (g) simultaneously releasing the catalyst of said charging compartments into the compartments of said feed hopper; and    (h) returning said charging hopper to said catalyst supply site for refilling thereof with catalyst.    
     
     
         16 . The method of    claim 15   , comprising: 
 (a) providing electronic signals responsive to the weight of catalyst within said feed hopper; and    (b) adjusting the electrical supply to said vibrators responsive to said weight related electronic signals to maintain the amplitude of vibrator movement substantially constant at all conditions of catalyst weight within said feed hopper.    
     
     
         17 . The method of    claim 15   , comprising: 
 (a) measuring the amplitude of movement of said vibratory tray with said feed hopper full of catalyst and providing electronic signals responsive to the measured amplitude;    (b) adjusting the electrical supply to said vibrators responsive to weight responsive changes to said measured amplitude to maintain the amplitude of movement of said vibratory tray substantially constant at all conditions of catalyst weight within said feed hopper.    
     
     
         18 . A method for filling a multi-compartment catalyst charging hopper with a measured quantity of catalyst with each measuring compartment thereof containing substantially identical volumes of catalyst, comprising: 
 (a) providing a bulk catalyst hopper having a discharge outlet and a discharge gate movable to an open position to permit discharge of catalyst into said charging hopper and a closed position blocking discharge of catalyst from said discharge outlet;    (b) positioning a charging hopper at a fill position to receive discharge of catalyst from the discharge outlet of the bulk catalyst hopper;    (c) opening said gate for a sufficient period of time to overfill each of the measuring compartments of said charging hopper,    (d) closing said gate;    (e) removing excess catalyst from each of the measuring compartments of the charging hopper; and    (f) moving the charging hopper from said fill position.    
     
     
         19 . The method of    claim 18   , wherein said step of positioning comprises: 
 (a) placing an empty charging hopper on a movable trolley of said bulk hopper, with the movable trolley located at a start position;    (b) moving the movable trolley to a loading position where the catalyst charging hopper is located to receive catalyst from the bulk hopper discharge outlet; and said charging hopper has been overfilled, returning the movable trolley to the start position.    
     
     
         20 . The method of    claim 18   , comprising: 
 vibrating the charging hopper during filling thereof to settle catalyst in the multiple measuring compartments of the charging hopper and to ensure complete filling of each of the multiple measuring compartments thereof.    
     
     
         21 . The method of    claim 18   , wherein said moving step comprising: 
 (a) moving a filled charging hopper from said fill position; and    (b) during said moving of the filled charging hopper applying a wiper to excess catalyst present on the charging hopper to wipe away the excess, thus leaving the charging hopper with accurately measured volumes of catalyst in each of the multiple measuring compartments thereof.    
     
     
         22 . The method of    claim 21   , wherein the wiper being a brush, the method comprising: 
 brushing away excess catalyst.    
     
     
         23 . The method of    claim 21   , wherein the wiper being a movable brush, the method comprising: 
 moving the movable brush against the excess catalyst for brushing away excess catalyst.    
     
     
         24 . The method of    claim 21   , wherein the wiper being a rotatable brush, the method comprising: 
 rotating the rotatable brush against the excess catalyst during return of the trolley from the fill position to the start position for brushing away excess catalyst.    
     
     
         25 . The method of    claim 18   , wherein a catch receptacle is located beneath said discharge outlet of said bulk hopper, said method comprising: 
 (a) during said moving step directing removed excess catalyst into the catch receptacle; and    (b) periodically returning excess catalyst from the catch receptacle to the bulk hopper.    
     
     
         26 . The method of    claim 18   , wherein the bulk hopper mechanism defining a substantially closed filling chamber, said method comprising: 
 removing air borne catalyst dust from the substantially closed filling chamber.    
     
     
         27 . A method for filling a multi-compartment catalyst charging hopper with a measured quantity of catalyst with each measuring compartment thereof containing substantially identical volumes of catalyst, comprising: 
 (a) providing a bulk catalyst hopper having a discharge outlet and a discharge gate movable to an open position to permit discharge of catalyst into said charging hopper and a closed position blocking discharge of catalyst from said discharge outlet;    (b) positioning a charging hopper on a movable trolley at a start position and moving the trolley and charging hopper to fill position to receive discharge of catalyst from the discharge outlet of the bulk catalyst hopper;    (c) opening said discharge gate for a sufficient period of time to overfill each of the measuring compartments of said charging hopper;    (d) closing said discharge gate;    (e) moving said movable trolley with the overfilled charging hopper thereon from said fill position to said start position; and    (f) during said moving causing contact of excess catalyst of the overfilled charging hopper with a brush thus brushing excess catalyst from each of the measuring compartments of the charging hopper.    
     
     
         28 . Apparatus for filling a multiple compartment catalyst charging hopper such that each of the multiple measuring compartments thereof contain substantially identical volumes of catalyst, comprising: 
 (a) a bulk hopper having a discharge outlet;    (b) a discharge gate being movable to an open position permitting discharge of catalyst from said discharge outlet and being movable to a closed position blocking the discharge of catalyst from said discharge outlet;    (c) a trolley adapted for support of a charging hopper and being movable from a start position where the charging hopper is manually accessible to a fill position where the charging hopper is positioned for receiving catalyst from said discharge outlet;    (d) means for moving said trolley from said start position to said fill position and for returning said trolley from said fill position to said start position; and    (e) means for removing excess catalyst from the charging hopper during said returning of said trolley from said fill position to said start position.    
     
     
         29 . The apparatus of    claim 28   , wherein; 
 (a) a track extending from said start position to said fill position;    (b) said trolley having wheels having rolling engagement with said track; and    (c) said means for moving said trolley being a linear motor mounted to said apparatus and having driving connection with said trolley.    
     
     
         30 . The apparatus of    claim 28   , wherein said means for removing excess catalyst from said catalyst charging hopper comprising; 
 a brush disposed for engagement with excess catalyst on said catalyst charging hopper during movement of said trolley from said fill position to said start position.    
     
     
         31 . The apparatus of    claim 30   , wherein: 
 a vibrator being mounted to said trolley and, when energized, causing vibration of said trolley for settling catalyst within each of the multiple measuring compartments of the catalyst charging hopper.    
     
     
         32 . The apparatus of    claim 28   , comprising: 
 (a) a base structure; and    (b) means adjustably supporting said bulk catalyst hopper on said base structure and being adapted for controlled elevational positioning of said bulk catalyst hopper relative to said base structure.