Improvements in or relating to catalyst carriers for tubular reactors and related methods

Abstract

This disclosure provides a catalyst carrier (10) for insertion into a reactor tube of a tubular reactor, the catalyst carrier comprising a container for holding the catalyst and a seal (104) for sealing between the container and the reactor tube. The seal (104) includes at least a first sealing layer (126) and a second sealing layer (127), each sealing layer including a plurality of deflectable tongues (160) separated by a notch (161). The second sealing layer (127) is rotated relative to the first sealing layer (126) such that the notch (161) of the second sealing layer (127) aligns with the deflectable tongues (160) of the first sealing layer (126).

Description

[0001] This disclosure relates to improvements and related methods for catalyst supports used in tubular reactors. In particular, this disclosure relates to sealing components for catalyst supports inserted into reactor tubes of a tubular reactor. Background Technology

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

[0003] For some reactions, the heat effect is moderate, making them either harmless or easily controllable. In some cases, the heat effect is small enough that large-diameter tubes can be used. The advantage of this is that a large amount of catalyst can be contained within the tube.

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

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

[0006] Therefore, in attempts to alleviate these problems, alternative methods have been developed specifically for more exothermic or endothermic reactions, in which the catalyst is not directly packed into the reactor tube, but is contained in multiple catalyst supports configured to be located within the reactor tube.

[0007] WO2011 / 048361 describes a first type of such catalyst support. This arrangement attempts 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 holding the catalyst in 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-like portion extends upward from the perforated outer wall of the annular container, extending upward from 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-like portion.

[0008] A second type of such catalyst support is described in WO2012 / 136971. In this arrangement, the catalyst support includes a container for holding the 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 location 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 beyond the outer surface of the skirt.

[0009] A third type of such catalyst support is described in WO2016 / 050520. In this arrangement, the catalyst support includes a container for holding the catalyst in 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 a distance that extends radially beyond the outer wall of the support. The outer wall of the support has an orifice located below the seal.

[0010] The seals of this type of catalyst support play a crucial role in its use. The seals must ensure that the liquid and gas flow within the reactor core follows the desired path. Specifically, the seals must ensure that reactants do not bypass the catalyst contained within the vessel by flowing between the exterior of the vessel and the interior surface of the reactor tubes.

[0011] Importantly, the seal should not be subjected to buckling when the catalyst carrier is inserted into the reactor tube, as buckling would create a gap between the seal and the inner surface of the reactor tube, thus forming a bypass channel for liquids and gases. Furthermore, large and unpredictable forces may be required to deform the seal during installation, which could make loading the tube difficult.

[0012] One object of the present invention is to provide a seal for a catalyst support that overcomes the problems of previous designs. Summary of the Invention

[0013] In a first aspect of this disclosure, a catalyst support for insertion into a reactor tube of a tubular reactor is provided, the catalyst support comprising a container for retaining the catalyst in use and a seal for sealing between the container and the inner surface of the reactor tube.

[0014] The catalyst support has a longitudinal axis that can be aligned with the longitudinal axis of the reactor tube during use, so as to facilitate the installation of the catalyst support into the reactor tube;

[0015] The sealing element includes at least a first sealing layer and a second sealing layer;

[0016] The first sealing layer and the second sealing layer each include a plurality of deflectable tongues separated by notches;

[0017] The second sealing layer rotates and shifts relative to the first sealing layer around the longitudinal axis of the catalyst carrier, so that the notch of the second sealing layer aligns with the deflectable tongue of the first sealing layer.

[0018] Therefore, the deflectable tongue of one sealing layer can be used to close and at least partially seal a notch in another sealing layer.

[0019] Advantageously, the seal of this disclosure is particularly suitable for forming a seal with the inner surface of the reactor tube. The deflectable tongue provides the seal with means to adapt to changes in the overall inner diameter and inner surface shape of the reactor tube.

[0020] The notch allows the seal to deform without buckling.

[0021] Furthermore, the use of at least two sealing layers allows each sealing layer to be manufactured thinner, and therefore more flexible compared to a single layer of equal thickness. The use of such sealing layers also improves the seal between each sealing layer and the pipe wall.

[0022] The use of at least two sealing layers provides an effective means of preventing liquids and gases from bypassing through the notch.

[0023] The primary function of the seal is to prevent or reduce the bypassing of material around the catalyst support. In practice, the seal does not need to block all bypassing. The permissible bypass level will depend on the application and the amount of catalyst support present in each tube. The bypassing of material around the catalyst support is preferably less than 10% by volume, more preferably less than 5% by volume, and even more preferably less than 2% by volume.

[0024] Seals can also be used to provide resistance to the inner wall of the tube. Ideally, this resistance allows the catalyst support containing the catalyst to remain in place within the tube without additional support. Self-supporting catalyst supports may be advantageous in some applications.

[0025] The seal can also be used to center the catalyst carrier within the tube, ensuring a uniform space around the catalyst carrier and the inner wall of the tube (where the catalyst carrier is placed). Centering facilitates heat transfer and efficient material flow through the tube.

[0026] The first and second sealing layers may overlap each other. Alternatively, the first and second sealing layers may be face-to-face on the carrier before installation. While an axial gap may be provided between each sealing layer before insertion, it is preferred that the sealing layers be face-to-face (or at least substantially so) when installed into the reactor tube to minimize bypass.

[0027] The first and second sealing layers may comprise separate sealing elements. Alternatively, the first and second sealing layers may comprise a first portion and a second portion of an integral sealing element. Optionally, the integral sealing element may be a helical element.

[0028] Each of the first and second sealing layers may include a notched outer edge forming a plurality of deflectable tongues thereon. For example, each sealing layer may be formed from a single sheet of material. The notched outer edge may be formed by a suitable method (such as cutting, stamping, etc.). If necessary, additional steps may be performed on the seal to remove burrs or to alter the properties of the sealing material after shape formation, thereby changing its elasticity.

[0029] The notch may include sidewalls that are parallel or bifurcate towards the outer edge of the corresponding sealing layer. The notch may be U-shaped or V-shaped. The shape of the notch can be varied to make it easier to manufacture. For example, a U-shape suitable for stamping processes can be used. The notch shapes in adjacent seals may be the same or different. Advantageously, providing an initial gap between the sidewalls of the notch allows the notch to close at least partially without buckling when the sealing layer is deformed by the reactor tube wall.

[0030] The first and second sealing layers may extend vertically from the container. Alternatively, at least the distal ends of the tongues of the first and second sealing layers may be angled toward the ends of the container. This arrangement improves the ease of inserting the catalyst carrier into the reactor tube.

[0031] The first and second sealing layers may include annular elements. The annular elements may conform to the shape of the inner surface of the reactor tube. The annular elements may be circular.

[0032] In some embodiments, the catalyst support may include three or more sealing layers, each sealing layer including a plurality of deflectable tongues separated by notches; each sealing layer may be rotatably offset relative to at least one of the other sealing layers about the longitudinal axis of the catalyst support, such that the notch of each sealing layer may be aligned with the deflectable tongue of at least one of the other sealing layers. Optionally, the notch of each sealing layer may be aligned with the deflectable tongue of one or two adjacent sealing layers.

[0033] In some implementations, the catalyst support may include four, five, or six sealing layers.

[0034] In some implementations, the sealing layer can be attached separately to the catalyst carrier.

[0035] In some implementations, the inner edges of one or more sealing layers may be attached together. This attachment may occur before or after the sealing layers are attached to the container.

[0036] Each sealing layer may include a key or keyway for engaging complementary keyways or keys on the container to maintain relative rotational alignment between the sealing layers. Advantageously, this helps ensure proper alignment of the deflectable tongues and notches of the different sealing layers.

[0037] 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 and top surfaces. A sealing layer may be attached to the carrier outer wall and / or the top surface.

[0038] The outer wall of the carrier may include multiple holes, and a sealing layer may be attached to the carrier wall above the multiple holes.

[0039] Each container may further 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 that closes the annular chamber, and a bottom surface that closes the annular chamber.

[0040] The first and second sealing layers can have the same or different thicknesses. Different thicknesses can be used to construct different sealing layers with different properties, including, for example, flexibility, rigidity, compressibility, etc. In some embodiments, the thickness of each sealing layer is from 15 micrometers to 500 micrometers (0.015 mm to 0.5 mm). The sealing layers can have the same thickness or different thicknesses. For example, a thicker lower / outer seal provides insertion resistance and stability during processing, while a thinner second upper / inner sealing layer provides flexibility to seal against the first layer.

[0041] The first and second sealing layers may be made of the same or different materials. Preferably, the sealing layer is formed of a material that is not reactive to the expected reaction in the tubular reactor. For example, the material may be carbon steel, aluminum, stainless steel, other alloys, or any material capable of withstanding the reaction conditions.

[0042] In a second aspect of this disclosure, a method for mounting a catalyst support into a reactor tube of a tubular reactor is provided, the method comprising the steps of:

[0043] i) Provide an installation tool that includes a movable hammer configured to push a catalyst carrier into a reactor tube;

[0044] ii) Using a movable hammer, the catalyst carrier is pushed into the reactor tube, so that the container of the catalyst carrier is received inside the reactor tube; and

[0045] iii) The catalyst carrier is pushed into the reactor tube such that the seal of the catalyst carrier contacts the inner surface of the reactor tube and is deformed by the inner surface, and at least the first and second sealing layers of the seal are deformed by the contact between the seal and the inner surface.

[0046] Both the first and second sealing layers may include multiple notches, and pushing the catalyst carrier into the reactor tube can cause the notches to close at least partially.

[0047] Both the first and second sealing layers may include a plurality of deflectable tongues separated by notches, and pushing the catalyst carrier into the reactor tube may cause the plurality of deflectable tongues of one of the first and second sealing layers to at least partially seal the notches of the other of the first and second sealing layers.

[0048] Depending on the weight and strength of the catalyst support, the seal can provide an insertion resistance of up to 100 N. The minimum resistance can be equal to the weight of the catalyst support containing the catalyst. In some embodiments, the resistance can be greater than 0.5 N and less than 70 N, preferably greater than 15 N and less than 50 N.

[0049] The seal can be fixed to the catalyst carrier or releasably attached to the catalyst carrier. A releasably attached seal may be advantageous if the seal is damaged or deformed, for example, during catalyst filling or transport.

[0050] The methods and catalyst supports disclosed herein can be effectively used in a wide range of processes. Examples of suitable applications include processes and reactors for exothermic reactions such as: reactions for the production of methanol, reactions for the production of ammonia, methanation reactions, transfer reactions, oxidation reactions (such as the formation of maleic anhydride and the ethylene oxide reaction), etc. Particularly preferred applications are for processes and reactors for carrying out Fischer-Tropsch reactions.

[0051] Endothermic reactions (such as preconversion, dehydrogenation, etc.) can also be carried out in conjunction with the methods and catalyst supports disclosed herein.

[0052] The catalyst support disclosed herein may be filled or partially filled with any catalyst suitable for the intended reaction. For example, Fischer-Tropsch catalysts may be used for Fischer-Tropsch reactions. Cobalt-containing Fischer-Tropsch 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.

[0053] 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. Attached Figure Description

[0054] Embodiments of this disclosure will now be described by way of example only with reference to the accompanying drawings, in which:

[0055] Figure 1 This is a perspective view of the catalyst support;

[0056] Figure 2 yes Figure 1 A cross-sectional view of the catalyst support;

[0057] Figure 3 yes Figure 1 A perspective view of the catalyst support after decomposition;

[0058] Figure 4 This is a plan view of the sealing layer used for the catalyst support;

[0059] Figure 5 It is a schematic side view showing the arrangement of multiple sealing layers; and

[0060] Figure 6 This is a plan view of the first and second sealing layers used as catalyst supports. Detailed Implementation

[0061] In the following description, aspects and embodiments of this disclosure will be illustrated by way of example only with reference to exemplary constructions of catalyst supports. However, it should be understood that catalyst supports may take various general forms according to this disclosure. For example, catalyst support 10 may take other general forms, including, but not limited to, those disclosed in WO2011 / 048361, WO2012 / 136971 and WO2016 / 050520, the entire contents of which are incorporated herein by reference.

[0062] Furthermore, any references to orientation in this specification, such as terms like top, bottom, upper, lower, above, and below, are used relative to the orientation of the components shown in the referenced drawings, but should not be construed as limiting the potential orientation of these components in actual use. For example, a component described as vertically oriented may also be horizontally oriented.

[0063] According to the example of catalyst support 10 of this disclosure, in Figures 1 to 3 The example is shown below.

[0064] The catalyst support 10 typically includes a container sized such that its dimensions are smaller than the internal dimensions of the reactor tube, which will be placed inside the reactor tube during use. Typically, a seal (discussed further below) is provided, sized such that it interacts with the inner wall of the reactor tube when the catalyst support 10 is in place within the reactor tube. Parameters such as the support length and diameter can be selected to accommodate different reactions and reactor tube configurations.

[0065] like Figures 1 to 3 As shown, the catalyst carrier 10 may include a container 100 for retaining catalyst particles during use. The container 100 typically has a bottom surface 101 closing the lower end of the container 100 and a top surface 102 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.

[0066] like Figure 2 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 perforated 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. In addition to one or more discharge holes (not shown) that may be provided in the lower end of the inner channel 112, the lower end of the inner channel 112 may be closed by a channel end surface 116. The channel end surface 116 may be integrally formed with or separate from the inner container wall 111.

[0067] like Figure 3As shown in the exploded view, the catalyst carrier 10 may be formed from multiple individual components, which may be assembled together by any suitable means, including, for example, welding. In some embodiments, such 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 one or more annular sealing layers 126, 127.

[0068] The catalyst support 10 can be formed of any suitable material. Such materials are typically chosen to withstand the operating conditions of the reactor. Typically, the catalyst support is made of carbon steel, aluminum, stainless steel, other alloys, or any material capable of withstanding the reaction conditions.

[0069] The appropriate thickness of the components (except for the annular sealing layers 126, 127) will be from about 0.1 mm to about 1.0 mm, preferably from about 0.3 mm to about 1.0 mm.

[0070] The perforated inner tube 120 may include a perforated inner container wall 111. The perforated intermediate tube 121 may include a perforated outer container wall 113. The outer tube 122 may include a carrier outer wall 103 and define an orifice 105. The bottom cap 123 may include a bottom surface 101 and / or an annular bottom surface 115. The bottom cap 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 cap 125 may include an annular top surface 114 and may include at least a portion of the top surface 102.

[0071] The size of the perforations on the perforated inner tube 120 and the perforated intermediate tube 121 will be selected 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 perforations may be larger in size but have a filter screen covering the perforations to ensure that the catalyst is maintained within the annular container 110.

[0072] It should be understood that a perforation can have any suitable construction. In fact, when a wall or tube is described as a perforation, what is required is the presence of a device that allows reactants and products to pass through the wall or tube.

[0073] The seal 104 may include at least a first sealing layer 126 and a second sealing layer 127. The seal 104 may include more than two sealing layers 126, 127. For example, it may include four, five or six sealing layers.

[0074] Figure 4 An example of a sealing layer 126 is shown. Figure 5 This illustrates how multiple sealing layers 126a to 126f can be arranged to form a seal 104. Figure 6Another example of a seal 104 formed by two sealing layers 126, 127 is shown.

[0075] Sealing layers 126 and 127 may include portions of an integral sealing element (e.g., a spiral element). Alternatively, and as... Figures 4 to 6 As shown, each sealing layer 126, 127 may include a separate sealing element.

[0076] The first sealing layer 126 and the second sealing layer 127 overlap each other. Preferably, layers 126 and 127 are in face-to-face contact.

[0077] Each sealing layer 126, 127 may include a separate sealing ring.

[0078] Each sealing layer 126, 127 can be flexible.

[0079] Each sealing layer 126, 127 may include an annular element. The outer edge of each annular element may typically be configured to match the shape of the inner surface of the reactor tube.

[0080] The annular element can be circular. In some examples, the outer diameter can be 80 mm to 90 mm, optionally about 85 mm. The annular element may have a central hole 162 for receiving the catalyst support 10. The central hole 162 may have a diameter of 55 mm to 65 mm, optionally about 60 mm.

[0081] Considering the inner diameter of the reactor tube in which the catalyst support 10 is to be installed, the outer diameter can be selected to achieve the desired insertion force of the catalyst support 10. Preferably, an insertion resistance greater than the weight of the catalyst support containing the catalyst and less than 100 N is desirable.

[0082] Each sealing layer 126, 127 includes a plurality of deflectable tongues 160 separated by a notch 161. Thus, each of the first sealing layer 126 and the second sealing layer 127 (and any additional sealing layers) may include an outer edge 163 with a notch.

[0083] Each sealing layer 126, 127 may include 5 to 80 deflectable tongues 160, optionally 8 to 60 deflectable tongues 160, optionally about 40 deflectable tongues 160.

[0084] Each pair of deflectable tongues 160 can be separated by a notch 161.

[0085] Each sealing layer 126, 127 can be formed from a single sheet of material. The notched outer edge 163 can be formed by a suitable method (such as cutting, stamping, etc.).

[0086] The materials of each sealing layer 126 and 127 may be the same or different. Each sealing layer 126 and 127 may be formed of carbon steel, aluminum, stainless steel, other alloys or any material capable of withstanding reactive conditions.

[0087] The thicknesses of the sealing layers 126 and 127 may be the same or different. Different thicknesses can be used to construct different sealing layers with different properties, including, for example, flexibility, rigidity, compressibility, etc. Each sealing layer 126 and 127 may have a certain thickness, which is selected to achieve the insertion force and flexibility required to achieve the deflectable tongue 160. In some examples, the thickness of each sealing layer 126 and 127 may be from 15 micrometers to 500 micrometers (0.015 mm to 0.5 mm).

[0088] The width of notch 161 can be from, for example Figure 4 The relatively narrow variation in the example to such Figure 6 The relative width in the example.

[0089] Notch 161 may include sidewall 164 (as in Figure 6 (As most clearly seen), these sidewalls are parallel or bifurcate toward the outer edges of the corresponding sealing layers 126, 127. The notch 161 can be U-shaped or V-shaped.

[0090] The second sealing layer 127 is preferably rotated and offset relative to the first sealing layer 126 about the longitudinal axis of the catalyst carrier 10, such that the notch 161 of the second sealing layer 127 is aligned with the deflectable tongue 160 of the first sealing layer 126.

[0091] The first sealing layer 126 and the second sealing layer 127 may extend vertically from the container 100. Alternatively, the first sealing layer 126 and the second sealing layer 127 may be angled toward the upper end of the container 100, for example, toward the top surface 102.

[0092] In some embodiments, the catalyst carrier 10 may include three or more sealing layers 126, 127, each sealing layer including a plurality of deflectable tongues 160 separated by notches 161. Each sealing layer 126, 127 may be rotatably offset relative to at least one of the other sealing layers 126, 127 about the longitudinal axis of the catalyst carrier 10, such that the notch 161 of each sealing layer 126, 127 may be aligned with the deflectable tongue 160 of at least one of the other sealing layers 126, 127. Preferably, the notch 161 of each sealing layer 126, 127 may be aligned with the deflectable tongue 160 of one or two adjacent sealing layers 126, 127. For example, as Figure 5 As shown, the notch 161 of the sealing layer 126c is aligned with the deflectable tongue 160 of the two sealing layers 126b and 126d.

[0093] The inner edges of the sealing layers 126 and 127 may be attached together. This attachment may be made before or after the sealing layers 126 and 127 are attached to the container 100, for example by welding.

[0094] Each sealing layer 126, 127 may include a key or keyway (not shown) for engaging complementary keyways or keys on the container 100 to maintain relative rotational alignment between the sealing layers 126, 127 and each other.

[0095] The interior of each sealing layer 126, 127 may define a clamping surface that is clamped and held between the top cover 125 and the annular top ring 124.

[0096] return Figures 1 to 3 The bottom surface 101 (e.g., bottom cap 123) may be shaped to engage with the upper end of another catalyst carrier 10. For example, the bottom surface 101 may include an annular groove 130 surrounding the perforated inner tube 120. The top cap 125 may be shaped 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 the annular plug 132. The shape and size of the annular ring 131 may be configured to be received in the annular groove 130.

[0097] The bottom surface 101 (e.g., bottom cover 123 and / or channel end surface 116) may include one or more drain holes. Where one or more drain holes are present, they may be covered by a filter screen.

[0098] The annular top ring 124 can be shaped and sized 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 hole of the annular top ring 124. The engagement of the top cover 125 with the annular top ring 124 can be used to clamp and hold the sealing layers 126, 127 of the seal 104 in place.

[0099] The top cover 125 may include a central inlet 134 in the annular plug 132 for allowing liquid and gas to enter the upper end of the inner channel 112. The annular ring 131 may include lateral holes 133, thereby allowing liquid and gas to reach the central inlet 134.

[0100] The top cap 125 and the annular top ring 124 together form a cap for the catalyst carrier 10, which can be used to seal the upper end of the annular container 110. Alternatively, a cap formed from a single component can be used.

[0101] The outer wall 103 of the carrier can be smooth or can be formed into a shape. Suitable shapes include folds, corrugations, etc.

[0102] The hole 105 in the outer wall 103 of the carrier can be of any construction. In some embodiments, the hole 105 can be a cavity or a groove.

[0103] 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 the seal may be located at a suitable point on the outer wall 103 of the carrier, as long as it is above the hole 105 in the outer wall 103 of the carrier.

[0104] In use, the catalyst carrier 10 can be installed in the reactor tube using any suitable means. A movable hammer can be used to push the catalyst carrier 10 into the reactor tube. During insertion, the seal 104 of the catalyst carrier 10 will contact and deform the inner surface of the reactor tube. Specifically, pushing the catalyst carrier 10 into the reactor tube will cause the first sealing layer 126 and the second sealing layer 127 of the seal 104 to deflect into contact with each other as they engage with the inner surface of the reactor tube.

[0105] Deformation of the first sealing layer 126 and the second sealing layer 127 may cause the notch 161 of one or both layers to be at least partially closed. Preferably, a plurality of deflectable tongues 160 of at least one of the first sealing layer 126 and the second sealing layer 127 at least partially seal the notch 161 of the other of the first sealing layer 126 and the second sealing layer 127.

[0106] The seal 104 provides an insertion resistance greater than the weight of the catalyst support containing the catalyst and less than 100 N.

Claims

1. A catalyst carrier for insertion into a reactor tube of a tubular reactor, the catalyst carrier comprising a container for retaining the catalyst in use and a seal for sealing between the container and an inner surface of the reactor tube; The catalyst support has a longitudinal axis that can be aligned with the longitudinal axis of the reactor tube during use, so as to facilitate the installation of the catalyst support into the reactor tube. The seal includes at least a first sealing layer and a second sealing layer; The first sealing layer and the second sealing layer each include a plurality of deflectable tongues separated by notches; The second sealing layer is rotated and offset relative to the first sealing layer about the longitudinal axis of the catalyst carrier, such that the notch of the second sealing layer is aligned with the deflectable tongue of the first sealing layer.

2. The catalyst support according to claim 1, wherein the first sealing layer and the second sealing layer overlap each other.

3. The catalyst support according to claim 2, wherein the first sealing layer and the second sealing layer are in face-to-face contact.

4. The catalyst support according to any one of claims 1 to 3, wherein the first sealing layer and the second sealing layer comprise separate sealing elements.

5. The catalyst carrier according to any one of claims 1 to 3, wherein the first sealing layer and the second sealing layer comprise a first portion and a second portion of an integral sealing element.

6. The catalyst carrier according to claim 5, wherein the integral sealing element is a spiral element.

7. The catalyst carrier according to any one of claims 1 to 3, wherein each of the first sealing layer and the second sealing layer includes a notched outer edge forming a plurality of deflectable tongues thereon.

8. The catalyst carrier according to any one of claims 1 to 3, wherein the notch includes sidewalls that are parallel or bifurcated toward the outer edge of the corresponding sealing layer.

9. The catalyst support according to claim 8, wherein the notch is U-shaped or V-shaped.

10. The catalyst carrier according to any one of claims 1 to 3, wherein the first sealing layer and the second sealing layer extend vertically from the container.

11. The catalyst carrier according to any one of claims 1 to 3, wherein at least the distal ends of the deflectable tongues of the first sealing layer and the second sealing layer are angled toward the end of the container.

12. The catalyst support according to any one of claims 1 to 3, wherein each of the first sealing layer and the second sealing layer comprises an annular element.

13. The catalyst carrier according to any one of claims 1 to 3, wherein the catalyst carrier comprises three or more sealing layers, each sealing layer comprising a plurality of deflectable tongues separated by notches; each sealing layer is rotated about the longitudinal axis of the catalyst carrier relative to at least one of the other sealing layers such that the notch of each sealing layer is aligned with the deflectable tongue of at least one of the other sealing layers.

14. The catalyst support according to claim 13, wherein the catalyst support comprises four, five or six sealing layers.

15. The catalyst carrier of claim 13, wherein the notch of each sealing layer is aligned with the deflectable tongue of one or two adjacent sealing layers.

16. The catalyst support according to any one of claims 1 to 3, wherein the inner edges of one or more sealing layers are attached together.

17. The catalyst support according to any one of claims 1 to 3, wherein each sealing layer includes a bond or keyway for engaging complementary keyways or bonds on the container to maintain relative rotational alignment between the sealing layers.

18. The catalyst support according to any one of claims 1 to 3, wherein each container includes a bottom surface at a lower end, a top surface at an upper end, and a support outer wall extending between the bottom surface and the top surface.

19. The catalyst support according to claim 18, wherein the sealing layer is attached to the outer wall of the support and / or the top surface.

20. The catalyst support of claim 18, wherein the outer wall of the support includes a plurality of pores, and the sealing layer is attached to the outer wall of the support above the plurality of pores.

21. The catalyst support according to any one of claims 1 to 3, 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.

22. The catalyst support according to any one of claims 1 to 3, wherein the first sealing layer and the second sealing layer have different thicknesses.

23. The catalyst support according to any one of claims 1 to 3, wherein the first sealing layer and the second sealing layer are made of different materials.

24. The catalyst carrier according to any one of claims 1 to 3, wherein the notches of the first sealing layer and the second sealing layer have different shapes.

25. A method for mounting a catalyst support according to any one of claims 1 to 24 into a reactor tube of a tubular reactor, the method comprising the steps of: i) Provide an installation tool, the installation tool including a movable hammer configured to push the catalyst carrier into the reactor tube; ii) Using the movable hammer, the catalyst carrier is pushed into the reactor tube, such that the container of the catalyst carrier is received inside the reactor tube; as well as iii) The catalyst carrier is pushed into the reactor tube such that the seal of the catalyst carrier contacts the inner surface of the reactor tube and is deformed by the inner surface, and at least the first sealing layer and the second sealing layer of the seal are deformed by the contact between the seal and the inner surface.

26. The method of claim 25, wherein both the first sealing layer and the second sealing layer include a plurality of notches, and the catalyst carrier is pushed into the reactor tube such that the notches are at least partially closed.

27. The method of claim 25 or claim 26, wherein both the first sealing layer and the second sealing layer include a plurality of deflectable tongues separated by notches, and the catalyst carrier is pushed into the reactor tube such that the plurality of deflectable tongues of one of the first sealing layer and the second sealing layer at least partially seal the notches of the other of the first sealing layer and the second sealing layer.

28. The method of claim 25 or claim 26, wherein the seal provides an insertion resistance greater than the weight of the catalyst carrier containing the catalyst and less than 100 N.

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