PETROVAL

Dense catalyst loading

- Improved performance of reactors - Densicat and Catapac technologies - Specialist know-how

1.The dense loading process

The advantages of Densicat/Catapac technologies

Better dense loading
During loading - More homogenous loading - Lower void space in the catalyst bed - 10 to 20% more catalyst can be loaded - Loading rate up to 25 t/h During operation - Maximum catalyst activity - Homogeneous distribution of the flow in the reactor - Reactor at maximum capacity.

Densicat and/or Catapac : Horizontal orientation of catalyst particles

Reminder of the sock loading process

During loading - Loading is not homogeneous - High void space in the catalyst bed - Reactor capacity not at maximum - Loading rate about 6 to 8 t/h - High risk of catalyst attrition - Risk of breakage if the technician walks on the bed during loading During operation - Preferential channels can form > Higher temperatures > Preferential coking/plugging > Shorter cycle - Compaction of the catalyst bed - Increased maintenance budget - Non optimised operation of the loaded catalyst.

The (PETROVAL) Dense Loading process

A certified, experienced technician
- Trained in the specific characteristics of the reactors - Certification renewed every year

A certified machine
- The latest available technology : Densicat and/or Catapac - Full maintenance before each job

Technical procedure in accordance with standards

- Catalyst density guaranteed before loading - Machine installed in accordance with PETROVAL standards - Inspection and checking of the catalyst bed profile - Fully documented report

Sock loading : Random catalyst particles orientation

2.Densicat and Catapac

For efficient dense loading, the PETROVAL solution : Densicat, Catapac

Best possible distribution of catalyst particles Efficient for all types of catalyst : - Cylindrical extrudes - Trilobe extrudes - Quadrilobe extrudes - Spherical - Tablets Reduces attrition and dust Fast and safe
Densicat

Maximum density and levelness of the catalyst bed

- Better activity and stability of the catalyst bed - Eliminates preferential paths

Very flexible technologies

Size and type of reactor
- Diameter from 0,4 to 7,5 m. - Reactor types : axial, radial, spherical, multi-bed, reactor with excentric manholes ... - The only procedures capable of loading very large reactors

Horizontal orientation of the particles

- Better contact between reactive phases

High loading rate

- High level of activity and better availability of the unit

Catalyst flow
- From 0,6 to 25 t/h - The only procedures capable of achieving very high catalyst flows without causing attrition

Maximum load volume

- These technologies permit loading up to 40cm below the distribution tray (depending on reactor diameter)

Catapac

Petroval know-how
More than 50 reactors / year / PETROVAL technician Each technician is trained for all types of dense loading Density guaranteed Flat profile of bed

3.The technical advantages

Evolution and product research : Densicat, a procedure in constant evolution

Densicat (a)
- Limitation of loading flow below 10 t/h - Densicat loading was limited to reactors with a diametre of less than 1,8 m

Objective 1: load density

Advantages of dense loading linked to density
- Load density is near to maximum density - The increase in density depends on the type and size of the material to be loaded: Type
Cylindrical extrudes Trilobe extrudes Quadrilobe extrudes Spherical Tablets

Evolution 1 (b)
- Optimisation of catalyst distribution by improvement of the loading flow - Flow limited to about 15 t/h - Problems observed : Too much catalyst flow in the centre of the reactor, hemispherical distribution not well managed

Density gained
14 % to 17 % to 17 % to 8 % to 12 % to 20 % 20 % 21 % 12 % 17 %

Evolution 2 (c)
- Modification of the strip layout for more reliable permeability during loading. - Better distribution. Flat distribution profile with a large catalyst flow, up to 25 t/h

For an existing reactor or for a new reactor, this increase in density allows: - Either to increase the conversion rate while maintaining the same operating conditions - Or to vary the operating conditions to your advantage while maintaining the same performance.

Evolution 3
In R&D phase.

Ojective 2 : optimum loading organisation

- Technical analysis and preparation of the worksite

- Choice of technology : Densicat or Catapac - Permanent on-site interface with the customer - Approval of the customers load targets (density, loading plan, organisation, etc.)

- Pre-loading report - Technical report approved by the PETROVAL technical manager

Petroval loading
Examples of poor dense loading

Dense load badly distributed

Concave dense load

Convex dense load

Correct dense loading

Objective 3: loading homogeneity

Correct dense loading
=37 =10 =6

Zone 3

- The orientation of the particles does not affect the flow - Orientation of catalyst pellets > Horizontal > Perpendicular to the flow Horizontal orientation of the pellets Densicat Zone Zone 2 Zone 3 Yes No No Maximum density Yes Yes No

Zone 2 Densicat Zone

PETROVAL : The dense loading specialist

Refineries and petrochemical sites More than 3 500 projects carried out since the 1990s and more than 1 200 reactors loaded Long term agreements and partnerships with > ExxonMobil, Shell, Total, BP > Loading performed in more than 50 countries around the world, on all six continents.

4. Examples of industrial applications

Zone Unit Reactor Team mobilised No. of loading shifts Quantity loaded Load height Reactor diametre Same type of loading

Europe DGO 1 bed 1 1 60 t 8,5 m 3,5 m 125/year

Zone Unit Reactor Team mobilised No. of loading shifts Quantity loaded Load height Reactor diametre Same type of loading

Europe Reforming Radial 1 1 25 t 10 m 2,8 m 15/year

Zone Unit Reactor Team mobilised No. of loading shifts Quantity loaded Load height Reactor diametre Same type of loading

Asia HDT 3 beds 2 (J/N) 6* 500 t 25 m 5,7 m 137/year

Zone Unit Reactor Team mobilised No. of loading shifts Quantity loaded Load height Reactor diametre Same type of loading

Asia Ammonia Co S200 1 1 35 t 14 m 1,2 m 15/year

Zone Unit Reactor Team mobilised No. of loading shifts Quantity loaded Load height Reactor diametre Same type of loading

USA HDS 6 beds 2 (J/N) 10* 450 t 35 m 4,5 m 45/year

Zone Unit Reactor Team mobilised No. of loading shifts Quantity loaded Load height Reactor diametre Same type of loading

Europe Anilin Tubular

(11800 tubes 1)

1 1 15 t 3m 3,5 m 5/year

Zone Unit Reactor 8 reactors Team mobilised No. of loading shifts Quantity loaded Load height Reactor diametre Same type of loading

Asia ARDS double beds 4 (J/N) 25* 800 t 20 m 4,8 m 25/year

Zone Unit Reactor Team mobilised No. of loading shifts Quantity loaded Load height Reactor diametre Same type of loading

Europe Powerformer Sphrical 1 1 36 t 4,7 m 6,3 m 10/year

* Internal assembling stations included

PETROVAL quality charter + PETROVAL technology + PETROVAL reactiveness

= optimization of maintenance shutdown and catalyst reliability

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PETROVAL
PETROVAL SA
PETROVAL SA - Parc Econormandie - BP 66 - 76430 Saint Romain de Colbosc - France Tl. : +33 (0)2 35 31 00 00 - Fax : +33 (0)2 35 31 35 35 - E-Mail : petroval@petroval.com PETROVAL LP - PO BOX 56625 - Houston, Texas 77256-6625 - United States Phone: +1 713 527 9575 - Fax: +1 713 529 7573 - E-mail: petroval@petroval.com

Cration : Cox-Solutions cratives