Method and apparatus for installing and removing catalyst carriers

Abstract

A method for installing a catalyst carrier (10) into a first selected reaction tube (8a) of a tubular reactor (1). The method includes the steps of: i) providing an installation tool (20) comprising: a) an installation frame (21); b) a movable plunger (22) mounted to the installation frame and configured to push one or more catalyst carriers into the first selected reaction tube; and c) one or more anchors (23) for releasably attaching the installation frame to the tubular reactor; ii) attaching the installation tool (20) to the tubular reactor (1) by engaging the one or more anchors (23) located in one or more reaction tubes (8b) adjacent to the first selected reaction tube (8a) to align the movable plunger (22) with the first selected reaction tube (8a); and iii) actuating the movable plunger (22) to push the one or more catalyst carriers (10) into the first selected reaction tube (8a).

Description

[0001] This disclosure relates to methods and apparatus for installing and removing catalyst supports. In particular, this disclosure relates to installation tools, methods, and systems for installing catalyst supports into the reaction tubes of tubular reactors. Additionally, this disclosure relates to methods and accessories for installing catalyst supports into such reaction tubes and for emptying such reaction tubes that were initially at least partially filled with catalyst supports. Furthermore, this disclosure relates to catalyst supports and associated components for installation into such reaction tubes. Background Technology

[0002] Conventionally, a so-called fixed-bed tubular reactor comprises a reactor shell containing multiple tubes, typically cylindrical, which are usually directly filled with catalyst particles. In operation, a heat transfer medium flows through the reactor shell outside these tubes, thereby regulating the temperature of the catalyst within the tubes through heat exchange across the tube walls. Thus, when the reaction is exothermic, the heat transfer medium allows heat to be removed from the catalyst, and when the reaction is endothermic, the heat transfer medium provides heat to the catalyst.

[0003] For some reactions, the heat effect is moderate, so they do not cause problems or can be easily managed. In some cases, the heat effect is small enough that large-diameter tubes can be used. The advantage of doing so is that a large amount of catalyst can be contained within the tube.

[0004] However, for more exothermic or endothermic reactions, efficient heat transfer through the tube wall to the heat transfer medium is necessary to control conditions within the reactor and maintain a stable operating temperature to avoid adverse effects. For exothermic reactions, such effects can include the occurrence of side reactions, damage to the catalyst (e.g., through sintering of catalytic active sites), and, in the worst case, thermal runaway. Adverse effects of endothermic reactions can include reaction quenching.

[0005] To achieve the desired efficiency, the surface area of ​​the tube wall per unit length must be maximized. Historically, this was achieved by installing a larger number of smaller diameter tubes. In some reactions, size constraints mean that the inner diameter of the tubes is only about 15 mm to 40 mm. However, the use of such multiple tubes increases the cost and complexity of the reactor.

[0006] Therefore, in an attempt to mitigate these problems, an alternative approach has been developed, particularly for more exothermic or endothermic reactions, in which the catalyst is not directly loaded into the reaction tube, but is contained in multiple catalyst supports configured to sit inside the reaction tube.

[0007] WO2011 / 048361 describes a first type of such catalyst support. This arrangement seeks to optimize heat transfer at the tube wall, allowing for the use of larger tubes and smaller catalyst particles with larger volumes, even for more exothermic or endothermic reactions. The catalyst support described in WO2011 / 048361 includes an annular container for retaining the catalyst during use. The container has a perforated inner wall defining the tube, a perforated outer wall, a top surface sealing the annular container, and a bottom surface sealing the annular container. The surface sealing the bottom of the tube is formed by the inner wall of the annular container. A skirt extends upward from the perforated outer wall of the annular container from a position at or near the bottom surface of the container to a position below the location of the seal. The seal is located at or near the top surface and extends a distance from the container beyond the outer surface of the skirt.

[0008] WO2012 / 136971 describes a second type of such catalyst support. In this arrangement, the catalyst support includes: a container for holding a monolithic catalyst in use, the container having a bottom surface that closes the container and a skirt extending upward from the bottom surface of the container to a position below and spaced apart from a seal, the skirt being positioned such that a space exists between the outer surface of the monolithic catalyst and the skirt; and a seal located at or near the top surface of the monolithic catalyst and extending a distance from the monolithic catalyst beyond the outer surface of the skirt.

[0009] WO2016 / 050520 describes a third type of such catalyst support. In this arrangement, the catalyst support includes a container for retaining the catalyst during use. The container has a bottom surface and a top surface that close the container. An outer wall of the support extends from the bottom surface to the top surface, and a seal extends from the container beyond the outer wall of the support. The outer wall of the support has an opening located below the seal.

[0010] This method, tool, and system can be applied to any catalyst support suitable for insertion into a tubular reactor.

[0011] In tubular reactors, hundreds or even thousands of these catalyst supports may be present, making rapid and efficient loading crucial for users. Furthermore, for optimal performance of both the catalyst support and the reactor, loading should ensure proper alignment of the catalyst support within the reaction tube. In heat-exchange tubular reactors, it is also desirable to place the catalyst support within the heat exchange zone to prevent uncontrolled heating or cooling. Additionally, if necessary, it is desirable to develop suitable equipment and methods for removing the catalyst support from the reaction tube.

[0012] The purpose of this disclosure is to provide apparatus and methods for loading and unloading catalyst supports to address these problems. Summary of the Invention

[0013] In a first aspect of this disclosure, a method is provided for mounting a catalyst support into a first selected reaction tube of a tubular reactor, the method comprising the steps of:

[0014] i) Provide an installation tool, which includes:

[0015] a) Install the rack;

[0016] b) A movable plunger, which is mounted to the mounting frame and configured to push one or more catalyst supports into the first selected reaction tube;

[0017] and

[0018] c) One or more anchors for releasably attaching the mounting frame to the tubular reactor;

[0019] ii) Attaching the installation tool to the tubular reactor by engaging one or more anchors located in one or more reaction tubes adjacent to the first selected reaction tube, so as to align the movable plunger with the first selected reaction tube; and

[0020] iii) Actuate the movable plunger to push the one or more catalyst supports into the first selected reaction tube.

[0021] A second aspect of this disclosure provides an installation tool for mounting a catalyst support into a selected reaction tube of a tubular reactor, the installation tool comprising:

[0022] a) Install the rack;

[0023] b) A movable plunger, mounted to the mounting frame and configured to push one or more catalyst supports into the selected reaction tube; and

[0024] c) One or more anchors for engaging one or more reaction tubes located adjacent to the selected reaction tube, so as to releasably attach the mounting frame to the tubular reactor.

[0025] A third aspect of this disclosure provides an installation system for mounting a catalyst support into a reaction tube of a tubular reactor, the installation system comprising:

[0026] Installation tools, as provided in the second aspect, and configured for installation in the top or bottom space of the tubular reactor;

[0027] A power source, which can be located outside the tubular reactor and is configured to move a movable plunger of the installation tool; and

[0028] One or more hoses are used to supply power from the power source to the installation tool.

[0029] This method and system can be applied to any catalyst support to be inserted into a tubular reactor.

[0030] In some implementations, the power source may alternatively be located inside the tubular reactor.

[0031] Advantageously, the installation tool facilitates the loading of the catalyst carrier into the reaction tube of the tubular reactor. The installation tool also facilitates proper alignment of the catalyst carrier during loading. In particular, the engagement of one or more anchors improves the alignment of the movable plunger with the selected reaction tube. Advantageously, the engagement of one or more anchors in one or more reaction tubes adjacent to the first selected reaction tube avoids the need for any part of the anchoring system to be located within or extend into the first selected reaction tube. This results in a simpler and faster loading method.

[0032] The one or more reaction tubes adjacent to the first selected reaction tube may be one or more reaction tubes immediately adjacent to the first selected reaction tube, or alternatively, one or more reaction tubes close to the first selected reaction tube.

[0033] In step ii) of the method of the first aspect, the mounting tool may be attached such that the mounting frame is located in the top or bottom space of the tubular reactor outside the reaction tubes. The mounting frame may be located above the upper tube sheet of the tubular reactor or below the lower tube sheet of the tubular reactor. In the case of a vertically oriented tubular reactor, it is generally preferred to load the catalyst carrier from the top of the tubular reactor. Therefore, in some preferred embodiments, the mounting tool may be located above the upper tube sheet in the top space of a vertically oriented tubular reactor.

[0034] Advantageously, the size of the installation tool can be set to fit into the top or bottom space of the tubular reactor. Step i) of the method of the first aspect may also include inserting the installation tool into the top or bottom space of the tubular reactor through an access port of the tubular reactor.

[0035] Advantageously, the dimensions of the installation tool can be configured to allow the installation rack to be moved into and out of the top or bottom space. This allows the installation tool to be completely removed from the tubular reactor after loading is complete, meaning that components do not need to be left inside the tubular reactor during operation, which could otherwise obstruct gas flow into or out of the reaction tube.

[0036] The movable plunger can be a powered plunger or a manually driven plunger. The movable plunger can be switched between a powered mode in which it moves under power and a manual mode in which it is manually driven. The movable plunger can be a hydraulic plunger, a pneumatic plunger, or an electromechanical plunger.

[0037] Advantageously, powered plungers can improve operating efficiency by providing increased and consistent insertion force to the catalyst support. However, in some cases, it may be desirable to use manually driven plungers or manually driven normally powered plungers.

[0038] In some embodiments, the installation tool may be coupled to a power source for moving the movable plunger, which may be located outside the tubular reactor. Positioning the power source outside the tubular reactor is advantageous if internal space is limited. This power source may include a hydraulic, pneumatic, or electrical source. For example, in some embodiments, the power source may be a hydraulic source connected to the installation tool via one or more hydraulic hoses that extend through an access port in the tubular reactor. This arrangement allows for the use of a larger hydraulic source (unsuitable for use through the access port) and also allows for a reduction in the size of the installation tool.

[0039] In some other embodiments, the installation tool may include a power source located inside the tubular reactor for moving the movable plunger. In this case, the power source may include a hydraulic source, a pneumatic source, or an electrical source. For example, in some embodiments, the power source may be an electrical source, such as an electric motor directly mounted on the mounting frame.

[0040] In step iii) of the method of the first aspect, an insert assembly of one, two, three, or more catalyst supports can be pushed into the first selected reaction tube by a single stroke of the movable plunger. Step iii) of the method of the first aspect can be repeated once or more to push one or more additional insert assemblies into the first selected reaction tube.

[0041] The mounting frame may define a loading station for receiving the one or more catalyst carriers. The loading station may be configured to hold an insert assembly of one, two, three, or more catalyst carriers, and a movable plunger may be configured to push the insert assembly of catalyst carriers into the first selected reaction tube in a single stroke.

[0042] Advantageously, forming the catalyst support as an insert assembly can improve operational efficiency by reducing the loading time of the mounting tool, especially when the insert assembly is pre-formed. The insert assembly can also be used to maintain the mutual alignment of the catalyst supports in the setup, reducing the chance of misalignment during insertion of the reaction tube.

[0043] Pushing the insert assembly into the first end of the first selected reaction tube can cause one or more catalyst supports to be ejected from the second end of the first selected reaction tube. For example, when the installation tool is used on a reaction tube initially filled with catalyst supports, pushing the catalyst supports into the first end can be used to discharge the catalyst supports from the second end. In this way, the catalyst supports in the reaction tube can be replaced efficiently. All catalyst supports initially in the reaction tube can be replaced in this manner (e.g., when it is desired to completely refresh the catalyst in the reaction tube). Alternatively, in this case (e.g., when the initial vessel in the reaction tube needs to be replaced due to, for example, catalyst poisoning), only a few catalyst supports at the second end can be replaced. The second end can be the lower end or the upper end of a tubular reactor.

[0044] The first aspect of the method may further include removing any of the one or more anchors that are not aligned with the reaction tube from the installation tool when the movable plunger is aligned with the first selected reaction tube. For this purpose, the one or more anchors may be removable from the installation tool.

[0045] When loading reaction tubes (especially those on or near the periphery of a tubular reactor), it may not always be present beneath each anchor of the mounting tool. In such cases, the anchors can be removed from the mounting frame. For example, one, two, or three anchors can be removed from a mounting tool with four anchors. The anchor(s) remaining attached to the mounting frame can be used to anchor the mounting tool.

[0046] The first aspect of the method may also include using one or more stabilizing feet attached to the mounting rack to stabilize the mounting tool.

[0047] Stabilizing feet can be used to provide stability to the installation tool, such as reducing or preventing the installation frame from swaying, tipping, or tilting during use. Each stabilizing foot may include, for example, a height-adjustable screw, a foot, a pad, a plate, etc. Each stabilizing foot may be configured to contact the tube sheet between the reaction tubes directly or indirectly, for example by having a sufficiently small size to fit between the reaction tubes. Alternatively, each stabilizing foot may be configured to span one or more reaction tubes, for example by having a foot plate.

[0048] Stabilizing feet can be used in conjunction with anchors. For example, each anchor can have an associated stabilizing foot. Stabilizing feet can be positioned on or near anchors. For example, in the case of an installation tool with a generally quadrilateral foundation shape, each corner can be provided with an anchor and a stabilizing foot. Before or after engaging the anchors, the stabilizing feet can engage with the protruding surfaces of the tube sheet and / or reaction tube via foot plates to reduce or eliminate lifting or tipping of the installation frame during anchor anchoring.

[0049] The first aspect of the method may also include leveling the installation tool by adjusting one or more of the stabilizing feet.

[0050] Advantageously, the stabilizing foot can be used to ensure that the longitudinal (e.g., vertical) axis of the movable plunger is aligned with the longitudinal axis of the reaction tube.

[0051] The one or more stabilizing feet can be used to replace any of the one or more anchors removed from the installation tool. As noted above, it may sometimes be necessary to remove one or more anchors because they will not align with the reaction tube. In such cases, the stabilizing feet can be used to level and / or stabilize the installation tool. For example, in the case where the installation tool has a generally quadrilateral base shape, three corners can be anchored with anchors and one corner stabilized with a stabilizing foot, or, for example, two corners can be anchored with anchors and two corners stabilized with stabilizing feet, or, for example, one corner can be anchored with anchors and three corners stabilized with stabilizing feet.

[0052] The one or more anchors may include manually, hydraulically, pneumatically, or electrically expandable anchors. In some other embodiments, the one or more anchors may include spring-loaded anchors, optionally with spring-loaded cam mechanisms.

[0053] In step ii) of the method of the first aspect, each of the one or more anchors may be expanded to clamp the inner surface of the reaction tube. In some embodiments, the one or more anchors may be expanded using manual, hydraulic, pneumatic, or electric power. The same power source may be used to actuate the anchors and move the movable plunger. For example, the same hydraulic source may be connected to both. Alternatively, the anchors may be driven by a dedicated power source located on or near the mounting frame. For example, a manually operated hydraulic pump may be used.

[0054] In some other embodiments, the one or more anchors are spring-loaded and biased to expand and thus clamp the inner surface of the reaction tube.

[0055] The mounting frame may include a plurality of anchors for attaching the anchor to the mounting frame. The plurality of anchors may surround an opening adapted to allow passage of the one or more catalyst supports into the selected reaction tube. The mounting frame may include, for example, three anchors arranged in a triangle around the opening, or four anchors arranged in a quadrilateral around the opening.

[0056] When the installation tool is located in the bottom space for mounting against the lower tube sheet, the installation tool may be equipped with one or more supports. The supports may span between the mounting frame and the support of the tubular reactor. For example, the supports may extend from the platform of the mounting frame to contact the bottom plate of, for example, the tubular reactor, and be used to support and / or push the mounting frame upward against the lower tube sheet. The supports may include one or more extendable legs coupled to the platform. The extendable legs may be extendable, for example, manually, pneumatically, or hydraulically.

[0057] The movable plunger may include an alignment device that aligns the one or more catalyst carriers with the first selected reaction tube. The alignment device may include a first engagement portion that engages a second engagement portion of the one or more catalyst carriers. The first engagement portion may be resilient and / or spring-loaded. Preferably, the alignment device includes a centering device that aligns the one or more catalyst carriers on the central axis of the first selected reaction tube.

[0058] Advantageously, alignment devices can facilitate efficient operation of the installation tool by aiding in the alignment of the catalyst carrier during insertion. For example, when catalyst carriers are manually loaded into the installation tool, they may deviate slightly from their vertical orientation. Alignment devices can be used to capture the catalyst carrier and align it vertically at the start of the insertion stroke. In this way, loading of the installation tool can be performed more quickly because the operator does not need to check the precise alignment of the catalyst carrier during each loading operation.

[0059] The movable plunger can be configured to push one or more catalyst supports into a second selected reaction tube and optionally one or more other selected reaction tubes, while simultaneously pushing the one or more catalyst supports into the first selected reaction tube. Actuating the movable plunger can simultaneously push one or more catalyst supports into the first selected reaction tube, push one or more catalyst supports into the second selected reaction tube, and optionally push one or more catalyst supports into the one or more other selected reaction tubes. For this purpose, the movable plunger may include: a first plunger portion for pushing the one or more catalyst supports into the first selected reaction tube and a second plunger portion for simultaneously pushing the one or more catalyst supports into the second selected reaction tube; and optionally, one or more additional plunger portions for simultaneously pushing the one or more catalyst supports into one or more other selected reaction tubes.

[0060] Advantageously, the catalyst carrier can be loaded more quickly by using installation tools to load two, three, or more reaction tubes simultaneously.

[0061] The first approach may also include the following steps:

[0062] iv) Disengage the one or more anchors from the one or more reaction tubes located next to the first selected reaction tube;

[0063] v) Move the installation tool and reattach it to the tubular reactor by engaging the one or more anchors located in one or more reaction tubes adjacent to the second selected reaction tube, so as to align the movable plunger with the second selected reaction tube; and

[0064] vi) Actuate the movable plunger to push one or more catalyst supports into the second selected reaction tube.

[0065] The stabilizing feet can be repositioned and / or adjusted as needed to load the second selected reaction tube.

[0066] The third aspect of the installation system may also include:

[0067] A second installation tool, as provided in the second aspect, and configured for installation in the top or bottom space of the same tubular reactor; and

[0068] One or more hoses for supplying power from the power source to the second installation tool.

[0069] In some implementations, two, three, or more installation tools may be used simultaneously.

[0070] In a fourth aspect, this disclosure provides a method for mounting a catalyst support into a reaction tube of a tubular reactor, the tubular reactor being of the type comprising a plurality of reaction tubes extending between a first tube sheet and a second tube sheet, wherein a heat exchange zone is provided between the first tube sheet and the second tube sheet.

[0071] The method includes:

[0072] i) Provide multiple catalyst supports containing the catalyst;

[0073] ii) Provide support units; and

[0074] iii) Install the support unit and the plurality of catalyst carriers into the reaction tube, such that the support unit is aligned with the second tube sheet, and the plurality of catalyst carriers are arranged in a stacked manner adjacent to the support unit, such that all catalysts in the reaction tube are located in the heat exchange zone.

[0075] The fifth aspect of this disclosure provides a support unit for installation in the reaction tubes of a tubular reactor, the tubular reactor being of the type comprising a plurality of reaction tubes extending between a first tube sheet and a second tube sheet, wherein a heat exchange zone is provided between the first tube sheet and the second tube sheet;

[0076] The support unit includes an elongated body having a first end and a second end, the first end being configured to engage with a support surface of the tubular reactor when the support unit is installed in the reaction tube, and the second end being configured to engage with an end of a stack of catalyst supports adjacent to the support unit.

[0077] The length of the elongated body is configured to support the stacked components of the catalyst carrier, such that all the catalysts in the reaction tube are located within the heat exchange zone.

[0078] Advantageously, the support unit can be used to prevent the catalyst support containing the catalyst from being located at the height of the second tube sheet. Instead, all catalyst supports in the catalyst support containing the catalyst can be located within the heat exchange zone. This can lead to more optimized performance of the tubular reactor due to the improved heat exchange with all catalyst supports in the catalyst support.

[0079] Advantageously, the support unit can also be used to provide physical support for the catalyst support and maintain the catalyst support in the desired arrangement within the reaction tube.

[0080] The support unit may include an internal channel for passing liquids and gases through the support unit. Advantageously, the internal channel ensures that the presence of the support unit does not interfere with the flow of liquids and gases during operation of the reaction tube.

[0081] The support unit may include or be composed of tubular elements.

[0082] In some embodiments, the first tubesheet may be an upper tubesheet, and the second tubesheet may be a lower tubesheet. The support unit may be installed at the height of the lower tubesheet, and the plurality of catalyst supports may be stacked on top of the support unit such that all the catalyst within the reaction tube is located above the height of the lower tubesheet within the heat exchange zone. After insertion, the support unit may be located at the bottom of the stacked arrangement, optionally engaging with a support surface of the tubular reactor. The support surface may also be a temporary or other form of platform installed within the tubular reactor.

[0083] In some other embodiments, the first tube sheet may be a first end tube sheet, and the second tube sheet may be a second end tube sheet. The support unit may be mounted to be aligned with the second end tube sheet, and the plurality of catalyst carriers may be stacked on one side of the support unit such that all the catalysts in the reaction tube are located on one side of the second end tube sheet in the heat exchange zone.

[0084] The support unit may be pushed into the reaction tube first, followed by the plurality of catalyst supports. This is particularly likely from the top of the reaction tube. Alternatively, the support unit may be pushed into the reaction tube last, after the plurality of catalyst supports. This is particularly likely from the bottom of the reaction tube.

[0085] Advantageously, the support unit can be configured to be pushed into the reaction tube using the mounting tools and / or mounting systems described in the second and third aspects above. It is advantageous to facilitate efficient operation by providing mounting tools configured to perform multiple functions.

[0086] The support unit can be attached to one or more catalyst supports to form an insert assembly. This attachment can be releasable or permanent. The insert assembly can be pushed into the reaction tube in a single operation, with the support unit at the foremost position.

[0087] The support unit can be attached to one or more catalyst supports to form the insert assembly using cooperative formations.

[0088] The fourth aspect of the method may also include providing a spacer element for aligning the support unit with the inner surface of the reaction tube. The spacer element may also optionally serve as a seal between the support unit and the inner surface of the reaction tube.

[0089] The fourth aspect of the method may further include forming a seal between the support unit and the inner surface of the reaction tube, such that liquids and gases carried along the reaction tube are preferentially guided through the interior of the support unit. To facilitate this, the support unit may also include a seal for sealing between the support unit and the inner surface of the reaction tube; and optionally, the seal is or includes a spacer element for aligning the support unit with the inner surface of the reaction tube. Because the sealing function is secondary to the alignment function, the seal may be omitted to some extent.

[0090] The fourth aspect of the method may also include selecting the material and any contents of the support unit to be non-reactive relative to the intended process conditions of the tubular reactor.

[0091] In a sixth aspect, this disclosure provides a method for mounting a catalyst support into a reaction tube of a tubular reactor, the tubular reactor being of the type comprising a plurality of reaction tubes extending between a first tube sheet and a second tube sheet, wherein a heat exchange zone is provided between the first tube sheet and the second tube sheet;

[0092] The method includes:

[0093] i) Provide multiple catalyst supports containing the catalyst;

[0094] ii) Provide spacer units;

[0095] iii) Install the plurality of catalyst supports into the reaction tube, and then install the spacer unit such that the spacer unit is aligned with the first tube sheet, and the plurality of catalyst supports are arranged in a stacked manner adjacent to the spacer unit, such that all catalysts in the reaction tube are located in the heat exchange zone.

[0096] The seventh aspect of this disclosure provides a spacer unit for installation in the reaction tubes of a tubular reactor, the tubular reactor being of the type comprising a plurality of reaction tubes extending between a first tube sheet and a second tube sheet, wherein a heat exchange zone is provided between the first tube sheet and the second tube sheet;

[0097] The spacer unit includes an elongated body having a first end configured to engage with the end of a stack of catalyst supports and a second end configured to engage with an installation tool.

[0098] The length of the elongated body is configured such that the stack of catalyst supports can be fully displaced into the reaction tube, so that all the catalysts in the reaction tube are located in the heat exchange zone.

[0099] Advantageously, the spacer unit can be used to prevent the catalyst support containing the catalyst from being positioned at the height of the first tube sheet. Instead, all catalyst supports within the catalyst support containing the catalyst can be located within the heat exchange zone. This can lead to more optimized performance of the tubular reactor due to the improved heat exchange with all catalyst supports within the catalyst support.

[0100] The spacer unit may include an internal channel for passing liquids and gases through the spacer unit. Advantageously, the internal channel ensures that the presence of the spacer unit does not interfere with the flow of liquids and gases during operation of the reaction tube.

[0101] The spacer unit may include or consist of a tubular element.

[0102] In some embodiments, the first tube sheet can be an upper tube sheet, and the second tube sheet can be a lower tube sheet. The spacer unit can be installed at the height of the upper tube sheet, and the plurality of catalyst supports can be stacked below the spacer unit, such that all the catalyst in the reaction tube is located below the height of the upper tube sheet in the heat exchange zone. Installing the spacer unit may include pushing the spacer unit into the reaction tube to displace the plurality of catalyst supports downward within the reaction tube, such that the catalyst in the uppermost catalyst support is located below the height of the upper tube sheet. These embodiments are particularly suitable for reactors with vertical alignment.

[0103] In some other embodiments, the first tube sheet may be a first end tube sheet, and the second tube sheet may be a second end tube sheet. The spacer unit may be mounted aligned with the first end tube sheet, and the plurality of catalyst supports may be stacked on one side of the spacer unit such that all the catalysts within the reaction tube are located on one side of the first end tube sheet within the heat exchange zone. These embodiments are particularly suitable for reactors with horizontal alignment.

[0104] The sixth aspect of the method may further include: once the catalyst carrier is installed, removing the spacer unit from the reaction tube to leave the last catalyst carrier of the stacked arrangement positioned such that the catalyst in the last catalyst carrier is located within the heat exchange zone.

[0105] The sixth aspect of the method may further include inserting a second spacer unit abutting the distal catalyst support. The second spacer unit may include a spacer portion extending outside the reaction tube and a support portion located at the end outside the reaction tube. The second spacer unit may thus span between the distal catalyst support and the support surface of the tubular reactor. The support surface may be a support grid extending through the open end of the reaction tube.

[0106] The spacer unit may not be attached to the catalyst support and may be freely movable within the reaction tube for easy removal. Alternatively, the spacer unit may be attached to one or more catalyst supports to form an insert assembly. This attachment may be releasable or permanent. The insert assembly may be pushed into the reaction tube in a single operation, with the spacer unit at the rear.

[0107] The spacer unit is attached to the one or more catalyst supports to form the insert assembly, which can be provided using cooperating formations on the spacer unit and the one or more catalyst supports. To facilitate this, the spacer unit may include one or more cooperating formations disposed on the spacer unit for engaging one or more cooperating formations on the one or more catalyst supports.

[0108] The material and any contents of the spacer unit may be non-reactive relative to the intended process conditions of the tubular reactor.

[0109] The elongated body may include an abutting surface for engaging a reference surface of the reaction tube, optionally engaging an end face of the reaction tube. The abutting surface may include an outwardly extending flange having an outer diameter configured to be larger than the inner diameter of the reaction tube.

[0110] The second end of the elongated body may include a support for engaging a movable plunger with an installation tool.

[0111] The first end of the elongated body may include a skirt-like portion for engaging with the end of a catalyst support. Optionally, an annular skirt-like portion for engaging with an annular rim or an annular groove may be provided at the end of the catalyst support.

[0112] By fixing the length of the spacer unit between the first end face of the spacer unit and the adjacent face of the spacer unit, and inserting the spacer unit into the reaction tube until the adjacent face engages with the reference face of the reaction tube, optionally engaging with the end face of the reaction tube, the position of the last catalyst carrier stacked in the reaction tube can be controlled.

[0113] The multiple catalyst supports and the spacer unit can be configured to be installed into the reaction tube using the same installation tool. The installation tool can use a movable plunger to push the multiple catalyst supports and the spacer unit into the reaction tube.

[0114] Advantageously, the spacer unit can be configured to be pushed into the reaction tube using the mounting tools and / or mounting systems described in the second and third aspects above. It is advantageous to facilitate efficient operation by providing mounting tools configured to perform multiple functions.

[0115] The eighth aspect of this disclosure provides a method for at least partially emptying a reaction tube of a tubular reactor that was initially at least partially filled with catalyst supports, each of which is of the type containing a catalyst and has a seal that engages with the inner surface of the reaction tube.

[0116] The method includes:

[0117] i) Provides multiple ejector units;

[0118] ii) Install the first ejector assembly of one or more ejector units in the ejector unit to the first end of the reaction tube to contact and displace the last catalyst support in the reaction tube, thereby pushing the catalyst support in the reaction tube toward the second end of the reaction tube;

[0119] iii) Install the subsequent ejection assembly of one or more ejector units in the ejector unit into the first end of the reaction tube to contact and displace the ejection assembly of the one or more ejector units already located in the reaction tube, thereby further pushing the catalyst support toward the second end of the reaction tube;

[0120] iv) Repeat step iii) once or more until three or more catalyst supports in the catalyst support are displaced to the second end of the reaction tube and discharged from the second end of the reaction tube.

[0121] The ninth aspect of this disclosure provides an ejector unit for removing a catalyst support from a reaction tube of a tubular reactor, the ejector unit comprising an elongated body having a first end configured to engage with the catalyst support and a second end configured to engage with an installation tool.

[0122] The maximum diameter of the slender body is configured to be smaller than the inner diameter of the reaction tube, so that the ejector unit can slide freely inside the reaction tube.

[0123] Advantageously, the ejector unit can be used to facilitate efficient complete or partial emptying of the reaction tube, and also to facilitate efficient replacement of the catalyst support within the reaction tube. Specifically, once the catalyst support has been discharged from the reaction tube, the ejector unit can be easily removed from the reaction tube. In particular, when the reaction tube is vertically oriented, the ejector unit can be self-discharged from the lower end of the reaction tube under gravity.

[0124] When it is desired to completely empty the reaction tube, such as for maintenance or inspection, the ejector assembly of one or more ejector units can be sequentially installed at the first end of the reaction tube until all catalyst carriers have been discharged from the second end. Since the first ejector assembly is installed at the second end, the timing of the discharge of the last catalyst carrier is readily apparent to the operator.

[0125] When it is desired to partially empty the reaction tube, such as to replace one or more poisoned catalyst supports, an ejector assembly of one or more sufficient ejector units can be sequentially installed into the first end of the reaction tube until the required amount of catalyst support has been discharged from the second end. For example, an ejector assembly of three ejector units can be installed in the lower end of the reaction tube to discharge the three types of catalyst support from the upper end of the reaction tube. Subsequently, the ejector assembly can be discharged from the lower end of the reaction tube by gravity.

[0126] When it is desired to replace the catalyst support in the reaction tube with a new one, this can be achieved without first emptying the reaction tube. Instead, the new catalyst support can be installed in the first end of the reaction tube, causing the old catalyst support to be discharged from the second end. Advantageously, the ejector assembly of one or more ejector units can be installed in the first end of the reaction tube in a first step, followed by the installation of the new catalyst support. Since the ejector assembly appears at the second end, the point in time when the last old catalyst support is discharged from the reaction tube is readily apparent to the operator. This avoids the disadvantage of any old catalyst support potentially remaining in the reaction tube due to miscounting.

[0127] The ejector unit may include a rigid portion for propelling the catalyst support through a tube. The rigid portion may be of any shape intended to propel the catalyst support under uniformly applied force. Suitablely, the ejector unit may include or consist of a tubular element.

[0128] In some implementations, the first end may be the top end of the reaction tube, and the second end may be the bottom end of the reaction tube.

[0129] The ejector unit can be configured to have a maximum diameter smaller than the inner diameter of the reaction tube, so that it can slide freely within it.

[0130] The method in the eighth aspect may also include the following steps:

[0131] v) After the final catalyst carrier is discharged from the second end of the reaction tube, the plurality of ejector units are allowed to slide out of the second end of the reaction tube under gravity.

[0132] The ejector unit can be of any length that can be installed within the tube. Where space permits within the installation equipment and / or reactor, this length can correspond to one catalyst support, two catalyst supports, three catalyst supports, or more catalyst supports. If desired, an ejector assembly comprising two or more ejector units can be used.

[0133] The first ejector assembly and / or subsequent ejector assemblies may include two or more ejector units attached to each other. This attachment may be releasable or permanent. To facilitate this, the ejector unit may also include one or more cooperating formations disposed on or toward the first end of the ejector unit for engaging one or more cooperating formations on or toward the second end of another ejector unit.

[0134] The first end of the ejector unit can also be configured to engage with the end of another ejector unit.

[0135] The second end of the elongated body may include a support for engaging a movable plunger with an installation tool.

[0136] The first end of the elongated body may include a skirt-like portion for engaging with the end of a catalyst support and / or the end of another ejection unit.

[0137] The first ejector assembly and the subsequent ejector assembly can each be pushed into the reaction tube by a single stroke of the installation tool.

[0138] The catalyst support and the plurality of ejector units can be configured to be inserted into the reaction tube using the same installation tool. The installation tool can use a movable plunger to push the catalyst support and the plurality of ejector units into the reaction tube.

[0139] Advantageously, the ejector unit can be configured to be pushed into the reaction tube using the mounting tools and / or mounting systems described in the second and third aspects above. Advantageously, efficient operation is facilitated by providing mounting tools configured to perform multiple functions.

[0140] The ninth aspect of this disclosure provides a method for mounting a catalyst support into the reaction tube of a tubular reactor, the method comprising the following steps:

[0141] i) Provides multiple catalyst supports;

[0142] ii) Join two or more of the multiple catalyst supports together to form an insert assembly;

[0143] iii) Load the insertion set into the installation tool; and

[0144] iii) Use the installation tool to push the insert assembly into the reaction tube.

[0145] The eleventh aspect of this disclosure provides a plurality of catalyst supports for insertion into a reaction tube of a tubular reactor, each of the plurality of catalyst supports including a container for holding a catalyst in use, the container extending between an upper end and a lower end of the catalyst support.

[0146] Each catalyst support includes one or more upper cooperating formations disposed on or toward the upper end of the container and one or more lower cooperating formations disposed on or toward the lower end of the container;

[0147] The one or more upper cooperative formations are configured to engage with the one or more lower cooperative formations;

[0148] Two or more of the multiple catalyst supports may be stacked together, wherein adjacent catalyst supports are joined together by joining one or more lower cooperating members and one or more upper cooperating members.

[0149] Advantageously, by joining two or more catalyst supports together to form an insert assembly, efficient operation can be facilitated by aiding in the alignment of the catalyst supports during insertion. For example, cooperative formations can promote proper mutual alignment of the catalyst supports within the insert assembly. In this way, two, three, or more catalyst supports can be efficiently and flexibly joined together to have a common longitudinal axis.

[0150] Furthermore, using cooperative formations to generate insert sets can improve operational efficiency by simplifying the manual handling of catalyst supports. In particular, two, three, or more catalyst supports can be loaded into the mounting tool in a single operation; for example, loading can be done manually with one hand.

[0151] The installation tool can be the installation tool mentioned in the second aspect above.

[0152] The insertion set may include at least two catalyst supports, optionally at least three catalyst supports, or optionally more than three catalyst supports.

[0153] The insertion assembly may include a stacked arrangement of catalyst supports, wherein adjacent catalyst supports are joined together using cooperative formations disposed on or toward the upper end of each catalyst support and on or toward the lower end of each catalyst support. The joining may be a releasable or permanent joining.

[0154] The one or more upper cooperative formations and the one or more lower cooperative formations may be configured to engage and disengage via relative rotational movement of the adjacent catalyst supports. Adjacent catalyst supports may be rotatably locked together. The one or more upper cooperative formations and the one or more lower cooperative formations may form one or more bayonet assemblies.

[0155] A second insert assembly may be provided, which can be formed by bonding two or more additional catalyst supports. This bonding can be releasable or permanent. An installation tool may be used to push the second insert assembly into the reaction tube after the first insert assembly, thereby further pushing the first insert assembly into the reaction tube.

[0156] Each container may include a bottom surface at the lower end, a top surface at the upper end, and a carrier outer wall extending between the bottom surface and the top surface.

[0157] Each container may also include a seal extending beyond the outer wall of the carrier; and optionally, the outer wall of the carrier may include an opening located below the seal.

[0158] One or more upper cooperative formations may be disposed above the seal.

[0159] Each container may also include an annular chamber for retaining the catalyst in use, the annular chamber having a perforated inner chamber wall defining an inner channel, a perforated outer chamber wall, a top surface closing the annular chamber, and a bottom surface closing the annular chamber.

[0160] The methods, tools, systems, and associated components of this invention can be efficiently used in a variety of processes. Examples of suitable uses include methods and reactors for exothermic reactions, such as reactions for the preparation of methanol, reactions for the preparation of ammonia, methanation reactions, shift reactions, oxidation reactions, such as reactions for the formation of maleic anhydride and ethylene oxide. Particularly preferred uses are in methods and reactors for carrying out Fischer-Topsy reactions.

[0161] Endothermic reactions (such as pre-reforming, dehydrogenation, etc.) can also be carried out in conjunction with the methods, tools, systems and related components of the present invention.

[0162] The catalyst support disclosed herein may be filled or partially filled with or contain any catalyst suitable for the intended reaction. For example, a Fischer-Topsch catalyst may be used for the Fischer-Topsch reaction. Cobalt-containing Fischer-Topsch catalysts are preferred. The catalyst may be provided as catalyst particles or as a bulk catalyst feed. The catalyst may be provided as a single catalyst bed or multiple catalyst beds. The catalyst support may be configured to promote axial and / or radial flow through the catalyst. In some embodiments, the catalyst support may be configured to preferentially promote radial flow through the catalyst.

[0163] The catalyst support disclosed herein can be formed from any suitable material. Such materials are typically chosen to withstand the operating conditions of a tubular reactor. The catalyst support can be made of carbon steel, aluminum, stainless steel, other alloys, or any material capable of withstanding the reaction conditions.

[0164] The catalyst support disclosed herein advantageously allows the catalyst to be used in moderately to highly exothermic or endothermic reactions. This catalyst support allows for the use of large reaction tubes, resulting in a significant reduction in the weight and cost of a reactor of a given capacity. Attached Figure Description

[0165] Embodiments of this disclosure will now be described by way of example only with reference to the accompanying drawings, in which:

[0166] Figure 1 This is a schematic diagram of a tubular reactor;

[0167] Figure 2 yes Figure 1 A schematic perspective view of a portion of the interior of a tubular reactor;

[0168] Figure 3 This is a diagram illustrating the system installation;

[0169] Figure 4 This is a side view of the installation tools used to install the system;

[0170] Figure 5 yes Figure 4 A perspective view of the mounting rack for the installation tools;

[0171] Figure 6 yes Figure 5 A magnified view of a portion;

[0172] Figure 7 yes Figure 4 A cross-sectional view of the alignment device for the installation tool;

[0173] Figure 8 yes Figure 1 A schematic diagram of the reaction tube layout of a tubular reactor;

[0174] Figure 9 This is a cross-sectional view of the catalyst support;

[0175] Figure 10 yes Figure 9 A perspective view of the catalyst support after decomposition;

[0176] Figure 11 yes Figure 9 A perspective view of the catalyst support;

[0177] Figure 12 This is a side view of two catalyst supports stacked together;

[0178] Figure 13 yes Figure 12 A cross-sectional view of the device;

[0179] Figure 14 This is a perspective view of the support unit;

[0180] Figure 15 yes Figure 14 Side view of the supporting unit;

[0181] Figure 16 yes Figure 14 Top view of the support unit;

[0182] Figure 17 It is installed in a reaction tube with multiple catalyst supports. Figure 14 A schematic cross-sectional view of the supporting unit;

[0183] Figure 18 This is a perspective view of the spacer unit;

[0184] Figure 19 yes Figure 18 A cross-sectional view of the spacer unit;

[0185] Figure 20 It is a reaction tube installed above the catalyst carrier. Figure 18 A schematic cross-sectional view of the spacer unit;

[0186] Figure 21 This is a perspective view of the ejector unit;

[0187] Figure 22 yes Figure 21 Side view of the ejector unit; and

[0188] Figure 23 yes Figure 21 Top plan view of the ejector unit. Detailed Implementation

[0189] In the following description, aspects and embodiments of the present disclosure are illustrated by way of example only, with reference to a vertically oriented tubular reactor having a plurality of vertical reaction tubes extending between an upper tube sheet and a lower tube sheet. However, it should be understood that the present disclosure can also be applied to other configurations of tubular reactors in which other orientations may be employed.

[0190] Furthermore, any reference to orientation in this specification; such as terms like top, bottom, upper, lower, above, below, etc.; the term "orientation" is used relative to the orientation of the components shown in the referenced drawings, but should not be considered as a limitation on the potential orientation of these components in actual use. For example, a component described as vertically oriented may also be horizontally oriented.

[0191] Figure 1 A typical layout of the tubular reactor 1 of this disclosure is shown. The tubular reactor 1 includes a shell 2. The interior of the shell can be divided into a top space 3, a heat exchange zone 4, and a bottom space 5 by two tube sheets (upper tube sheet 6 and lower tube sheet 7). The upper tube sheet 6 separates the top space 3 from the heat exchange zone 4. The lower tube sheet 7 separates the bottom space 5 from the heat exchange zone 4.

[0192] Multiple reaction tubes 8 extend between the upper tube sheet 6 and the lower tube sheet 7. A large number of reaction tubes 8 can be provided, for example, between 20 and 5000 reaction tubes 8. Each reaction tube 8 may have an inner diameter, for example, between 20 mm and 150 mm. In some embodiments, the inner diameter may be approximately 85 mm.

[0193] Each reaction tube 8 is intended to be filled or substantially filled with a stacked arrangement of catalyst supports 10 (not shown). Examples of suitable catalyst supports 10 are shown in... Figures 9 to 13 As shown in the diagram and will be further described below. In particular, it is generally desirable that the catalyst carriers 10 cover all or substantially all of the length of the reaction tubes 8 between the upper tube sheet 6 and the lower tube sheet 7, i.e., they cover all or substantially all of the length of the heat exchange zone 4.

[0194] Typically, when filling the reaction tube 8, the catalyst carrier 10 is loaded into the upper end of the reaction tube 8, and when emptying the reaction tube 8, it is discharged from the lower end of the reaction tube 8. However, it should be understood that the reverse may occur. This may be particularly desirable when the catalyst carrier in the upper end of the reaction tube 8 needs to be replaced. In this case, the catalyst carrier 10 at the upper end can be discharged from the upper end of the reaction tube 8, for example, by loading one or more catalyst carriers 10 into the lower end of the reaction tube 8 to push the catalyst carrier 10 at the upper end out of the reaction tube 8.

[0195] The top space 3 provides access to the upper end of the reaction tube 8 to allow the catalyst carrier 10 to be loaded into the reaction tube 8. An access port 11 may be provided in the housing 2 to allow access to the top space 3. The access port 11 may be, for example, a manhole or other access panel that can be selectively opened and closed.

[0196] The bottom space 5 provides access to the lower end of the reaction tube 8 to allow unloading of the catalyst support 10 from the reaction tube 8.

[0197] According to one aspect of this disclosure, an installation tool 20 is provided, which can be used to install the catalyst carrier 10 into the reaction tube 8.

[0198] like Figures 2 to 7 As shown, the installation tool 20 typically includes at least one installation frame 21, a movable plunger 22 mounted to the installation frame 21, and one or more anchors 23 for anchoring the installation frame 21 to one of the tube sheets of the tubular reactor 1.

[0199] like Figure 5 As shown, the mounting frame 21 may include a platform 24 from which four support legs 25 extend, each terminating at a foot 26. The feet 26 may be separate. However, in the example shown, the first pair of feet 26 engage together to form a first support plate 27a, and the second pair of feet 26 engage together to form a second support plate 27b.

[0200] Mounting frame 21 may include a plurality of anchor seats for attaching anchors 23 to mounting frame 21. Each anchor seat may be disposed in one of the legs 26. Anchor seats may include openings 28 in the legs 26, the openings being sized and shaped to receive anchors 23.

[0201] Multiple anchors, such as openings 28, may surround opening 40, which is adapted to allow catalyst carrier 10 to pass through to enter reaction tube 8, as will be further described below. Opening 40 may be centrally located between the anchors.

[0202] Mounting frame 21 may include, for example, three anchors arranged in a triangle around opening 40, or four anchors arranged in a quadrilateral around opening 40, such as... Figure 5 The example shown is illustrated.

[0203] One or more handles 29, such as a pair of handles 29, may be provided for lifting the installation tool 20. The handles 29 may be mounted to the platform 24.

[0204] The movable plunger 22 can be configured to push one or more catalyst supports in the catalyst support 10 into the reaction tube 8.

[0205] The movable plunger 22 can be a powered plunger or a manually driven plunger. The movable plunger 22 can be switched between a powered mode in which it moves under power and a manual mode in which it is manually driven. The movable plunger 22 can be a hydraulic plunger, a pneumatic plunger, or an electromechanical plunger.

[0206] The movable plunger 22 can be mounted to the platform 24 of the mounting frame 21, and at least a portion thereof can extend through the plunger opening 41 provided on the platform 24, such as... Figure 5 As shown. The longitudinal axis of the movable plunger 22 can be aligned with the opening 40.

[0207] The movable plunger 22 may include an alignment device 50 that aligns the catalyst carrier 10 with the selected reaction tube 8a during use. Figure 7 and Figure 8 As shown in more detail, the alignment device 50 may include a first engagement portion that engages a second engagement portion of the catalyst carrier 10. The alignment device 50 may be coupled to an end of the movable plunger 22 and may be located below the platform 24. In particular, the alignment device 50 may be coupled to a movable piston of the movable plunger 22 and may move with it.

[0208] The first engagement portion may be resilient and / or spring-loaded. The first engagement portion may include a pin 51 slidably mounted within a bore 52 of a collar 53. A spring 54 may be provided to bias the pin 51 into an extended configuration. The pin 51 may be centrally located within the collar 53. The distal end of the pin 51 may be provided with a head 55, which may be shaped to engage a portion of the catalyst carrier 10. The head 55 may have a conical surface 56.

[0209] The collar 53 may include a downward-facing rim 57. A clearance space 58 may be provided between the rim 57 and the pin 51.

[0210] The installation tool 20 may form part of an installation system that further includes a power source 30. The power source 30 may be located outside the tubular reactor 1 and is configured to move the movable plunger 22 of the installation tool 20. For example, as Figure 3 As shown, one or more hoses 31 may be provided for supplying power from a power source 30 to the installation tool 20. The power source 30 may be a hydraulic, pneumatic, or electrical source. In some embodiments, the power source 30 may be an electrical source, such as an electric motor that can be directly mounted to the mounting frame 21. However, in other embodiments, the power source 30 may be a hydraulic source, such as a hydraulic power unit (HPU) 32, a hydraulic power unit, or other hydraulic pump. The HPU 32 may be located outside the housing 2 and connected to the installation tool 20 via one or more hoses 31, and in particular, a movable plunger 22.

[0211] Anchor 23 is used to releasably engage the mounting frame 21 to the tubular reactor 1, and thus releasably engage the mounting tool 20 to the tubular reactor.

[0212] An anchor 23 may be provided for each anchor seat of the mounting frame 21. For example, each opening 28 may have an associated anchor 23.

[0213] Anchor 23 can be removed from mounting frame 21.

[0214] like Figure 6 As most clearly shown, each anchor 23 may include a manually, hydraulically, pneumatically, or electrically expandable anchor. Alternatively, each anchor 23 may include a spring-loaded anchor, such as a spring-loaded cam device.

[0215] exist Figure 5 and Figure 6In the example shown, anchor 23 is hydraulically activated and includes an anchor housing 60 extending through opening 28 and legs 61 that can expand radially outward by hydraulic action. Anchor housing 60 can be coupled to foot 26 and / or support plates 27a, 27b. Legs 61 are movable between a retracted configuration, in which they can be inserted into reaction tube 8, and in the expanded configuration, they can clamp the inner surface of reaction tube 8.

[0216] Anchor 23 can be configured to engage one or more reaction tubes 8b located adjacent to a selected reaction tube 8a, so that the mounting frame 21 can be releasably attached to the tubular reactor 1. For example... Figure 8 As shown, reaction tube 8b can be one or more reaction tubes 8 adjacent to the first selected reaction tube 8a, or alternatively, one or more reaction tubes close to the first selected reaction tube 8a.

[0217] Anchor 23 can be expanded using manual, hydraulic, pneumatic, or electric power. The same power source 30 (e.g., HPU 32) can be used to actuate anchor 23 and move movable plunger 22. Alternatively, anchor 23 can be actuated by a dedicated power source located on or near the mounting frame 21. For example, a manually operated hydraulic pump can be provided for this function.

[0218] The mounting tool 20 may also be equipped with stabilizing feet 70. Stabilizing feet 70 can be used to stabilize and / or level the mounting frame 21 before, during and / or after the anchors 23 are engaged in the reaction tube 8.

[0219] Each stabilizing leg 70 may include a pin 72 or similar object extending through an opening 71 in the mounting frame 21. An opening 71 may be provided in each leg 26 of the mounting frame 21. One or more openings 71 may be provided in each support plate 27a, 27b.

[0220] Pin 72 may be axially movable relative to aperture 71. In one example, pin 72 and aperture 71 may include interlocking threads that allow pin 72 to rotate to adjust the proportion by which pin 72 extends downward below leg 26.

[0221] The stabilizing foot 70 can be used in conjunction with the anchor 23. For example, each anchor 23 may have an associated stabilizing foot 70. The stabilizing foot 70 may be located on or near the anchor 23. Figure 5 In the example shown, the mounting frame 21 has a generally quadrilateral basic shape, and each corner may be provided with an anchor 23 and a stabilizing foot 70.

[0222] Before engaging anchor 23, stabilizing foot 70 can be engaged directly or indirectly by means of the plate abutting the surface of tube sheets 6, 7 and / or reaction tube 8, so as to reduce or eliminate lifting or tipping of mounting frame 21 during anchor 23 expansion.

[0223] Mounting frame 21 may define a loading station 65 for receiving one or more catalyst carriers 10. Loading station 65 may include a clearance space 64 within mounting frame 21 that extends from opening 40 to alignment device 50, for example, between support legs 25.

[0224] One or more sides of the mounting frame 21 may be provided with a cover plate 66. One side may be provided with a door 67 that can be opened and closed to allow the catalyst carrier 10 to be loaded into the loading station 65. The door 67 may include a door sensor to prevent operation of the movable plunger 22 unless the door 67 is closed.

[0225] The installation tool 20 may include a control unit 75. The control unit 75 may include a user interface 76 providing one or more actuators and one or more indicators for controlling and monitoring the operation of the installation tool 20. The control unit 75 may be mounted to the installation rack 21, or it may be a separate unit operatively connected to at least the movable plunger 22. This connection may be wired or wireless.

[0226] The installation tool 20 may include one or more sensors. In addition to the gate sensor described above, other sensors may be provided. For example, a tilt sensor may be provided to cut off the operation of the movable plunger 22 if the angle of the longitudinal axis of the movable plunger 22 deviates from the longitudinal axis of the reaction tube 8 by more than a threshold amount. An insertion force sensor may be provided, for example, to limit the maximum insertion force applied by the movable plunger 22.

[0227] exist Figures 9 to 13 Examples of catalyst carrier 10 that can be used with installation tool 20 according to this disclosure are shown by way of example. However, it should be understood that catalyst carrier 10 may take various forms according to this disclosure. For example, and as described herein, catalyst carrier 10 may take other forms, including but not limited to those disclosed in WO2011 / 048361, WO2012 / 136971 and WO2016 / 050520, the contents of which are incorporated herein by reference in their entirety.

[0228] The catalyst support 10 may typically include a container whose dimensions are configured to be smaller than the internal dimensions of the reaction tube 8 in which the catalyst support is placed during use. Typically, a seal is provided, sized such that it interacts with the inner wall of the reaction tube 8 when the catalyst support 10 is properly positioned within the reaction tube 8. Parameters such as support length and diameter can be selected to accommodate different reactions and configurations of the reaction tube 8.

[0229] like Figures 9 to 13 As shown, the catalyst carrier 10 may include a container 100 for retaining the catalyst during use. The container 100 typically has a bottom surface 101 that closes the lower end of the container 100 and a top surface 102 located at the upper end of the container 100. An outer wall 103 of the carrier may extend from the bottom surface 101 to the top surface 102. A seal 104 may extend from the container 100 a distance beyond the outer wall 103 of the carrier. The outer wall 103 of the carrier may have an opening 105 located below the seal 104.

[0230] like Figure 9 As shown, in at least some embodiments, the catalyst carrier 10 may more specifically include an annular container 110 for retaining the catalyst in use. The annular container 110 may include a perforated inner container wall 111 defining an inner channel 112 and a perforated outer container wall 113 concentrically arranged around the inner container wall 111. An annular top surface 114 may close the upper end of the annular container 110, and an annular bottom surface 115 may close the lower end of the annular container 110. The lower end of the inner channel 112 may be closed by a channel end surface 116, except for one or more drainage openings (not shown) that may be provided in the lower end of the inner channel 112. The channel end surface 116 may be integrally formed with or separately formed from the container inner wall 111.

[0231] like Figure 10 As shown in the exploded view, the catalyst support 10 may be formed from multiple individual components, which may be assembled together by any suitable means, including, for example, welding. In some embodiments, these components may include a perforated inner tube 120, a perforated intermediate tube 121, an outer tube 122, a bottom cap 123, an annular top ring 124, a top cap 125, and an annular sealing ring 126.

[0232] The catalyst support 10 can be formed of any suitable material. Such materials will typically be chosen to withstand the reactor's operating conditions. Generally, the catalyst support will be made of carbon steel, aluminum, stainless steel, other alloys, or any material capable of withstanding the reaction conditions.

[0233] The appropriate thickness of the component will be from about 0.1 mm to about 1.0 mm, preferably from about 0.3 mm to about 1.0 mm.

[0234] The perforated inner tube 120 may include a perforated container inner wall 111. The perforated intermediate tube 121 may include a perforated container outer wall 113. The outer tube 122 may include a carrier outer wall 103 and define an opening 105. The bottom cover 123 may include a bottom surface 101 and / or an annular bottom surface 115. The bottom cover 123 may also extend across the perforated inner tube 120 to include a channel end surface 116. The annular top ring 124 and the top cover 125 may include an annular top surface 114 and may include at least a portion of the top surface 102. The annular sealing ring 126 may include a seal 104.

[0235] The perforation size in the perforated inner tube 120 and the perforated intermediate tube 121 will be selected, such as to allow reactants and products to flow uniformly through the catalyst while retaining the catalyst within the annular container 110. Therefore, it should be understood that their size will depend on the size of the catalyst particles used. In an alternative arrangement, the perforation size may be set to be relatively large, but with a filter screen covering the perforations to ensure that the catalyst remains within the annular container 110.

[0236] It should be understood that perforation can be any suitable construction. In fact, when a wall or tube is described as perforated, all that is required is the existence of a device that allows reactants and products to pass through the wall or tube.

[0237] A bottom surface 101 (e.g., a bottom cap 123) may be formed to engage with the upper end of another catalyst carrier 10. For example, the bottom surface 101 may include an annular groove 130 surrounding a perforated inner tube 120. A top cap 125 may be formed to engage in the annular groove 130 of another catalyst carrier 10. For example, the top cap 125 may include an annular ring 131 erected from an annular plug 132. Figure 13 As shown, the shape and size of the annular ring 131 can be set to be received in the annular groove 130.

[0238] The bottom surface 101, such as the bottom cover 123 and / or the channel end surface 116, may include one or more drainage holes. If one or more drainage holes are present, they can be covered with a filter screen.

[0239] The shape and size of the annular top ring 124 can be configured to engage in the upper end of the outer tube 122. The annular plug 132 of the top cover 125 can have an outer diameter configured to engage with the central opening of the annular top ring 124. The engagement of the top cover 125 with the annular top ring 124 serves to clamp and hold the annular sealing ring 126 in place.

[0240] The top cover 125 may include a central inlet 134 in the annular plug 132 for allowing liquids and gases to enter the upper end of the internal channel 112. The annular ring 131 may include a lateral opening 133 for allowing liquids and gases to reach the central inlet 134.

[0241] The outer wall 103 of the carrier can be smooth or it can be shaped. Suitable shapes include pleats, corrugations, etc.

[0242] The opening 105 in the outer wall 103 of the carrier can be of any construction. In some embodiments, the opening 105 can be a hole or a groove.

[0243] The seal 104 can be formed in any suitable manner. However, it will generally be sufficiently compressible to accommodate the minimum diameter of the reaction tube 8. The seal 104 will generally be a flexible sliding seal. In some embodiments, the seal 104 may include a deformable flange 140 extending from the outer wall 103 or top surface 102 of the catalyst carrier 10. The flange 140 may be sized to be larger than the inner diameter of the reaction tube 8 such that when the catalyst carrier 10 is inserted into the reaction tube 8, it deforms to fit inside the reaction tube 8 and interact with it.

[0244] exist Figure 9 In the example shown, the deformable flange 140 includes the outer portion of the annular sealing ring 126. The inner portion 141 of the annular sealing ring 126 defines a clamping surface that is sandwiched and held between the top cap 125 and the annular top ring 124. The deformable flange 140 may be angled relative to the inner portion 141. The deformable flange 140 may be angled toward the upper end of the catalyst carrier 10.

[0245] The outer wall 103 of the carrier may continue above the seal 104. Thus, the seal 104 may be located at the top of the catalyst carrier 10, optionally as part of the top surface 102, or if the seal is located above the opening 105 in the outer wall 103 of the carrier, it may be located at a suitable point on the outer wall 103 of the carrier.

[0246] The catalyst support 10 can be configured to attach together in a stacked arrangement. For example, adjacent catalyst supports 10 can be joined together by bonding one or more cooperative formations.

[0247] In some embodiments, each catalyst carrier 10 may include an upper cooperating formation 150 disposed on or toward the upper end of the container 100 and a lower cooperating formation 151 disposed on or toward the lower end of the container 100.

[0248] Adjacent catalyst supports 10 can be joined together by attaching a lower cooperative formation 151 on one catalyst support 10 to an upper cooperative formation 150 on the adjacent catalyst support 10.

[0249] The upper cooperative formation 150 and the lower cooperative formation 151 can be configured to join and disjoint by relative rotational movement of adjacent catalyst supports 10. For example, the upper cooperative formation 150 and the lower cooperative formation 151 can be in the form of a bayonet assembly.

[0250] In some embodiments, the upper cooperative formation 150 is disposed above the seal 104. For example, the upper cooperative formation 150 may be disposed on or as part of the upper portion of the annular ring 131 and / or the outer wall 103 of the carrier.

[0251] Two or more catalyst supports in catalyst support 10 can be joined together to form an insert assembly, such as... Figure 12 and Figure 13 As shown. The insert assembly may include, for example, two, three or more catalyst supports 10, with one catalyst stacked on top of another. The catalyst supports 10 may be permanently joined together by means such as welding. However, more preferably, the catalyst supports 10 may be releasably joined together. The releasable joining may be, for example, through the cooperative formations 150, 151 described above.

[0252] The loading station 65 of the installation tool 20 can be configured to hold one, two, three or more inserts of catalyst carriers 10, and the movable plunger 22 can be configured to push the inserts of catalyst carriers 10 into the first selected reaction tube 8a in a single stroke.

[0253] The installation tool 20 can be used to install the catalyst carrier 10 into the first selected reaction tube 8a of the tubular reactor 1. The use of the installation tool 20 when positioned in the headspace 3 will be described by way of example only.

[0254] In the first step, the mounting frame 21 can be inserted into the top space 3 or bottom space 5 of the tubular reactor 1 through the access port 11. The mounting frame 21 can be lifted manually by the handle 29 or by using a crane.

[0255] Mounting frame 21 can be connected to power source 30 via a hose passing through access port 11.

[0256] Next, the mounting frame 21 can be positioned on the upper tube sheet 6. The mounting frame 21 can be aligned with the selected reaction tube 8a to be filled, such that the upper end of the selected reaction tube 8a is aligned with the opening 40 between the support leg 26 of the mounting frame 21.

[0257] Next, if any of the legs 26 and their openings 28 are not aligned with the reaction tube 8b next to the selected reaction tube 8a, the anchor 23 of each such leg 26 can be removed.

[0258] Next, one or more anchors 23 attached to the mounting frame 21 are inserted into the reaction tube 8b such that the legs 26 and support plates 27a, 27b (if present) are in contact with the top of the reaction tube 8 and / or the upper tube sheet 6. The legs 26 and / or support plates 27a, 27b may span the top of more than one reaction tube 8.

[0259] Next, one or more stabilizing feet 70 can be used to securely mount the frame 21. Pins 72 can be actuated to engage with the upper tube sheet 6 between the reaction tubes 8. The stabilizing feet 70 can engage with the upper tube sheet 6, particularly at each location where the anchors 23 have been removed. However, the stabilizing feet 70 can also engage at locations where the anchors 23 are still present.

[0260] Next, the stabilizing foot 70 can be adjusted to level the mounting frame 21 and / or ensure that the longitudinal (e.g., vertical) axis of the movable plunger 22 is aligned with the longitudinal axis of the selected reaction tube 8a.

[0261] Next, door 67 can be opened, and catalyst carrier 10 or an insert assembly including multiple catalyst carriers 10 can be loaded into loading station 65.

[0262] Next, as the door 67 closes again, the installation tool 20 can be actuated via the user interface 76 to actuate the movable plunger 22. The movable plunger 22 can then push one or more catalyst carriers 10 into the first selected reaction tube 8a.

[0263] During the movement of the movable plunger 22, the alignment device 50 captures and vertically aligns the catalyst carrier 10. The tapered surface 56 of the head 55 on the pin 51 engages in the central inlet 134 of the uppermost catalyst carrier 10 during the initial movement of the movable plunger – particularly before the rim 57 contacts the uppermost catalyst carrier 10. Due to the angled surface of the tapered surface 56, the movement of the head 55 will cause the uppermost catalyst carrier 10 (and any other connected catalyst carriers 10) to be correctly vertically aligned. During subsequent movement of the movable plunger 22, the pin 51 retracts into the bore 52 against the bias of the spring 54, allowing the rim 57 to engage with the top surface 102 of the catalyst carrier 10, where the annular ring 131 is accommodated in the clearance space 58 of the alignment device 50. During subsequent movement of the movable plunger 22, the catalyst carrier 10 can be forcibly driven into the reaction tube 8a.

[0264] The process can be repeated once or multiple times to push one or more additional inserts of the catalyst support 10 into the selected reaction tube 8a.

[0265] Once the selected reaction tube 8a has been filled with the catalyst carrier 10 to the desired extent, the mounting frame 21 can be removed by disengaging one or more anchors 23. The mounting frame 21 can then be moved to align with another selected reaction tube 8a and reattached in the same manner as described above. Thus, the mounting tool 20 can be used to sequentially fill each reaction tube 8 of the tubular reactor 1.

[0266] The installation tool 20 can be configured to simultaneously install the catalyst carrier 10 into two or more reaction tubes 8. For example, the movable plunger 22 may include a first plunger portion for pushing the catalyst carrier 10 into a first selected reaction tube 8a and a second plunger portion for simultaneously pushing the catalyst carrier 10 into a second selected reaction tube 8a. A third plunger portion may also be provided for simultaneously filling a third selected reaction tube 8a. Four or more plunger portions may be provided as needed. The plunger portions may be driven by a common actuator, such as a single hydraulic piston.

[0267] During insertion into the reaction tube 8, the seal 104 of the catalyst carrier 10 can be sealingly engaged with the inner surface of the reaction tube 8. In particular, the engagement of the seal 104 against the reaction tube 8 may cause deformation of the seal 104.

[0268] The deformation of seal 104 can generate resistance that helps maintain the axial position of catalyst carrier 10 within reaction tube 8 after installation. Additionally, the deformation of seal 104 can facilitate a liquid-tight and / or gas-tight seal between the upper end of catalyst carrier 10 and the inner surface of reaction tube 8.

[0269] Once installed in the reaction tube 8, the catalyst carriers 10 can be arranged in a stacked configuration, with one catalyst carrier on top of another, where their longitudinal axes are aligned and coincident.

[0270] When used in a tubular reactor 1 with a downward flow, the reactants flow downward through the reaction tube 8 and thus first contact the top surface 102 of the uppermost catalyst support 10 in the stacked formation. The seal 104 prevents the reactants from passing around the sides of the catalyst support 10. Therefore, the top surface 102 guides the reactants inward through the lateral opening 133 into the central inlet 134 at the upper end of the inner channel 112 within the inner wall 111 of the container, defined by the perforated inner tube 120.

[0271] The reactants then enter the annular container 110 through the perforated inner tube 120 and then radially through the catalyst bed toward the outer wall 113 of the container defined by the perforated intermediate tube 121. During this process, the reactants come into contact with the catalyst, and a reaction occurs to form the products.

[0272] Unreacted reactants and products then flow out of the annular container 110 through the perforated intermediate tube 121. The carrier outer wall 103, defined by the outer tube 122, then guides the reactants and products upward between the inner surface of the carrier outer wall 103 and the perforated intermediate tube 121 until they reach the opening 105 in the carrier outer wall 103. The reactants and products are then guided through the opening 105 and flow downward between the outer surface of the carrier outer wall 103 and the inner surface of the reaction tube 8 in the event of heat transfer.

[0273] Then, unreacted reactants and products can come into contact with the top surface 102 of the catalyst support 10 below the stacked formation, and the above process can be repeated. This pattern can be repeated as reactants and products pass downward through the stacked formation until they are collected from the lower end of the reaction tube 8.

[0274] Some of the products, especially liquid products, can be discharged from the inner channel 112 through drainage holes provided in the end surface 116 of the channel and enter the inner channel 112 of the catalyst support 10 below. These products can then continue to be discharged downwards from the stacked formation of the catalyst support 10 and collected from the lower end of the reaction tube 8.

[0275] According to another aspect of this disclosure, a support unit 200 is provided for installation in the reaction tube 8 of the tubular reactor 1.

[0276] As shown, via Figures 14 to 17 In the example, the support unit 200 includes an elongated body 201 having a first end 202 and a second end 203. The first end is configured to engage with a support surface of the tubular reactor 1 when the support unit 200 is installed in the reaction tube 8, and the second end is configured to engage with an end of a stack of catalyst carrier 10 adjacent to the support unit 200.

[0277] The elongated body 201 may include a tubular member 204. The tubular member 204 may be hollow and defines an inner hole 205 that extends completely through the elongated body 201 from a first end 202 to a second end 203.

[0278] The diameter of the elongated body 201 can be configured to engage with the catalyst carrier 10. For example, the upper rim 210 of the elongated body 201 disposed at or toward the second end 203 can have a diameter sized to engage with the bottom surface 101 of the catalyst carrier 10 (e.g., with the bottom cover 123). In some embodiments, the upper rim 210 can be sized to engage within an annular groove 130 of the catalyst carrier 10.

[0279] The support unit 200 may also include a spacer element 207 for aligning the support unit 200 with the inner surface of the reaction tube 8. The spacer element 207 may extend radially outward from the elongated body 201.

[0280] The material and any contents of the support unit 200 may be non-reactive relative to the intended process conditions of the tubular reactor 1.

[0281] The elongated body 201 may be provided with an identification mark 211 to indicate that it does not contain a catalyst. The identification mark 211 may be etched, printed, applied or applied to the outer surface of the elongated body 201, for example.

[0282] The support unit 200 may be attached to one or more catalyst supports 10 to form an insert assembly. For example, the support unit 200 may include one or more cooperative formations 206 for engaging one or more cooperative formations of one or more catalyst supports 10. The cooperative formations 206 may be disposed on or toward a second end 203. In some embodiments, the cooperative formations 206 may be configured to engage or be disposed on or toward a lower cooperative formation 151 disposed on or toward a lower end of the container 100 of the catalyst support 10.

[0283] The cooperative formation 206 and the lower cooperative formation 151 can be configured to engage and disengage by relative rotational movement. For example, the cooperative formation 206 and the lower cooperative formation 151 can be in the form of a bayonet assembly.

[0284] In use, the support unit 200 and multiple catalyst carriers 10 can be installed in the reaction tube 8, such that the support unit 200 is aligned with the lower tube sheet 7, and the multiple catalyst carriers 10 are arranged in a stacked manner adjacent to the support unit 200, so that all the catalysts in the reaction tube 8 are located within the heat exchange zone 4. For example, all the catalysts in the reaction tube 8 can be located above the height of the lower tube sheet 7 within the heat exchange zone 4.

[0285] To facilitate this, the length of the elongated body 201 can be suitably configured to support the stack of catalyst carriers 10, wherein the lowermost catalyst carrier 10 is positioned above the height of the lower tube sheet 7, as shown below. Figure 17 As shown.

[0286] Typically, after insertion, the support unit 200 will be located at the bottom of the stacked arrangement. The support unit 200, and particularly the first end 202, can engage with the support surface 12 of the tubular reactor 1.

[0287] During installation, for example in a vertically oriented tubular reactor 1, a support unit 200 may first be pushed into the upper end of the reaction tube 8, followed by the pushing of multiple catalyst carriers 10 into that upper end. The support unit 200 may be installed independently or as part of an insert assembly, with the support unit 200 at the foremost position. Alternatively, the catalyst carriers 10 and the support unit 200 may be installed in the lower end of the reaction tube 8, with the support unit 200 installed last.

[0288] As described above, the support unit 200 can be installed into the reaction tube 8 using the installation tool 20. Specifically, the second end 203 can be configured to be actuated by a movable plunger 22. For example, as... Figure 16 As shown, the elongated body 201 may have a flange 212 at or toward the second end 203, the size and shape of which are set to engage with the rim 57 of the alignment device 50.

[0289] According to another aspect of this disclosure, a spacer unit 300 is provided for installation in a reaction tube 8 of a tubular reactor 1.

[0290] As shown in the figure, through Figures 18 to 20 In the example, spacer unit 300 includes an elongated body 301 having a first end 302 and a second end 303. The first end is configured to engage with the end of a stack of catalyst carrier 10, and the second end is configured to engage with a mounting tool, which may be mounting tool 20 as described above.

[0291] The elongated body 301 may include a tubular member 304. The tubular member 304 may be hollow and defines an inner hole 305 that extends completely through the elongated body 301 from a first end 302 to a second end 303.

[0292] The elongated body 301 may include an abutting surface 306 for abutting against a reference surface of the reaction tube 8, optionally engaging with an end face of the reaction tube 8. The abutting surface 306 may be located at or toward a second end 303. The abutting surface 306 may include an outwardly extending flange 307 having an outer diameter configured to be larger than the inner diameter of the reaction tube 8.

[0293] The second end 303 of the elongated body 301 may include a support 308 for engaging with a movable plunger 22 of the mounting tool 20. An inner flange 311 may be disposed within the support 308, which may be engaged by the movable plunger 22 (particularly the rim 57 of the alignment device 50).

[0294] The diameter of the elongated body 301 can be configured to engage with the catalyst carrier 10. For example, the lower rim 310 of the elongated body 301, disposed at or toward the first end 302, can have a diameter sized to engage with the top surface 102 of the catalyst carrier 10, for example, with the upper end of the top cover 125 and / or the annular top ring 124 and / or the outer wall 103 of the carrier. For example, the lower rim 310 can be disposed on the annular skirt portion 312.

[0295] The material and any contents of the spacer unit 300 may be non-reactive relative to the intended process conditions of the tubular reactor 1.

[0296] In use, the catalyst carrier 10 can be installed into the reaction tube 8 (e.g., as described above), and then the spacer unit 300 can be installed such that the spacer unit 300 is aligned with the upper tube sheet 6, and the catalyst carrier 10 is arranged in a stacked manner adjacent to the spacer units 300, so that all the catalyst in the reaction tube 8 is located within the heat exchange zone 4, such as... Figure 20 As shown.

[0297] The position of the catalyst carrier 10 at the very end (e.g., top) of the stacked arrangement in the reaction tube 8 can be controlled by fixing the length of the spacer unit 300 between the lower rim 310 and the adjacent surface 306, and inserting the spacer unit 300 into the reaction tube 8 until the adjacent surface 306 abuts against the reference surface of the reaction tube 8 (e.g., against the upper end surface of the reaction tube 8).

[0298] The length of the elongated body 301 can be configured such that the stack of catalyst carriers 10 can be fully displaced into the reaction tube 8, so that all the catalysts in the reaction tube 8 are located in the heat exchange zone 4.

[0299] The spacer unit 300 can be installed at the height of the upper tube sheet 6, wherein the catalyst carrier 10 is arranged in a stacked manner below the spacer unit 300, such that all the catalyst in the reaction tube 8 is located below the height of the upper tube sheet 6 in the heat exchange zone 4.

[0300] After the catalyst carrier 10 is installed in the desired position, the spacer unit 300 may remain in the reaction tube 8 or alternatively may be removed from the reaction tube 8 to leave the stacked last catalyst carrier 10 positioned such that the catalyst in the last catalyst carrier is located within the heat exchange zone 4.

[0301] Optionally, a second spacer unit may be installed against the distal catalyst carrier 10 in place of spacer unit 300. The second spacer unit may span between the distal catalyst carrier 10 and the support surface of the tubular reactor 1. For example, the support surface may be an upper support mesh extending through the open end of the reaction tube 8. During operation of the tubular reactor 1, the second spacer unit may mitigate or prevent upward creep of the catalyst carrier 10 within the reaction tube 8.

[0302] According to another aspect of this disclosure, an ejector unit 400 for discharging the catalyst support 10 from the reaction tube 8 is provided.

[0303] As shown in the figure, through Figures 21 to 23 In the example, the ejector unit 400 includes an elongated body 401 having a first end 402 and a second end 403. The first end is configured to engage with the end of a stack of catalyst carrier 10, and the second end is configured to engage with a mounting tool, which may be the mounting tool 20 as described above.

[0304] The elongated body 401 may include a tubular member 404. The tubular member 404 may be hollow and defines an inner hole 405 that extends completely through the elongated body 401 from a first end 402 to a second end 403.

[0305] The maximum diameter of the slender body 401 is configured to be smaller than the inner diameter of the reaction tube 8, so that the ejector unit 400 can slide freely within the reaction tube 8.

[0306] The first end 402 of the ejector unit 400 may also be configured to engage the second end 403 of another ejector unit 400.

[0307] The ejector units 400 may be attached to each other to form an ejector assembly.

[0308] The ejector unit 400 may include a cooperative formation disposed on or toward the first end 402 for engaging a cooperative formation (not shown) on or toward the second end 403 of another ejector unit 400.

[0309] The second end 403 of the elongated body 401 may include a support 406 for engaging with a movable plunger 22 of the installation tool 20. An inner flange 411 may be disposed within the support 406, which may be engaged by the movable plunger 22, particularly the rim 57 of the alignment device 50.

[0310] The first end portion 402 may include a skirt-like portion 415 for engaging with the end portion of the catalyst carrier 10 and / or the end portion of another ejector unit 400. For example, the lower rim 408 of the skirt-like portion 415 may have a diameter sized to engage with the top surface 102 of the catalyst carrier 10, such as with the upper end portion of the top cap 125 and / or the annular top ring 124 and / or the outer wall 103 of the carrier. The lower rim 408 may also be sized to engage with the inner flange 411 of the lower ejector unit 400.

[0311] In use, by first installing the first ejector assembly of one or more ejector units in ejector unit 400 to the upper end of reaction tube 8 to contact and move the uppermost catalyst carrier 10 inside reaction tube 8 downward, thereby pushing the catalyst carrier 10 inside reaction tube 8 toward the lower end of reaction tube 8, reaction tube 8, which was initially at least partially filled with catalyst carrier 10, can be emptied (partially or completely).

[0312] Installation tool 20 can be used to push ejector unit 400 into reaction tube 8.

[0313] One or more additional ejector sets of one or more ejector units in ejector unit 400 may then be inserted to contact and further displace ejector unit 400 already in reaction tube 8, thereby pushing catalyst carrier 10 further toward the second end of reaction tube 8.

[0314] In this way, some or all of the catalyst carriers in the catalyst carrier 10 in the reaction tube 8 can be moved to the lower end of the reaction tube 8 and discharged from the lower end.

[0315] After the last catalyst carrier in the catalyst carrier 10 is discharged from the lower end of the reaction tube 8, the multiple ejector units 400 can slide out of the lower end of the reaction tube 8 under the action of gravity, as they can slide freely within the reaction tube 8.

[0316] Other aspects and implementations of this disclosure are set forth in the following provisions:

[0317] Clause A1. A method for mounting a catalyst support into a first selected reaction tube of a tubular reactor, the method comprising the steps of:

[0318] i) Provide an installation tool, the installation tool comprising:

[0319] a) Install the rack;

[0320] b) A movable plunger, which is mounted to the mounting frame and configured to push one or more catalyst supports into the first selected reaction tube; and

[0321] c) One or more anchors for releasably attaching the mounting frame to the tubular reactor;

[0322] ii) The installation tool is attached to the tubular reactor by engaging one or more anchors located in one or more reaction tubes adjacent to the first selected reaction tube, so as to align the movable plunger with the first selected reaction tube;

[0323] as well as

[0324] iii) Actuate the movable plunger to push the one or more catalyst supports into the first selected reaction tube.

[0325] Clause A2. The method according to Clause A1, wherein in step ii), the mounting tool is attached such that the mounting frame is located in the top or bottom space of the tubular reactor outside the reaction tubes; and optionally, the mounting frame is located above the upper tube sheet of the tubular reactor or below the lower tube sheet of the tubular reactor.

[0326] Clause A3. The method according to Clause A1 or Clause A2, wherein step i) further includes inserting the installation tool into the top or bottom space of the tubular reactor through the access port of the tubular reactor.

[0327] Clause A4. The method according to any of the preceding clauses, wherein the movable plunger is a power plunger or a manually driven plunger.

[0328] Clause A5. The method according to Clause A4, wherein the movable plunger is switchable from a power mode in which the movable plunger moves under power and a manual mode in which the movable plunger is manually driven.

[0329] Clause A6. According to any of the preceding clauses, the installation tool is coupled to a power source for moving the movable plunger located outside the tubular reactor; and optionally, the power source includes a hydraulic source, a pneumatic source, or an electrical source.

[0330] Clause A7. The method according to any one of Clauses A1 to A6, wherein the installation tool includes a power source located inside the tubular reactor for moving the movable plunger; and optionally, wherein the power source includes a hydraulic source, a pneumatic source, or an electrical source.

[0331] Clause A8. The method according to any of the preceding clauses, wherein in step iii), an insert set of one catalyst carrier, two catalyst carriers, three catalyst carriers or more catalyst carriers is pushed into the first selected reaction tube by a single stroke of the movable plunger.

[0332] Clause A9. The method according to Clause A8, wherein step iii) is repeated once or more to push one or more additional insert sets into the first selected reaction tube.

[0333] Clause A10. The method according to Clause A8 or Clause A9, wherein pushing the insert set into the first end of the first selected reaction tube causes one or more catalyst supports to be pushed out of the second end of the first selected reaction tube.

[0334] Clause A11. The method according to any of the preceding clauses further includes removing any of the one or more anchors that are not aligned with the reaction tube from the installation tool while the movable plunger is aligned with the first selected reaction tube.

[0335] Clause A12. The method according to any of the preceding clauses further includes using one or more stabilizing feet coupled to the mounting rack to stabilize the mounting tool.

[0336] Clause A13. The method according to Clause A12 further includes leveling the mounting tool by adjusting one or more of the stabilizing feet.

[0337] Clause A14. The method according to Clause A12 or Clause A13, wherein the one or more stabilizing feet are used in place of any of the one or more anchors removed from the installation tool.

[0338] Clause A15. The method according to any of the preceding clauses, wherein in step ii), each of the one or more anchors is expanded to grip the inner surface of the reaction tube.

[0339] Clause A16. The method described in Clause A15, wherein the one or more anchors are expanded using manual power, hydraulic power, pneumatic power, or electric power.

[0340] Clause A17. The method according to Clause A15, wherein the one or more anchors are spring-loaded and biased to expand thereby gripping the inner surface of the reaction tube.

[0341] Clause A18. The method according to any of the preceding clauses, wherein the movable plunger includes an alignment device that aligns the one or more catalyst supports with the first selected reaction tube.

[0342] Clause A19. The method according to Clause A18, wherein the alignment device includes a first engagement portion that engages a second engagement portion of the one or more catalyst supports; and optionally, wherein the first engagement portion is resilient and / or spring-loaded.

[0343] Clause A20. The method according to any of the preceding clauses, wherein the movable plunger is configured to push one or more catalyst carriers into a second selected reaction tube and optionally one or more additionally selected reaction tubes, while simultaneously pushing the one or more catalyst carriers into a first selected reaction tube; and actuating the movable plunger to simultaneously push one or more catalyst carriers into the first selected reaction tube and one or more catalyst carriers into the second selected reaction tube, and optionally one or more catalyst carriers into the one or more additionally selected reaction tubes.

[0344] Clause A21. The method described according to any of the preceding clauses further includes the following steps:

[0345] iv) Disengage the one or more anchors from the one or more reaction tubes located next to the first selected reaction tube;

[0346] v) Move the mounting tool and reattach it to the tubular reactor by engaging the one or more anchors located in one or more reaction tubes adjacent to the second selected reaction tube, so as to align the movable plunger with the second selected reaction tube; and

[0347] vi) Actuate the movable plunger to push one or more catalyst supports into the second selected reaction tube.

[0348] Clause A22. An installation tool for mounting a catalyst support into a selected reaction tube of a tubular reactor, the installation tool comprising:

[0349] a) Install the rack;

[0350] b) A movable plunger, mounted to the mounting frame and configured to push one or more catalyst supports into the selected reaction tube; and

[0351] c) One or more anchors for engaging one or more reaction tubes located adjacent to the selected reaction tube, so as to releasably attach the mounting frame to the tubular reactor.

[0352] Clause A23. The installation tool as described in Clause A22, wherein the movable plunger is a manual plunger, hydraulic plunger, pneumatic plunger, or electromechanical plunger.

[0353] Clause A24. The installation equipment as described in Clause A22 or Clause A23, wherein the installation rack is defined as a loading station for receiving the one or more catalyst carriers.

[0354] Clause A25. The installation tool according to Clause A24, wherein the loading station is configured to hold an insert assembly of one, two, three, or more catalyst carriers, and the movable plunger is configured to push the insert assembly of catalyst carriers into the first selected reaction tube in a single stroke.

[0355] Clause A26. An installation tool according to any one of Clauses A22 to A25, wherein the one or more anchors are removable from the installation tool.

[0356] Clause A27. An installation tool according to any one of Clauses A22 to A26, wherein the one or more anchors are expandable for gripping the inner surface of the reaction tube.

[0357] Clause A28. An installation tool according to any one of Clauses A22 to A27, wherein the one or more anchors include manually, hydraulically, pneumatically, or electrically expandable anchors.

[0358] Clause A29. An installation tool according to any one of Clauses A22 to A27, wherein one or more anchors include spring-loaded anchors, optionally spring-loaded cam devices.

[0359] Clause A30. The mounting tool according to any one of Clauses A22 to A29, the mounting tool further includes one or more stabilizing feet connected to the mounting frame.

[0360] Clause A31. An installation tool according to any one of Clauses A22 to A30, wherein the movable plunger includes an alignment device for aligning the one or more catalyst supports with the first selected reaction tube.

[0361] Clause A32. The installation tool according to Clause A31, wherein the alignment device includes a first engagement portion for engaging a second engagement portion of the one or more catalyst supports; and optionally, wherein the first engagement portion is resilient and / or spring-loaded.

[0362] Clause A33. An installation tool according to any one of Clauses A22 to A32, wherein the movable plunger comprises: a first plunger portion for pushing the one or more catalyst carriers into a first selected reaction tube and a second plunger portion for simultaneously pushing the one or more catalyst carriers into a second selected reaction tube; and optionally, one or more additional plunger portions for simultaneously pushing the one or more catalyst carriers into one or more additional selected reaction tubes.

[0363] Clause A34. An installation tool according to any one of Clauses A22 to A33, wherein the installation frame includes a plurality of anchor seats for engaging the anchors to the installation frame; wherein the plurality of anchor seats surround an opening adapted to allow passage of the one or more catalyst supports to enter the selected reaction tube.

[0364] Clause A35. The installation tool as described in Clause A34, wherein the installation frame includes three anchors arranged in a triangle around the opening, or four anchors arranged in a quadrilateral around the opening.

[0365] Clause A36. An installation system for mounting a catalyst support into a reaction tube of a tubular reactor, the installation system comprising:

[0366] The installation tool according to any one of clauses A22 to A35 is configured for installation in the top or bottom space of the tubular reactor;

[0367] A power source, which can be located outside the tubular reactor and is configured to move a movable plunger of the mounting tool; and

[0368] One or more hoses for supplying power from the power source to the installation tool.

[0369] Clause A37. The installation system according to Clause A36 further includes:

[0370] The second installation tool according to any one of clauses A22 to A35, the second installation tool being configured for installation in the top or bottom space of the same tubular reactor; and

[0371] One or more hoses, the one or more hoses being used to supply power from the power source to the second installation tool.

[0372] Clause A38. An installation system according to any one of Clauses A36 to A37, wherein the power source includes a manual source, a hydraulic source, a pneumatic source, or an electrical source.

[0373] Clause B1. A method for mounting a catalyst support into a reaction tube of a tubular reactor, said tubular reactor being of the type comprising a plurality of reaction tubes extending between a first tube sheet and a second tube sheet, wherein a heat exchange zone is provided between the first tube sheet and the second tube sheet;

[0374] The method includes:

[0375] i) Provide multiple catalyst supports containing the catalyst;

[0376] ii) Provide support units; and

[0377] iii) Install the support unit and the plurality of catalyst carriers into the reaction tube, such that the support unit is aligned with the second tube sheet, and the plurality of catalyst carriers are arranged in a stacked manner adjacent to the support unit, such that all catalysts in the reaction tube are located in the heat exchange zone.

[0378] Clause B2. The method according to Clause B1, wherein the first tube sheet is an upper tube sheet and the second tube sheet is a lower tube sheet, and the support unit is mounted at the height of the lower tube sheet, and the plurality of catalyst carriers are arranged in a stacked manner on top of the support unit such that all catalysts in the reaction tube are located above the height of the lower tube sheet in the heat exchange zone.

[0379] Clause B3. The method according to Clause B2, wherein the support unit, after insertion, is located at the bottom of the stacked arrangement and optionally engages against the support surface of the tubular reactor.

[0380] Clause B4. The method according to Clause B1, wherein the first tube sheet is a first end tube sheet and the second tube sheet is a second end tube sheet, and the support unit is mounted to be aligned with the second end tube sheet, and the plurality of catalyst carriers are arranged in a stacked arrangement on one side of the support unit such that all catalysts in the reaction tube are located on one side of the second end tube sheet within the heat exchange zone.

[0381] Clause B5. The method according to any one of Clauses B1 to B4, wherein the support unit is first pushed into the reaction tube, and subsequently the plurality of catalyst supports are pushed into the reaction tube.

[0382] Clause B6. The method according to any one of Clauses B1 to B5, wherein the support unit is attached to one or more catalyst supports to form an insert assembly; and optionally, the insert assembly is pushed into the reaction tube in a single operation, wherein the support unit is at the foremost position.

[0383] Clause B7. The method according to Clause 6, wherein the support unit is attached to the one or more catalyst supports to form the insert assembly using a cooperative forming compound.

[0384] Clause B8. The method according to any one of Clauses B1 to B7, the method further comprising providing a spacer element for aligning the support unit with the inner surface of the reaction tube.

[0385] Clause B9. The method according to any one of Clauses B1 to B8, the method further comprising forming a seal between the inner surfaces of the support unit and the reaction tube, such that liquids and gases carried along the reaction tube are preferentially directed through the interior of the support unit.

[0386] Clause B10. The method according to any one of Clauses B1 to B9 further includes selecting the material and any contents of the support unit to be non-reactive relative to the intended process conditions of the tubular reactor.

[0387] Clause B11. A support unit for installation in the reaction tubes of a tubular reactor, the tubular reactor being of the type comprising a plurality of reaction tubes extending between a first tube sheet and a second tube sheet, wherein a heat exchange zone is provided between the first tube sheet and the second tube sheet;

[0388] The support unit includes an elongated body having a first end and a second end, the first end being configured to engage with a support surface of the tubular reactor when the support unit is installed in the reaction tube, and the second end being configured to engage with an end of a stack of catalyst carriers adjacent to the support unit.

[0389] The length of the elongated body is configured to support the stack of catalyst carriers, such that all catalysts within the reaction tube are located within the heat exchange zone.

[0390] Clause B12. The support unit as described in Clause B11 is capable of being attached to one or more catalyst supports to form an insert assembly.

[0391] Clause B13. The support unit according to Clause B12 further includes one or more cooperative formations for joining one or more cooperative formations of one or more catalyst supports.

[0392] Clause B14. The support unit according to any one of Clauses B11 to B13 further includes a spacer element for aligning the support unit with the inner surface of the reaction tube.

[0393] Clause B15. The support unit according to any one of Clauses B11 to B14 further includes a seal for sealing between the support unit and the inner surface of the reaction tube; and optionally, said seal is or includes a spacer element for aligning the support unit with the inner surface of the reaction tube.

[0394] Clause B16. A support unit according to any one of Clauses B11 to B15, wherein the material of the support unit and any contents thereof are non-reactive with respect to the intended process conditions of the tubular reactor.

[0395] Clause C1. A method for mounting a catalyst support into a reaction tube of a tubular reactor, said tubular reactor being of the type comprising a plurality of reaction tubes extending between a first tube sheet and a second tube sheet, wherein a heat exchange zone is provided between the first tube sheet and the second tube sheet;

[0396] The method includes:

[0397] i) Provide multiple catalyst supports containing the catalyst;

[0398] ii) Provide spacer units;

[0399] iii) Install the plurality of catalyst carriers into the reaction tube, and then install the spacer unit such that the spacer unit is aligned with the first tube sheet, and the plurality of catalyst carriers are arranged in a stacked arrangement adjacent to the spacer unit, such that all catalysts in the reaction tube are located in the heat exchange zone.

[0400] Clause C2. The method according to Clause C1, wherein the first tube sheet is an upper tube sheet and the second tube sheet is a lower tube sheet, and the spacer unit is mounted at the height of the upper tube sheet, and the plurality of catalyst carriers are arranged in a stacked manner below the spacer unit such that all catalysts in the reaction tube are located below the height of the upper tube sheet in the heat exchange zone.

[0401] Clause C3. The method according to Clause C2, wherein installing the spacer unit includes pushing the spacer unit into the reaction tube to displace the plurality of catalyst carriers within the reaction tube downward such that the catalyst in the uppermost catalyst carrier is below the height of the upper tube sheet.

[0402] Clause C4. The method according to Clause C1, wherein the first tube sheet is a first end tube sheet and the second tube sheet is a second end tube sheet, and the spacer unit is mounted to be aligned with the first end tube sheet, and the plurality of catalyst carriers are arranged in a stacked arrangement on one side of the spacer unit such that all catalysts in the reaction tube are located on one side of the first end tube sheet within the heat exchange zone.

[0403] Clause C5. The method according to any one of Clauses C1 to C4, the method further comprising removing the spacer unit from the reaction tube to leave the last catalyst carrier of the stacked arrangement positioned such that the catalyst in the last catalyst carrier is located within the heat exchange zone.

[0404] Clause C6. The method according to Clause C5 further includes inserting a second spacer unit against the distal catalyst carrier; and optionally, wherein the second spacer unit spans between the distal catalyst carrier and the support surface of the tubular reactor; and optionally, wherein the support surface is a support grid extending across the open end of the reaction tube.

[0405] Clause C7. The method according to any one of Clauses C1 to C6, wherein the spacer unit is attached to one or more catalyst supports in the catalyst support to form an insert assembly; and the insert assembly is pushed into the reaction tube in a single operation, wherein the spacer unit is at the rear.

[0406] Clause C8. The method according to Clause C7, wherein spacer units are attached to the one or more catalyst supports to form the insert assembly using cooperative formations provided on the support unit and the one or more catalyst supports.

[0407] Clause C9. The method according to any one of Clauses C1 to C8, wherein the position of the last catalyst carrier stacked in the reaction tube is controlled by fixing the length of the spacer unit between a first end face of the spacer unit and an adjacent face of the spacer unit, and inserting the spacer unit into the reaction tube until the adjacent face engages with a reference face of the reaction tube, optionally abutting against an end face of the reaction tube.

[0408] Clause C10. The method according to any one of Clauses C1 to C9, wherein the plurality of catalyst supports and the spacer units are configured to be mounted into the reaction tube using the same mounting tool.

[0409] Clause C11. The method according to Clause C10, wherein the installation tool uses a movable plunger to push the plurality of catalyst supports and the spacer unit into the reaction tube.

[0410] Clause C12. A spacer unit for installation in the reaction tubes of a tubular reactor, the tubular reactor being of the type comprising a plurality of reaction tubes extending between a first tube sheet and a second tube sheet, wherein a heat exchange zone is provided between the first tube sheet and the second tube sheet;

[0411] The spacer unit includes an elongated body having a first end configured to engage with the end of a stack of catalyst carriers and a second end configured to engage with a mounting tool.

[0412] The length of the elongated body is configured such that the stack of catalyst supports can be sufficiently displaced into the reaction tube, such that all catalysts within the reaction tube are located within the heat exchange zone.

[0413] Clause C13. The spacer unit as described in Clause C12, wherein the spacer unit is releasably attachable to one or more catalyst supports to form an insert assembly.

[0414] Clause C14. The spacer unit according to Clause C13, the spacer further includes one or more cooperative formations disposed on the spacer unit for engaging one or more cooperative formations on the one or more catalyst supports.

[0415] Clause C15. A spacer unit according to any one of Clauses C12 to C14, wherein the material and any contents of the spacer unit are non-reactive with respect to the intended process conditions of the tubular reactor.

[0416] Clause C16. A spacer unit according to any one of Clauses C12 to C15, wherein the elongated body includes an abutment surface for engaging with a reference surface of the reaction tube, and optionally engaging with an end face of the reaction tube.

[0417] Clause C17. The spacer unit according to Clause C16, wherein the adjacent surface includes an outwardly extending flange having an outer diameter configured to be larger than the inner diameter of the reaction tube.

[0418] Clause C18. A spacer unit of any of Clauses C12 to C17, wherein the second end of said elongated body includes a bracket for engaging a movable plunger of an installation tool.

[0419] Clause C19. The spacer unit according to any one of Clauses C12 to C18, wherein the first end of the elongated body includes a skirt-like portion for engaging with the end of the catalyst carrier; optionally, the annular skirt-like portion is for engaging with an annular rim or annular groove disposed at the end of the catalyst carrier.

[0420] Clause D1. A method for at least partially emptying a reaction tube of a tubular reactor that was initially at least partially filled with catalyst supports, each of the catalyst supports being of a catalyst-containing type and having a seal engaging with the inner surface of the reaction tube;

[0421] The method includes:

[0422] i) Provides multiple ejector units;

[0423] ii) Install a first ejector assembly of one or more ejector units in the ejector unit to a first end of the reaction tube to contact and displace the last catalyst support in the reaction tube, thereby pushing the catalyst support in the reaction tube toward a second end of the reaction tube;

[0424] iii) Install a subsequent ejection assembly of one or more ejector units in the ejector unit into the first end of the reaction tube to contact and displace the ejection assembly of the one or more ejector units already in the reaction tube, thereby further pushing the catalyst support toward the second end of the reaction tube;

[0425] iv) Repeat step iii) once or more until three or more catalyst supports in the catalyst carrier are displaced to the second end of the reaction tube and discharged from the second end of the reaction tube.

[0426] Clause D2. The method according to Clause D1, wherein the first end is the top end of the reaction tube and the second end is the bottom end of the reaction tube.

[0427] Clause D3. The method described in Clause D1 or Clause D2, wherein the ejector unit is configured to have a maximum diameter smaller than the inner diameter of the reaction tube so as to slide freely therein.

[0428] Clause D4. The method according to any one of Clauses D1 to D3, the method further comprising the following steps:

[0429] v) After the catalyst support is discharged from the second end of the reaction tube, the plurality of ejector units are allowed to slide out of the second end of the reaction tube under gravity.

[0430] Clause D5. The method according to any one of Clauses D1 to D4, wherein the first ejector set and / or the subsequent ejector set comprises two or more ejector units attached to each other.

[0431] Clause D6. The method according to any one of Clauses D1 to D5, wherein both the first ejector assembly and the subsequent ejector assembly are pushed into the reaction tube by a single stroke of the installation tool.

[0432] Clause D7. The method according to any one of Clauses D1 to D6, wherein the catalyst support and the plurality of ejector units are configured to be inserted into the reaction tube using the same mounting tool.

[0433] Clause D8. The method according to Clause D7, wherein the installation tool uses a movable plunger to push the catalyst carrier and the plurality of ejector units into the reaction tube.

[0434] Clause D9. An ejector unit for removing a catalyst support from a reaction tube of a tubular reactor, the ejector unit comprising an elongated body having a first end configured to engage with the catalyst support and a second end configured to engage with an installation tool;

[0435] The maximum diameter of the elongated body is configured to be smaller than the inner diameter of the reaction tube, so that the ejector unit can slide freely within the reaction tube.

[0436] Clause D10. The ejector unit according to Clause D9, wherein the first end of the ejector unit is further configured to engage with the end of another ejector unit.

[0437] Clause D11. The ejector unit as described in Clause D9 or Clause D10 is capable of being attached to one or more other ejector units to form an ejection set.

[0438] Clause D12. The ejector unit according to Clause D11 further includes one or more cooperating formations disposed on or toward the first end of the ejector unit for engaging one or more cooperating formations on or toward the second end of another ejector unit.

[0439] Clause D13. An ejector unit according to any one of Clauses D9 to D12, wherein the second end of the elongated body includes a support for engaging a movable plunger of an installation tool.

[0440] Clause D14. An ejector unit according to any one of Clauses D9 to D13, wherein the first end of the elongated body includes a skirt for engaging with the end of a catalyst support and / or the end of another ejector unit.

[0441] Clause E1. A method for mounting a catalyst support into the reaction tube of a tubular reactor, the method comprising the steps of:

[0442] i) Provides multiple catalyst supports;

[0443] ii) Joining two or more of the plurality of catalyst supports together to form an insert set;

[0444] iii) Load the insertion set into the installation tool; and

[0445] iv) Use the installation tool to push the insert assembly into the reaction tube.

[0446] Clause E2. The method according to Clause E1, wherein the inserted set comprises at least two catalyst supports, optionally at least three catalyst supports, or optionally more than three catalyst supports.

[0447] Clause E3. The method according to Clause E1 or Clause E2, wherein the inserted set comprises a stacked arrangement of catalyst carriers, wherein adjacent catalyst carriers are releasably joined together using cooperative formations disposed on or toward the upper end of each catalyst carrier and on or toward the lower end of each catalyst carrier.

[0448] Clause E4. The method according to Clause E3, wherein the adjacent catalyst supports are rotated and locked together.

[0449] Clause E5. The method according to any one of Clauses E1 to E4, wherein the insert set comprises a first insert set and a second insert set, the second insert set being formed by releasably engaging two or more of the plurality of catalyst supports; wherein the mounting tool is used to push the second insert set into the reaction tube after the first insert set, thereby further pushing the first insert set into the reaction tube.

[0450] Clause E6. A plurality of catalyst supports for insertion into a reaction tube of a tubular reactor, each of the plurality of catalyst supports comprising a container for retaining catalyst in use, the container extending between an upper end and a lower end of the catalyst support;

[0451] Each catalyst support includes one or more upper cooperative formations disposed on or toward the upper end of the container and one or more lower cooperative formations disposed on or toward the lower end of the container;

[0452] The one or more upper cooperative formations are configured to engage with the one or more lower cooperative formations;

[0453] Two or more of the plurality of catalyst supports may be joined together in a stacked arrangement, wherein adjacent catalyst supports are joined together by joining one or more lower cooperating members and one or more upper cooperating members.

[0454] Clause E7. According to Clause E6, of the plurality of catalyst supports, wherein one or more upper cooperative formations and one or more lower cooperative formations are configured to engage and disengage via relative rotational movement of the adjacent catalyst supports.

[0455] Clause E8. A plurality of catalyst supports as described in Clause E7, wherein one or more upper cooperative formations and one or more lower cooperative formations form one or more bayonet assemblies.

[0456] Clause E9. A plurality of catalyst supports according to any one of Clauses E6 to E8, wherein each container includes a bottom surface at the lower end, a top surface at the upper end, and a support outer wall extending between the bottom surface and the top surface.

[0457] Clause E10. A plurality of catalyst supports as described in Clause E9, wherein each container further includes a seal extending beyond the outer wall of the support; and optionally, the outer wall of the support includes an opening located below the seal.

[0458] Clause E11. A plurality of catalyst supports as described in Clause E10, wherein one or more of the upper cooperative formations are disposed above the seal.

[0459] Clause E12. A plurality of catalyst supports according to any one of Clauses E9 to E11, wherein each container further comprises an annular chamber for retaining the catalyst in use, the annular chamber having a perforated inner chamber wall defining an inner channel, a perforated outer chamber wall, a top surface closing the annular chamber, and a bottom surface closing the annular chamber.

[0460] Clause E13. A catalyst support is one of a plurality of catalyst supports according to any one of clauses E6 to E12.

Claims

1. A method for mounting a catalyst support into a first selected reaction tube of a tubular reactor, the method comprising the steps of: i) Provide an installation tool, the installation tool comprising: a) Install the rack; b) A movable plunger, which is mounted to the mounting frame and configured to push one or more catalyst supports into the first selected reaction tube; and c) One or more anchors for releasably attaching the mounting frame to the tubular reactor; ii) Attaching the mounting tool to the tubular reactor by engaging one or more anchors located in one or more reaction tubes adjacent to the first selected reaction tube, so as to align the movable plunger with the first selected reaction tube; and iii) Actuate the movable plunger to push the one or more catalyst supports into the first selected reaction tube.

2. The method of claim 1, wherein in step ii), the mounting tool is attached such that the mounting frame is located in the top or bottom space of the tubular reactor outside the reaction tube.

3. The method according to claim 2, wherein the mounting frame is located above the upper tube sheet of the tubular reactor or below the lower tube sheet of the tubular reactor.

4. The method according to any one of claims 1-3, wherein step i) further includes inserting the installation tool into the top or bottom space of the tubular reactor through the access port of the tubular reactor.

5. The method according to any one of claims 1-3, wherein the movable plunger is a powered plunger or a manually driven plunger.

6. The method of claim 5, wherein the movable plunger is switchable between a power mode in which the movable plunger moves under power and a manual mode in which the movable plunger is manually driven.

7. The method according to any one of claims 1-3, The installation tool is coupled to a power source for moving the movable plunger located outside the tubular reactor; or The installation tool includes a power source located inside the tubular reactor for moving the movable plunger.

8. The method according to claim 7, wherein the power source includes a hydraulic source, a pneumatic source, or a power source.

9. The method according to any one of claims 1-3, wherein in step iii), an insert set of one catalyst carrier, two catalyst carriers, three catalyst carriers or more catalyst carriers is pushed into the first selected reaction tube by a single stroke of the movable plunger.

10. The method of claim 9, wherein step iii) is repeated once or more to push one or more additional insert sets into the first selected reaction tube.

11. The method of claim 9, wherein pushing the insert assembly into the first end of the first selected reaction tube causes one or more catalyst supports to be pushed out of the second end of the first selected reaction tube.

12. The method according to any one of claims 1-3, further comprising using one or more stabilizing feet coupled to the mounting frame to stabilize the mounting tool; and / or The one or more stabilizing feet are used to replace any of the one or more anchors removed from the installation tool.

13. The method of claim 12, further comprising leveling the mounting tool by adjusting one or more of the stabilizing feet.

14. The method according to any one of claims 1-3, wherein in step ii), each of the one or more anchors is expanded to grip the inner surface of the reaction tube.

15. The method of claim 14, wherein the one or more anchors are expanded using manual power, hydraulic power, pneumatic power or electric power.

16. The method of claim 14, wherein the one or more anchors are spring-loaded and biased to expand thereby gripping the inner surface of the reaction tube.

17. The method according to any one of claims 1-3, wherein the movable plunger includes an alignment device that aligns the one or more catalyst supports with the first selected reaction tube.

18. The method of claim 17, wherein the alignment device comprises a first engagement portion engaging a second engagement portion of the one or more catalyst supports.

19. The method of claim 18, wherein the first engagement portion is elastic and / or spring-loaded.

20. The method according to any one of claims 1-3, wherein the movable plunger is configured to push one or more catalyst supports into a second selected reaction tube while simultaneously pushing the one or more catalyst supports into a first selected reaction tube; and actuating the movable plunger to simultaneously push one or more catalyst supports into the first selected reaction tube and push one or more catalyst supports into the second selected reaction tube.

21. The method of claim 20, wherein the movable plunger is configured to push one or more catalyst supports into a second selected reaction tube and one or more additional selected reaction tubes, while simultaneously pushing the one or more catalyst supports into a first selected reaction tube; and actuating the movable plunger to simultaneously push one or more catalyst supports into the first selected reaction tube, and one or more catalyst supports into the second selected reaction tube, and one or more catalyst supports into the one or more additional selected reaction tubes.

22. The method according to any one of claims 1-3, further comprising the step of: iv) Disengage the one or more anchors from the one or more reaction tubes located next to the first selected reaction tube; v) Move the mounting tool and reattach it to the tubular reactor by engaging the one or more anchors located in one or more reaction tubes adjacent to the second selected reaction tube, so as to align the movable plunger with the second selected reaction tube; as well as vi) Actuate the movable plunger to push one or more catalyst supports into the second selected reaction tube.

23. An installation tool for mounting a catalyst support into a selected reaction tube of a tubular reactor, the installation tool comprising: a) Install the rack; b) A movable plunger, which is mounted to the mounting frame and configured to push one or more catalyst supports into a selected reaction tube; and c) One or more anchors for engaging one or more reaction tubes located adjacent to the selected reaction tubes, so that the mounting frame can be releasably attached to the tubular reactor.

24. The installation tool according to claim 23, wherein the movable plunger is a manual plunger, a hydraulic plunger, a pneumatic plunger, or an electromechanical plunger.

25. The installation tool according to claim 23 or claim 24, wherein the installation frame defines a loading station for receiving the one or more catalyst carriers.

26. The installation tool of claim 25, wherein the loading station is configured to hold an insertion set of one catalyst carrier, two catalyst carriers, three catalyst carriers or more catalyst carriers, and the movable plunger is configured to push the insertion set of catalyst carriers into the first selected reaction tube in a single stroke.

27. The installation tool according to claim 23 or claim 24, wherein the one or more anchors are expandable for gripping the inner surface of the reaction tube.

28. The installation tool according to claim 23 or claim 24, wherein: The one or more anchors include manually, hydraulically, pneumatically, or electrically expandable anchors; or The one or more anchors mentioned above include spring-loaded anchors.

29. The installation tool according to claim 28, wherein the spring-loaded anchor is a spring-loaded cam device.

30. The installation tool according to claim 23 or claim 24, the installation tool further comprising one or more stabilizing feet connected to the installation frame.

31. The installation tool according to claim 23 or claim 24, wherein the movable plunger includes an alignment device for aligning the one or more catalyst supports with the first selected reaction tube.

32. The installation tool of claim 31, wherein the alignment device includes a first engagement portion for engaging a second engagement portion of the one or more catalyst supports.

33. The installation tool according to claim 32, wherein the first engagement portion is resilient and / or spring-loaded.

34. The installation tool according to claim 23 or claim 24, wherein the movable plunger comprises: A first plunger portion for pushing the one or more catalyst supports into the first selected reaction tube and a second plunger portion for simultaneously pushing the one or more catalyst supports into the second selected reaction tube.

35. The installation tool of claim 34, wherein the movable plunger further comprises: One or more additional plunger sections for simultaneously pushing one or more catalyst supports into one or more additional selected reaction tubes.

36. The installation tool of claim 23 or claim 24, wherein the installation frame includes a plurality of anchor seats for attaching the anchors to the installation frame; wherein the plurality of anchor seats surround an opening adapted to allow the one or more catalyst carriers to pass through to the selected reaction tube.

37. The installation tool of claim 36, wherein the installation frame comprises three anchors arranged in a triangle around the opening, or four anchors arranged in a quadrilateral around the opening.

38. An installation system for mounting a catalyst support into a reaction tube of a tubular reactor, the installation system comprising: The installation tool according to any one of claims 23 to 37 is configured for installation in the top or bottom space of the tubular reactor; A power source, which can be located outside the tubular reactor and is configured to move the movable plunger of the mounting tool; and One or more hoses for supplying power from the power source to the installation tool.

39. The installation system according to claim 38, further comprising: The second installation tool is the installation tool according to any one of claims 23 to 37, and the second installation tool is configured for installation in the top or bottom space of the same tubular reactor; and One or more hoses, the one or more hoses being used to supply power from the power source to the second installation tool.

40. The installation system according to claim 38 or claim 39, wherein the power source includes a manual source, a hydraulic source, a pneumatic source, or a power source.

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