Improvements in or relating to catalyst supports for tubular reactors

Abstract

A method of tracking the use of catalyst carriers (10) within a tubular reactor (1), the tubular reactor (1) comprising a plurality of reaction tubes (8), each reaction tube (8) configured to receive a plurality of catalyst carriers (10), the method comprises, for each of at least some of the catalyst supports (10), the following steps: marking the catalyst support (10) with a support identifier (31); reading the carrier identifier (31) when the catalyst carrier (10) is installed in a reaction tube (8); and-accessing a database (41) to retrieve and / or record installation data associated with the identified catalyst support (10).

Description

[0001] The present disclosure relates to tracking the use of catalyst supports in tubular reactors. In particular, it relates to a method for tracking the use of catalyst supports in tubular reactors and a catalyst support tracking system. Background Art

[0002] Conventionally, so-called fixed bed tubular reactors include a reactor housing containing a plurality of tubes, which are generally cylindrical and which are generally directly filled with catalyst particles. In use, a heat transfer medium flows through the reactor housing outside these tubes and thereby regulates the temperature of the catalyst in the tubes by heat exchange across the tube walls. Thus, when the reaction is exothermic, the heat transfer medium will allow heat to be removed from the catalyst, and when the reaction is endothermic, the heat transfer medium will provide heat to the catalyst.

[0003] For some reactions, the heat effects of the reaction are modest so that they do not present a problem, or they can be easily managed. In some cases, the heat effects are small enough that large diameter tubes can be used. The benefit of this is that there is a large amount of catalyst within the tube.

[0004] However, for more exothermic or endothermic reactions, effective heat transfer through the tube wall to the heat transfer medium is necessary so that the conditions within the reactor can be controlled to maintain a stable operating temperature to avoid the occurrence of deleterious effects. For exothermic reactions, such effects may include the occurrence of side reactions, damage to the catalyst (such as by sintering catalytically active sites), and in the worst case, thermal runaway. Detrimental effects of endothermic reactions may include quenching of the reaction.

[0005] In order to achieve the desired efficiency, the wall surface area per unit length must be maximized. This was achieved in the past by installing a greater number of smaller diameter tubes. In some reactions, size restrictions mean that the internal diameter of the tube is only about 15mm to 40mm. However, the use of multiple tubes for this increases the cost and complexity of the reactor.

[0006] Therefore, in an attempt to alleviate these problems, alternative methods have been developed, particularly for more exothermic or endothermic reactions, in which the catalyst is not packed directly into the reaction tube, but rather is contained in a plurality of catalyst supports configured to be located within the reaction tube.

[0007] WO2011 / 048361, WO2012 / 136971 and WO2016 / 050520 describe some examples of catalyst supports configured for use in tubular reactors. WO2022 / 064214, WO2022 / 064210, WO2022 / 064211 and co-pending applications GB2202226.3 and GB2203700.6 disclose methods and apparatus for loading, retaining and removing catalyst supports in such tubular reactors.

[0008] The catalyst support can be effectively used in a wide range of processes. Examples of suitable uses include methods and reactors for exothermic reactions, such as reactions for preparing methanol, reactions for preparing ammonia, methanation reactions, shift reactions, oxidation reactions, such as reactions to form maleic anhydride and ethylene oxide, etc. A specific example of a catalyst support that can be used is in methods and reactors for performing Fischer-Tropsch reactions. The catalyst support can also be used for endothermic reactions, such as pre-conversion, dehydrogenation, etc.

[0009] Each reaction tube can contain a large number of catalyst supports, and a single tubular reactor can contain a large number of reaction tubes. Putting a tubular reactor into operation may require the installation of a very large number of catalyst supports. After the tubular reactor has been running for a period of time, the catalyst supports in some or all of the reaction tubes may need to be discharged and replaced, for example due to the deactivation of the catalyst contained in the catalyst support. The discharged catalyst support can be sent for post-treatment to regenerate or recycle the catalyst content. Summary of the invention

[0010] In a first aspect of the present disclosure, there is provided a method of tracking usage of catalyst supports within a tubular reactor, each tubular reactor comprising a plurality of reaction tubes, each reaction tube being configured to receive a plurality of catalyst supports, the method comprising the following steps for each of at least some of the catalyst supports:

[0011] - marking the catalyst support with a support identifier;

[0012] - reading the support identifier when installing the catalyst support into the reaction tube; and

[0013] - Accessing a database to retrieve and / or record installation data associated with the identified catalyst carrier.

[0014] In some examples, the support identifier may be read while the catalyst support is installed in the reaction tube or just before the catalyst support is installed in the reaction tube.

[0015] Tracking the use of catalyst carriers has many benefits. First, when a catalyst carrier is installed in a tubular reactor, installation data associated with the catalyst carrier can be retrieved from a database, and the data can be used to inform decisions about where the catalyst carrier should be installed, such as which reaction tube and / or which position within the reaction tube should be selected. This may be particularly advantageous when the catalyst carriers installed in the tubular reactor are not all identical but different in one or more aspects. For example, the amount and / or mass of the catalyst in the catalyst carrier may vary. The use of installation data can make it possible to make informed decisions about installation placement. In some examples, catalyst carriers containing less active catalysts can be placed in the hottest zone of the tubular reactor near the top of each reaction tube, and catalyst carriers containing more active catalysts can be placed in a lower position of the reaction tube.

[0016] Secondly, when the catalyst support is installed in the tubular reactor, the installation data associated with the catalyst support can be retrieved from the database and used to confirm that the catalyst support is allowed to be used with the tubular reactor. For example, the installation data can be used to check that the catalyst is of the correct type and the correct age.

[0017] Third, by recording installation data when catalyst carrier is installed in reaction tube, the installation position of each catalyst carrier in tubular reactor can be effectively tracked. This allows to analyze the performance of catalyst carrier individually and / or in groups after tubular reactor is operated. For example, it is possible to perform diagnostic test on catalyst carrier after use, and then use installation data to associate diagnostic discovery with known installation position in tubular reactor. For example, this diagnostic analysis can make it possible to identify the spatial trend of performance in single tubular reactor and the performance difference between pattern and tubular reactor.

[0018] Fourth, by recording the installation data when the catalyst carrier is installed in the reaction tube, the exhaust post-processing of the catalyst carrier can be more effectively performed. For example, by being able to identify the installation location of individual and / or grouped catalyst carriers and the time period they have been used, the recycling, regeneration and / or reuse of the catalyst carriers can be differentiated based on the operating conditions they have been exposed to.

[0019] In some examples, the installation data may include one or more of the following:

[0020] - Characteristic data of the catalyst support;

[0021] - Current usage data of the catalyst support; and

[0022] - Historical usage data of the catalyst support.

[0023] Current usage data refers to data associated with the current installation of the catalyst support, i.e. the location where the catalyst support is currently located or is currently being installed. Historical usage data refers to one or more previous installations of the catalyst support, such as previous uses of the catalyst support in the same or different reaction tubes and / or tubular reactors.

[0024] The characteristic data of the catalyst support may, for example, represent one or more of the following:

[0025] - Date of manufacture or overhaul of the catalyst support;

[0026] - the size and / or shape of the catalyst support;

[0027] - the type of catalyst included in the catalyst support, including for example the batch number;

[0028] - the amount of catalyst included in the catalyst support; and

[0029] -Whether the catalyst carrier is configured to receive a thermocouple.

[0030] Preferably, each time a catalyst support is installed in a reaction tube, at least the current usage data is recorded in the database. In this way, the database can include an up-to-date record of the current position of the catalyst support.

[0031] The current usage data of the catalyst support may, for example, represent one or more of the following:

[0032] - the identification of the tubular reactor in which the catalyst support is currently installed;

[0033] - the identification of the reaction tube in which the catalyst support is currently installed;

[0034] - the position, optionally sequential position, of the catalyst support within the reaction tube in which the catalyst support is currently installed; and

[0035] - Date and / or time of installation of the catalyst support into the reaction tube.

[0036] The historical usage data of the catalyst support may, for example, represent one or more of the following:

[0037] - identification of the tubular reactor or reactors in which the catalyst support has previously been installed;

[0038] - the identification of the reaction tube or tubes in which the catalyst support has previously been installed;

[0039] - the position, optionally sequential position, of the catalyst support within one or more reaction tubes in which the catalyst support has previously been installed; and

[0040] - the date and / or time of one or more previous installations of the catalyst support into one or more reaction tubes, typically including the corresponding date and / or time of discharge.

[0041] The historical usage data may include data for some or all of the previous working life of the catalyst support. In some examples, the historical usage data may cover the period of the working life of the catalyst support since the most recent regeneration or overhaul of the catalyst support. The historical usage data may also represent the pressure drop in a tubular reactor in which the catalyst support was previously installed during the operating period of the catalyst support.

[0042] In some examples, the method further includes selecting an installation location using the installation data retrieved from the database when installing the catalyst support into the tubular reactor.

[0043] In some examples, selecting an installation location may include selecting a reaction tube to receive the identified catalyst support and / or selecting a sequential position of the catalyst support within the reaction tube.

[0044] The method may further include:

[0045] - discharging the catalyst support from the reaction tube after the tubular reactor has been running for a period of time;

[0046] - reading the carrier identifier; and

[0047] - recording in the database the exposure time of the catalyst support associated with the operating period of the tubular reactor;

[0048] - optionally recording in the database the pressure drop of the reaction tube before and after the operating period.

[0049] The exposure time may be, for example, the period of time during which the catalyst support is installed, or the period of time during which the tubular reactor is operating while the catalyst support is installed, or may be the period of time during which one or more reactants actually flow through the catalyst support.

[0050] In some examples, the method includes using the installation data in the database to identify one or more installation locations of the catalyst support within one or more tubular reactors during one or more previous installations.

[0051] In some examples, the method includes using the installation data to calculate a cumulative exposure time of the catalyst support during one or more previous installations.

[0052] Preferably, the method further comprises using the mounting position to determine a treatment plan for the catalyst support.

[0053] Preferably, the method is performed on a majority, and most preferably all, of the catalyst supports installed in a tubular reactor.

[0054] In some examples, each catalyst carrier is marked with a unique carrier identifier representing a single catalyst carrier. This allows the most sophisticated tracking and analysis of catalyst carriers. In some alternative examples, the catalyst carrier can be marked with a carrier identifier representing a group of catalyst carriers, optionally a group of catalyst carriers sharing common characteristics. For example, the catalyst carriers configured to be installed in a specific zone of a tubular reactor can be marked with a common carrier identifier. The zone of a tubular reactor can be a vertical zone of a tubular reactor, such as an upper third, a middle third or a lower third. The zone of a tubular reactor can be a radial region of a tubular reactor, such as an outer annular third, a middle annular or a central region.

[0055] In some examples, the carrier identifier may include one or more of: a serial number, a one-dimensional code such as a barcode, a two-dimensional code such as a QR code, a color code, a pictogram, a pattern code, a radio frequency code such as an RFID tag, and an embossed etching or pattern.

[0056] In some examples, the carrier identifier may be visually readable by the human eye, however, in preferred examples, the method further comprises scanning the carrier identifier using a reader. For example, the reader may comprise a barcode reader, a camera or an RFID reader.

[0057] In some examples, the reader may include a portion of an installation tool for installing the catalyst support into the reaction tube. The reader may be configured to scan the catalyst support while the catalyst support is installed into the reaction tube.

[0058] In some other examples, the reader may include a handheld reader. For example, the reader may include a portion of a portable computing unit such as a mobile phone, a tablet computer, a PDA, or a laptop computer. The reader may allow a user located within the head space of the tubular reactor (i.e., at a location for mounting the catalyst support) to identify the support identifier.

[0059] In some examples, the method may further include marking each of at least some of the reaction tubes with a tube identifier and reading the tube identifier when installing the catalyst support into the reaction tube.

[0060] In some examples, access to the database may be performed at or near the location of the tubular reactor. For example, the database may be hosted on a portable computing unit such as a mobile phone, tablet, PDA, or laptop computer that is present at the tubular reactor, such as in the headspace during installation.

[0061] In other examples, accessing the database may involve communicating with a remote resource that is spatially far from the tubular reactor. For example, the database may be hosted on a virtual or physical server located in another location. Access to the database may be through an appropriate network connection, such as through a wired or wireless network. Public data networks may be used to communicate.

[0062] The database may be a manual, paper-based database. However, for reasons of operational efficiency, preferably the database is a computerized database. The database may be operably linked to a database user interface configured to allow input of data and queries to the database and retrieval of results and data from the database.

[0063] In a second aspect of the present disclosure, a catalyst carrier tracking system is provided, the catalyst carrier tracking system comprising:

[0064] - a plurality of catalyst supports, each catalyst support being labeled with a support identifier;

[0065] - one or more readers for reading the carrier identifier; and

[0066] - a database comprising installation data associated with the plurality of catalyst supports.

[0067] The installation data may include one or more of the following:

[0068] - Characteristic data of the catalyst support;

[0069] - Current usage data of the catalyst support; and

[0070] - Historical usage data of the catalyst support.

[0071] The characteristic data of the catalyst support may represent one or more of the following:

[0072] - Date of manufacture or overhaul of the catalyst support;

[0073] - the size and / or shape of the catalyst support;

[0074] - the type of catalyst included in the catalyst support, including for example the batch number;

[0075] - the amount of catalyst included in the catalyst support; and

[0076] -Whether the catalyst carrier is configured to receive a thermocouple.

[0077] The current usage data of the catalyst support may represent one or more of the following:

[0078] - the identification of the tubular reactor in which the catalyst support is currently installed or is being installed;

[0079] - the identification of the reaction tube in which the catalyst support is currently installed or is being installed;

[0080] - the position, optionally sequential position, of the catalyst support within the reaction tube in which the catalyst support is currently installed or is being installed; and

[0081] - Date and / or time of installation of the catalyst support into the reaction tube.

[0082] The historical usage data of the catalyst support may represent one or more of the following:

[0083] - identification of the tubular reactor or reactors in which the catalyst support has previously been installed;

[0084] - the identification of the reaction tube or tubes in which the catalyst support has previously been installed;

[0085] - the position, optionally sequential position, of the catalyst support within one or more reaction tubes in which the catalyst support has previously been installed; and

[0086] - the date and / or time of one or more previous installations of the catalyst support into one or more reaction tubes, typically including the corresponding date and / or time of discharge;

[0087] The historical usage data may also represent the pressure drop in a tubular reactor in which the catalyst support had been previously installed during an operating period of the catalyst support.

[0088] The catalyst support of the present disclosure may be filled or partially filled with any catalyst suitable for the intended reaction. For example, a Fischer-Tropsch catalyst can be used for a Fischer-Tropsch reaction. A cobalt-containing Fischer-Tropsch catalyst is preferred. The catalyst may be provided as catalyst particles or a catalyst monolith. 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.

[0089] The catalyst support of the present disclosure may be formed of any suitable material. Such materials are generally selected to withstand the operating conditions of the tubular reactor. The catalyst support may be made of carbon steel, aluminum, stainless steel, other alloys, or any material that can withstand the reaction conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0090] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0091] Figure 1 is a schematic side view of a tubular reactor;

[0092] Figure 2 yes Figure 1 A schematic diagram of the upper portion of a tubular reactor;

[0093] Figure 3 is a schematic diagram of a catalyst carrier tracking system according to the present disclosure;

[0094] Figure 4 is a flow chart of a method according to the present disclosure;

[0095] Figure 5 is used in Figure 1 A perspective view of a catalyst support used in a tubular reactor;

[0096] Figure 6 yes Figure 5 a cross-sectional view of a catalyst support; and

[0097] Figure 7 yes Figure 5 An exploded perspective view of a catalyst carrier. DETAILED DESCRIPTION

[0098] Hereinafter, by way of example only, various aspects and embodiments of the present disclosure are described 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 may also be applied to other configurations of tubular reactors that may adopt other orientations.

[0099] Furthermore, in this specification, any reference to orientation; for example, terms such as top, bottom, upper, lower, over, below, etc. are used relative to the orientation of parts shown in the referenced drawings, but should not be considered as limiting the potential orientation of such parts in actual use. For example, a component described as being oriented vertically may also be oriented horizontally.

[0100] Figure 1 1 shows a typical layout of a tubular reactor 1 of the present disclosure. The tubular reactor 1 includes a shell 2. The interior of the shell can be divided into a head space 3, a heat exchange zone 4, and a bottom space 5 by two tube sheets (an upper tube sheet 6 and a lower tube sheet 7). The upper tube sheet 6 separates the head space 3 from the heat exchange zone 4. The lower tube sheet 7 separates the bottom space 5 from the heat exchange zone 4.

[0101] A plurality of reaction tubes 8 extend between the upper tube plate 6 and the lower tube plate 7. A large number of reaction tubes 8 may be provided, for example, there may be between 20 reaction tubes 8 and 5000 reaction tubes 8. Each reaction tube 8 may have, for example, an inner diameter between 20 mm and 150 mm. In some embodiments, the inner diameter may be about 85 mm.

[0102] Each reaction tube 8 is intended to be filled or substantially filled with a stacked arrangement of catalyst supports 10. In particular, it is generally desired that the catalyst supports 10 cover the entire or substantially the entire length of the reaction tube 8 between the upper tube sheet 6 and the lower tube sheet 7, i.e. they cover the entire or substantially the entire length of the heat exchange zone 4.

[0103] The head space 3 may provide 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 inspection port 11 may be provided in the housing 2 to allow access to the head space 3. The inspection port 11 may be, for example, a manhole or other access panel that may be selectively opened and closed.

[0104] The bottom space 5 may provide access to the lower end of the reaction tube 8 to allow the catalyst support 10 to be unloaded from the reaction tube 8 .

[0105] Figure 2 An example of an installation tool 20 that can be used to install a catalyst support 10 into a reaction tube 8 is shown. The installation tool 20 may include a mounting frame, a hydraulic plunger mounted to the mounting frame, and one or more anchors for anchoring the mounting frame to the upper tube sheet 6 of the tubular reactor 1. The anchors are used to releasably engage the mounting frame to the tubular reactor 1, and thus releasably engage the installation tool 20 to the tubular reactor. The installation tool may form part of an installation system that additionally includes a power source. The power source may be located outside the tubular reactor 1 and is configured to move the movable plunger of the installation tool 20.

[0106] According to the present disclosure, a catalyst carrier tracking system and a method for tracking the use of a catalyst carrier 10 in a tubular reactor 1 are provided. Generally, as Figure 3 As shown, the catalyst carrier tracking system includes: a plurality of catalyst carriers 10, each catalyst carrier is marked with a carrier identifier 31; one or more readers 40 for reading the carrier identifier 31; and a database 41 including installation data associated with the plurality of catalyst carriers 10. Figure 4 As shown, the method comprises, for one or more catalyst carriers 10, marking the catalyst carrier 10 with a carrier identifier 31 in a first step S1. Then, in step S2, the method comprises reading the carrier identifier 31 when the catalyst carrier 10 is installed in the reaction tube 8. Then, in step S3, the method comprises accessing the database 41 to retrieve and / or record installation data associated with the identified catalyst carrier 10.

[0107] Preferably, the method is performed on most, and most preferably all, of the catalyst supports 10 installed in the tubular reactor 1 .

[0108] In order to better understand the present disclosure, first refer to Figures 5 to 7 An example of a general configuration of a catalyst carrier 10 is described. However, it will be appreciated that the catalyst carrier 10 may take various forms. For example, as with the examples described herein, the catalyst carrier 10 may take other general configurations, 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.

[0109] Each catalyst support 10 may typically include a container that is sized so that it has smaller dimensions than the internal dimensions of the reaction tube 8 in which the catalyst support is placed when in use. Typically, a seal will be provided that is sized so that when the catalyst support 10 is in position within the reaction tube 8, the seal interacts with the inner wall of the reaction tube 8. Parameters such as support length and diameter may be selected to accommodate different reactions and configurations of the reaction tube 8.

[0110] like Figures 5 to 7 As shown, the container 100 may generally have a bottom surface 101 closing the lower end of the container 100 and a top surface 102 located at the upper end of the container 100. A carrier outer wall 103 may extend from the bottom surface 101 to the top surface 102. A seal 104 may extend from the container 100 a distance that extends beyond the carrier outer wall 103. The carrier outer wall 103 may have an opening 105 located below the seal 104.

[0111] like Figure 6 As shown, the catalyst carrier 10 may more particularly include an annular container 110 for holding the catalyst in use. The annular container 110 may include a perforated container inner wall 111 defining an inner channel 112 and a perforated container outer wall 113 that may be arranged concentrically around the perforated container inner 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 drainage openings (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 formed integrally with the container inner wall 111 or separately.

[0112] like Figure 7 As shown in the exploded view of FIG. 1 , the catalyst carrier 10 may be formed of a plurality of separate components that may be assembled together in any suitable manner, 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 cover 123, an annular top ring 124, a top cover 125, and an annular sealing ring 126.

[0113] The catalyst support 10 may be formed of any suitable material. Such materials will generally be selected to withstand the operating conditions of the reactor. Typically, the catalyst support will be made of carbon steel, aluminum, stainless steel, other alloys, or any material that can withstand the reaction conditions.

[0114] Suitable thicknesses for the components will be from about 0.1 mm to about 1.0 mm, preferably from about 0.3 mm to about 1.0 mm.

[0115] 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 the carrier outer wall 103 and define the opening 105. The bottom cover 123 may include the bottom surface 101 and / or the 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 the annular top surface 114 and may include at least a portion of the top surface 102. The annular sealing ring 126 may include the seal 104.

[0116] The size of the perforations in the perforated inner tube 120 and the perforated intermediate tube 121 will be selected such as to allow reactants and products to flow evenly 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 size of the perforations can be set so that they are larger, but with a filter screen covering the perforations to ensure that the catalyst is retained within the annular container 110.

[0117] It should be understood that the perforations may be of any suitable configuration. In fact, where a wall or tube is described as being perforated, all that is required is that there is a means to allow reactants and products to pass through the wall or tube.

[0118] The bottom surface 101 (e.g., bottom cover 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 around the perforated inner tube 120. The top cover 125 may be shaped to engage in the annular groove 130 of another catalyst carrier 10. For example, the top cover 125 may include an annular ring 131 standing upright from an annular plug body 132. The shape and size of the annular ring 131 may be set to be received in the annular groove 130.

[0119] 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 may be covered with a filter.

[0120] The annular top ring 124 may be shaped and sized to engage in the upper end of the outer tube 122. The annular plug body 132 of the top cap 125 may have an outer diameter configured to engage with the central opening of the annular top ring 124. The engagement of the top cap 125 with the annular top ring 124 may serve to sandwich the annular sealing ring 126 and hold it in place.

[0121] The top cover 125 may include a central inlet 134 in the annular plug body 132 for enabling liquid and gas to enter the upper end of the internal passage 112. The annular ring 131 may include lateral openings 133 to enable liquid and gas to reach the central inlet 134.

[0122] The carrier outer wall 103 may be smooth or it may be shaped. Suitable shapes include pleats, corrugations, and the like.

[0123] The openings 105 in the carrier outer wall 103 may be of any configuration. In some embodiments, the openings 105 may be holes or slots.

[0124] The carrier outer wall 103 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 an opening 105 in the carrier outer wall 103, it may be located at a suitable point on the carrier outer wall 103.

[0125] The seal 104 can be sufficiently compressible to adapt to the minimum diameter of the reaction tube 8. The seal 104 can generally be a flexible sliding seal. The seal 104 can engage with the inner surface of the reaction tube 8 so that liquids and gases passing along the reaction tube 8 are preferentially guided to flow through the interior of the catalyst support 10. The seal 104 can, for example, be configured to form a sliding seal against the inner surface of the reaction tube 8.

[0126] exist Figures 5 to 7 In the illustrated example of , the seal 104 may include a deformable flange 140 extending from the carrier outer wall 103 or the top surface 102 of the catalyst carrier 10. The size of the flange 140 may be set to be larger than the inner diameter of the reaction tube 8 so 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 the reaction tube. The deformable flange 140 includes an outer portion of the annular sealing ring 126. The inner portion 141 of the annular sealing ring 126 may define a clamping surface that is sandwiched and held between the top cover 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.

[0127] As described above, according to the present disclosure, the catalyst carrier 10 is marked with the carrier identifier 31. Figures 5 to 7In the embodiment, the carrier identifier 31 is shown in the form of a one-dimensional barcode by way of example only. In other examples, the carrier identifier 31 may include one or more of the following: another form of a one-dimensional code serial number, a two-dimensional code such as a QR code, a color code, a pictogram, a pattern code, a radio frequency code such as an RFID tag, and an embossed etching or pattern.

[0128] The carrier identifier 31 may be located at any suitable position on the catalyst carrier 10. Preferably, the carrier identifier 31 is located on the carrier outer wall 103, thereby allowing the carrier identifier 31 to be easily read even when the catalyst carrier 10 is coupled end-to-end with other catalyst carriers 10.

[0129] The reader 40 may be a machine reader. Non-limiting examples of suitable readers include barcode readers, cameras, and RFID readers. The reader 40 may be a dedicated device or may be integrated as a part of a device having other functions. In some examples, the reader 40 may include a handheld reader. For example, the reader 40 may include a part of a portable computing unit such as a mobile phone, a tablet computer, a PDA, or a laptop computer. In some examples, the reader 40 may include a part of an installation tool 20, which may be used to install the catalyst carrier 10 into the reaction tube 8. The reader 40 may be configured to scan the carrier identifier 31 of the catalyst carrier 10 while the catalyst carrier 10 is installed into the reaction tube 8.

[0130] In some examples, the method may further include marking each of at least some of the reaction tubes 8 with a tube identifier 32, such as Figure 3 As shown. The tube identifier 32 can be read when the catalyst carrier 10 is installed into the reaction tube 8 in order to identify and record the specific reaction tube 8 selected for installation on the database 41. The tube identifier 32 can be located, for example, on the upper tube plate of the tubular reactor 1 adjacent to the upper opening of each reaction tube 8. The tube identifier 32 can be read by the same reader 40 used to read the carrier identifier 31 or by a different reader. For example, the installation tool 20 may include a first reader and a second reader, the first reader can face sideways to scan the carrier identifier 31, and the second reader can face downward to read the tube identifier 32.

[0131] The database 41 can preferably be a computerized database. The database 41 can be operably linked to a database user interface, which is configured to allow data to be input and inquiries to the database 41 and to retrieve results and data from the database 41. The database 41 can be hosted on a portable device such as a portable computing unit (e.g., a mobile phone, a tablet computer, a PDA, or a laptop computer), which can also be the same portable device incorporated into the reader 40. Alternatively, the database 41 can be remotely hosted on a physical or virtual server located, for example, far away from the tubular reactor 1 in space. The database 41 or database functions can be distributed on multiple devices, such as some data hosting, data analysis, and / or data presentation are performed on a portable device local to the tubular reactor 1, and some are performed on a remote resource (e.g., a remote server).

[0132] Where the database 41 is wholly or partially located at a remote location, accessing the database 41 may include communicating via a suitable network connection 42 (eg, via a wired or wireless network). A public data network may be used for communicating.

[0133] In use, during commissioning or refilling of the tubular reactor 1 or at other times as needed, the catalyst carrier 10 can be installed into the reaction tube 8 of the tubular reactor 1. According to the present disclosure, the catalyst carrier tracking system and method can be used to obtain, organize and utilize installation data on the catalyst carrier 10. Whenever its carrier identifier 31 is read by the reader 40, the installation data on the catalyst carrier 10 can be obtained and / or updated on the database 41.

[0134] The carrier identifier 31 may be read at various points during the life cycle of the catalyst carrier 10. For example, the carrier identifier 31 may be read when first manufactured, when installed in the reactor tube 8, when discharged from the reactor tube 8, when received at a new physical location, when subjected to a treatment regimen (e.g., regeneration, refilling, repair, or recycling), and / or when retired.

[0135] Each catalyst carrier 10 may be marked with a unique carrier identifier 31 representing an individual catalyst carrier 10. This allows for the most sophisticated tracking and analysis of the catalyst carriers 10. Alternatively, the catalyst carriers 10 may be marked with a carrier identifier 31 representing a group of catalyst carriers 10, optionally a group of catalyst carriers 10 sharing common characteristics (e.g. having the same type or amount of catalyst, or the same length, or the same date of manufacture, etc.).

[0136] The installation data may include one or more of the following:

[0137] - Characteristic data of the catalyst carrier 10;

[0138] - current usage data of the catalyst carrier 10; and

[0139] - Historical usage data of the catalyst carrier 10.

[0140] The characteristic data of the catalyst carrier 10 may represent, for example, one or more of the following:

[0141] - Date of manufacture or overhaul of the catalyst support 10;

[0142] - the size and / or shape of the catalyst support 10;

[0143] - the type of catalyst included in the catalyst support 10, including, for example, the batch number;

[0144] - the amount of catalyst included in the catalyst support 10; and

[0145] - Whether the catalyst carrier 10 is configured to receive a thermocouple.

[0146] The current use data may be data associated with the current installation of the catalyst carrier 10, i.e., the location where the catalyst carrier 10 is currently located or is currently being installed. In some examples, the current use data may be obtained and recorded in the database 41 when the catalyst carrier 10 is being installed in its current reaction tube 8. The carrier identifier 31 may be read by an operator performing the installation at the time and location of the installation.

[0147] In some examples, the current usage data in the database 41 can be considered to remain "current" until the next time the carrier identifier 31 of the catalyst carrier 10 is read. Preferably, each time the catalyst carrier 10 is installed into the reaction tube 8 or is moved or otherwise undergoes a substantial change, at least the current usage data is recorded in the database 41. In this way, the database 41 can include an up-to-date record of the current position and / or state of the catalyst carrier 10.

[0148] The current usage data of the catalyst support 10 may represent, for example, one or more of the following:

[0149] - the identification of the tubular reactor 1 in which the catalyst support 10 is currently installed;

[0150] - the identification of the reaction tube 8 in which the catalyst support 10 is currently installed;

[0151] - the position, optionally sequential position, of the catalyst support 10 within the reaction tube 8 in which the catalyst support 10 is currently being installed; and

[0152] - Date and / or time of installation of the catalyst support 10 into the reaction tube 8 .

[0153] The database 41 can use the data read from the tube identifier 32 (if present) to determine the identity of the reaction tube 8 in which the catalyst support 10 is currently installed. Alternatively, the identity of the reaction tube 8 can be manually recorded in the database 41 by an operator, such as by manual data entry using a portable device. Similarly, the identity of the tubular reactor 1 can be manually recorded in the database 41, such as by manual data entry using a portable device, for example, by an operator.

[0154] The “three-dimensional” position of a single catalyst support 10 within the tubular reactor 1 can be identified and tracked by, for example, recording the identification of the tubular reactor 1 plus the identification of the reaction tube 8 plus the sequential position of the catalyst support 10 within the reaction tube 8 .

[0155] The sequential position can be recorded as the position of the catalyst carrier 10 within the stack of catalyst carriers 10 counted from the top or bottom of the reaction tube 8. For example, the sequential position can be recorded as the sequential number installed into the top of the reaction tube 8, so that the "first" catalyst carrier 10 is located at the bottom of the reaction tube, followed by the "second", "third", "fourth" catalyst carriers 10 stacked on the top, and the "nth" catalyst carrier is located at the top of the reaction tube 8.

[0156] The database 41 may derive the installation height of the catalyst carrier 10 using characteristic data of the catalyst carrier 10 (eg, the record length of the catalyst carrier 10 ) and the sequential position of the catalyst carrier 10 .

[0157] The historical usage data may refer to one or more previous installations of the catalyst support 10, such as previous uses of the catalyst support 10 in the same or different reaction tubes 8 and / or tubular reactors 1. The historical usage data of the catalyst support 10 may, for example, represent one or more of the following:

[0158] - identification of one or more tubular reactors 1 in which the catalyst support 10 has previously been installed;

[0159] - the identification of one or more reaction tubes 8 in which the catalyst support 10 has previously been installed;

[0160] - the position, optionally a sequential position, of the catalyst support 10 within one or more reaction tubes 8 in which the catalyst support 10 has previously been installed; and

[0161] - Date and / or time of one or more previous installations of the catalyst support 10 into one or more reaction tubes 8, typically including a corresponding date and / or time of discharge.

[0162] The historical usage data may also represent the pressure drop in a tubular reactor in which the catalyst support had been previously installed during an operating period of the catalyst support.

[0163] When catalyst carrier 10 is installed in tubular reactor 1, installation data can be used to inform the decision of operating personnel.For example, the installation data retrieved from the database can be used to select the installation location.For example, installation data can indicate that catalyst carrier 10 will be optimally located in a specific area of ​​tubular reactor, such as lower third, middle third or upper third. The operating personnel can then arrange the catalyst carrier 10 (this arrangement can be carried out on site or off-site before catalyst carrier is delivered to tubular reactor 1) for installation accordingly. In another example, installation data can indicate that catalyst carrier 10 is specially configured to adapt to the passage of thermocouple.Therefore, the operating personnel can ensure that for the reaction tube 8 to receive thermocouple, only the catalyst carrier 10 of appropriate structure is installed.

[0164] Installation data may also be used to analyze the performance of the catalyst supports 10. By being able to track and identify groups or individual catalyst supports 10, the opportunities for post-operation analysis are significantly increased.

[0165] For example, the installation data may be used to track the installation position of the catalyst support 10 within the tubular reactor 1 during one or more previous installations.

[0166] For example, the installation data may be used to calculate exposure time and / or cumulative exposure time of the catalyst support during one or more previous installations.

[0167] The installation data can also be used to determine the treatment plan of the catalyst carrier 10 after it is discharged from the reaction tube 8. For example, this can determine that the catalyst carrier 10 can be immediately reused and reinstalled in the reaction tube 8. Alternatively, it can also be determined that the catalyst carrier 10 needs to be regenerated or recycled, etc.

[0168] During operation, after the reaction tubes 8 are filled with the catalyst supports 10, the tubular reactor 1 is operated so that one or more reactants pass through the reaction tubes 8 from the inlet end to the outlet end of each reaction tube. Figures 5 to 7In the downflow tubular reactor 1 of the catalyst carrier 10 shown, the reactant flows downward through each reaction tube 8, and therefore first contacts the top surface 102 of the topmost catalyst carrier 10. The seal 104 prevents the reactant from passing around the side of the catalyst carrier 10. Therefore, the top surface 102 guides the reactant to enter the center entrance 134 of the upper end of the inner channel 112 in the container inner wall 111 defined by the perforated inner tube 120 inwardly through the lateral opening 133. The reactant then enters the annular container 110 through the perforated inner tube 120, and then radially passes through the catalyst bed toward the container outer wall 113 defined by the perforated intermediate tube 121. During this process, the reactant contacts the catalyst, and the reaction occurs to form a product. Unreacted reactant and product then flow out of the annular container 110 through the perforated intermediate tube 121. The carrier outer wall 103 limited by outer tube 122 then guides reactants and products upwards between the inner surface of the carrier outer wall 103 and the perforated intermediate tube 121, until they arrive at the perforations 105 in the carrier outer wall 103. Then reactants and products are guided through the perforations 105, and flow downwards between the outer surface of the carrier outer wall 103 and the inner surface of the reaction tube 8 when heat transfer occurs. Then, unreacted reactants and products can contact the top surface 102 of the catalyst carrier 10 below the stacked formation, and the above process can be repeated. When reactants and products pass through the stacked formation downwards, this pattern can be repeated until they are collected from the lower end of the reaction tube 8. Some products in the product, especially liquid products, can be discharged from the inner channel 112 by the drain hole arranged in the channel end surface 116, enter the inner channel 112 of the catalyst carrier 10 below. Then, these products can continue to discharge the stacked formation of the catalyst carrier 10 downwards, and collect from the lower end of the reaction tube 8.

Claims

1. A method for tracking the use of catalyst supports in a tubular reactor, each tubular reactor comprising a plurality of reaction tubes, each reaction tube being configured to receive a plurality of catalyst supports, the method comprising the following steps for each catalyst support of at least some of the catalyst supports: - marking the catalyst support with a support identifier; - reading the support identifier when installing the catalyst support into a reaction tube; and - Accessing a database to retrieve and / or record installation data associated with the identified catalyst carrier.

2. The method of claim 1, wherein the installation data comprises one or more of: - characteristic data of the catalyst support; - current usage data of the catalyst support; and - Historical usage data of the catalyst support.

3. The method of claim 2, wherein the characteristic data of the catalyst support represents one or more of the following: - Date of manufacture or overhaul of the catalyst support; - the size and / or shape of the catalyst support; - the type of catalyst included in the catalyst support; - the amount of catalyst included in said catalyst support; and - Whether the catalyst carrier is configured to receive a thermocouple.

4. The method according to claim 2 or claim 3, wherein each time the catalyst support is installed in a reaction tube, at least the current usage data is recorded in the database.

5. The method according to any one of claims 2 to 4, wherein the current usage data of the catalyst support represents one or more of the following: - the identification of the tubular reactor in which the catalyst support is currently installed; - the identification of the reaction tube in which the catalyst support is currently installed; - the position, optionally sequential position, of the catalyst support within the reaction tube in which the catalyst support is currently installed; and - Date and / or time of installation of the catalyst support into the reaction tube.

6. The method according to any one of claims 2 to 5, wherein the historical usage data of the catalyst support represents one or more of the following: - identification of one or more tubular reactors in which the catalyst support has previously been installed; - the identification of one or more reaction tubes in which the catalyst support has previously been installed; - the position, optionally sequential position, of the catalyst support within one or more reaction tubes in which the catalyst support has previously been installed; and - Date and / or time of one or more previous installations of the catalyst support into one or more reaction tubes.

7. The method according to any one of the preceding claims, further comprising: - When installing the catalyst support into a tubular reactor, selecting an installation position using the installation data retrieved from the database.

8. The method of claim 7, wherein selecting an installation location comprises selecting a reaction tube to receive the identified catalyst carrier and / or selecting a sequential position of the catalyst carrier within a reaction tube.

9. The method according to any one of the preceding claims, further comprising: - discharging the catalyst support from the reaction tube after the tubular reactor has been running for a period of time; - reading the carrier identifier; as well as - recording in the database the exposure times of the catalyst support associated with the operating periods of the tubular reactor.

10. The method according to claim 9, further comprising: - recording the pressure drop of the reaction tube before and after the operating period in the database.

11. A method according to any one of the preceding claims, further comprising using the installation data in the database to identify one or more installation locations of the catalyst support within one or more tubular reactors during one or more previous installations.

12. A method according to any preceding claim, further comprising using the installation data to calculate a cumulative exposure time of the catalyst support during one or more previous installations.

13. The method of any one of the preceding claims, further comprising using the mounting position to determine a treatment plan for the catalyst support.

14. The method according to any one of the preceding claims, wherein the method is performed on a majority and preferably all of the catalyst supports installed in a tubular reactor.

15. A method according to any preceding claim, wherein each catalyst support is marked with a unique support identifier representing the individual catalyst support.

16. A method according to any one of claims 1 to 14, wherein the catalyst support is marked with a support identifier representing a group of catalyst supports, optionally a group of catalyst supports sharing a common property.

17. A method according to any one of the preceding claims, wherein the carrier identifier comprises one or more of: a serial number, a one-dimensional code such as a barcode, a two-dimensional code such as a QR code, a colour code, a pictogram, a pattern code, a radio frequency code such as an RFID tag, and an embossed etching or pattern.

18. The method of any preceding claim, further comprising scanning the carrier identifier using a reader, wherein the reader comprises a barcode reader, a camera or an RFID reader.

19. The method of claim 18, wherein the reader comprises a portion of an installation tool for installing the catalyst support into the reaction tube.

20. The method of claim 18, wherein the reader comprises a handheld reader; optionally, wherein the reader comprises a portion of a portable computing unit such as a mobile phone, tablet computer, PDA, or laptop computer.

21. The method of any one of the preceding claims, further comprising marking each of at least some of the reaction tubes with a tube identifier and reading the tube identifier when installing the catalyst support into a reaction tube.

22. A catalyst carrier tracking system, the catalyst carrier tracking system comprising: - a plurality of catalyst supports, each catalyst support being labeled with a support identifier; - one or more readers for reading said carrier identifier; and - a database comprising installation data associated with the plurality of catalyst supports.

23. The catalyst support tracking system of claim 22, wherein the installation data comprises one or more of the following: - characteristic data of the catalyst support; - current usage data of the catalyst support; and - Historical usage data of the catalyst support.

24. The catalyst carrier tracking system of claim 23, wherein the characteristic data of the catalyst carrier represents one or more of the following: - Date of manufacture or overhaul of the catalyst support; - the size and / or shape of the catalyst support; - the type of catalyst included in the catalyst support; - the amount of catalyst included in said catalyst support; and - Whether the catalyst carrier is configured to receive a thermocouple.

25. A catalyst support tracking system according to claim 23 or claim 24, wherein the current usage data of the catalyst support represents one or more of the following: - the identification of the tubular reactor in which the catalyst support is currently installed or is being installed; - the identification of the reaction tube in which the catalyst support is currently installed or is being installed; - the position, optionally sequential position, of the catalyst support within the reaction tube in which the catalyst support is currently installed or is being installed; and - Date and / or time of installation of the catalyst support into the reaction tube.

26. The catalyst support tracking system according to any one of claims 23 to 25, wherein the historical usage data of the catalyst support represents one or more of the following: - identification of one or more tubular reactors in which the catalyst support has previously been installed; - the identification of one or more reaction tubes in which the catalyst support has previously been installed; - the position, optionally sequential position, of the catalyst support within one or more reaction tubes in which the catalyst support has previously been installed; and The date and / or time of one or more previous installations of the catalyst support into one or more reaction tubes.

Images