Method and apparatus for controlled discharge of components from pipe

Abstract

The present invention provides a transfer device (40), system and method for controlled discharge of stacks of components from a tube, the transfer device (40) comprising: i) a frame (41) configured to be positioned near an outlet of the tube; and ii) a plurality of feed elements (61) mounted to the frame (41). The feed elements (61) are distributed around and along a feed path (80) extending through the frame (41) so as to contact, in use, components passing through the frame (41) along the feed path (80). One or more of the feed elements (61) comprises a tensioning mechanism for adjusting a level of friction between said one or more of the feed elements (61) and the component passing through the frame (41) along the feed path (80).

Description

[0001] The present disclosure relates to a method and apparatus for controlled discharge of components from a tube, in particular, a method and apparatus for controlled discharge of catalyst supports from a reaction tube of a tubular reactor. 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.

[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 carriers, and a single tubular reactor can include a large number of reaction tubes. Typically, each catalyst carrier includes a seal engaged with the inner wall of the reaction tube. The seal can be used to guide the fluid through the inside of the catalyst carrier in use, and can also be used to provide physical support to help maintain the vertical position of the catalyst carrier in the reaction tube.

[0010] From time to time it may be necessary to discharge the catalyst support from one or more of the reaction tubes. This may be for example for the purpose of maintaining the tubular reactor or replacing the catalyst support.

[0011] The present disclosure seeks to provide improvements in the discharge of components from tubes, as an example of improved discharge of catalyst supports from reaction tubes. Summary of the invention

[0012] In a first aspect of the present disclosure, there is provided a stacked conveyor for controlled discharge of components from a tube, the conveyor comprising:

[0013] i) a frame configured to be positioned adjacent an outlet of the tube; and

[0014] ii) a plurality of feed elements mounted to the frame, the feed elements being distributed about and along a feed path extending through the frame so as to contact, in use, a component passing through the frame along the feed path;

[0015] One or more of the feed elements include a tensioning mechanism for adjusting a level of friction between the one or more of the feed elements and a component passing through the frame along a feed path.

[0016] Advantageously, the conveyor can assist in the controlled discharge of the components. This has advantages both for the discharge of the components from the outlet of the tube and optionally for the simultaneous insertion of the components into the inlet of the tube. In particular, the feed elements with their tensioning mechanisms can allow the controlled passage of the components through the feed path by providing a controllable and adjustable frictional resistance to the movement of the components. The controlled passage of the components through the feed path allows the speed and timing of the discharge of the components to be controlled. It also optionally allows the components to be inserted into the inlet of the tube simultaneously in a controlled manner. In particular, the conveyor can enable the insertion of the components into the inlet of the tube to be controlled by the action of discharging the components from the outlet of the tube, rather than in the opposite way.

[0017] This may be particularly advantageous when the component is not self-supporting in the tube, that is, they will naturally slide down the tube toward the outlet only under the action of gravity. When inserted into an empty or partially empty tube, such non-self-supporting components may be damaged due to falling into the tube and impacting the base of the tube or the top component stacked in the tube. Therefore, in the exemplary case of the catalyst carrier in the reaction tube, it is generally preferred to use a self-supporting component, such as by arranging a seal on the catalyst carrier that is frictionally engaged with the inner wall of the tube. However, this solution will increase the force required for inserting the component into the tube, which may then require machine assistance, such as using a hydraulic cylinder to insert the component. Beneficially, the conveying device of the present invention can enable the use of non-self-supporting components in the tube and enable a safe and controllable method for enabling the components of filling and / or emptying and / or replacing the tube.

[0018] This benefit reduces the chance of spontaneous or uncontrolled emission of a component. This is particularly beneficial where, as in the case of a catalyst support, the components may each have a reasonable mass and a stack of components may contain a considerable amount of the components, resulting in a potentially high cumulative mass acting on the lowest component closest to the outlet of the reaction tube. A high cumulative mass within a stack of components may result in uncontrolled emission, especially in the event that the physical integrity of the components changes over time.

[0019] In some examples, each feed element of the plurality of feed elements includes a tensioning mechanism.

[0020] In some examples, the plurality of feed elements include feed elements at two, optionally three or more levels along the feed path. Beneficially, increasing the number of levels of feed elements present can reduce the risk of lateral deflection of components during feeding by reducing the vertical spacing between adjacent levels. In some examples, components can be connected together by, for example, friction push fits, and reducing lateral deflection during discharge can beneficially reduce the risk of components spontaneously disconnecting from each other.

[0021] Preferably, the plurality of feed elements comprises at least an upper feed element and a lower feed element.

[0022] In some examples, the spacing between the upper feed element and the lower feed element is substantially equal to the longitudinal length of each component in the component. This can be particularly beneficial, wherein the components each have a common external configuration and each include features, such as an enlarged portion at a point along the length of the component, such as a seal in the case of a catalyst carrier, which feature must be fed through the feed element. By configuring the spacing between the upper feed element and the lower feed element to be substantially equal to the longitudinal length of the component, it can be ensured that the features (e.g., seals) of adjacent components all contact the feed element simultaneously. The structure can be used as a natural brake to discharge the component, thereby helping to prevent the component from being spontaneously discharged only due to gravity. For example, the tensioning of the tensioning mechanism can be set so that if no feed element is driven externally, the stacking of the component will stop and be stationary in the manner that the features (e.g., seals) of adjacent components contact the upper feed element and the lower feed element. External input is then required to feed the enlarged portion (e.g., seal) through the feed element.

[0023] In some examples, the multiple feed elements further include a middle feed element positioned between the upper feed element and the lower feed element. Beneficially, one or more of the middle feed elements can be used to drive the component, that is, to provide an external input to move the component along the feed path. This can be particularly useful in the above examples to allow the enlarged portion (e.g., seal) of the component to be fed through the upper feed element and the lower feed element. One or more driven feed elements can be arranged at other levels. For example, one or more feed elements in the feed element of the upper level and / or the lower level and / or the level arranged above the upper level or below the lower level can be driven feed elements.

[0024] In some examples, the spacing between adjacent levels of feed elements along the feed path is less than the longitudinal length of each of the components.

[0025] In some examples, each level of feed elements along the feed path includes at least three feed elements. More than three feed elements may be provided at each level, for example four or five. It is preferred that at least three feed elements are present at each level and preferably at least four feed elements are present at each level in order to help maintain the roundness of the components during feeding.

[0026] In some examples, the plurality of feed elements are circumferentially distributed around the longitudinal axis of the feed path at two, three, four or more locations.The feed elements may be regularly distributed around the circumference of the feed path.

[0027] In a preferred example, the plurality of feed elements include or consist of a plurality of feed wheels. However, the present disclosure extends to feed elements in other forms. For example, the feed element may include or consist of a tracked element, such as a track, or a reciprocating pad, or a reciprocating finger, etc.

[0028] In some examples, one or more of the feed wheels is a driven wheel configured to be rotationally driven to feed the component along the feed path.

[0029] In some examples, the one or more driven wheels are driven by manual power or motor power.

[0030] In some examples, the conveying device further comprises one or more handles coupled to the one or more driven wheels for rotating the driven wheels. The handles may be rotated, for example, by hand.

[0031] Preferably, at least one driven wheel is arranged at each level in at least two levels along the feed path. For example, at least one driven wheel can be arranged at each of the upper level and the middle level, or at each of the middle level and the lower level, or at each of the upper level, the middle level and the lower level. Beneficially, at least one driven wheel in the driven wheel can be configured to always be spaced apart from the enlarged portion (e.g., seal) of the component, so that the driving force can always be applied to the body of at least one component in the component along the feed path. For example, as described above, the enlarged portion (e.g., seal) of the adjacent component can be configured to contact the upper feed element and the lower feed element (e.g., feed wheel) simultaneously. In such examples, it may be beneficial to ensure that the at least one driven feed wheel (or other feed element) is arranged at the middle level of the feed element, so that the drive is applied to the body of a component in the component spaced apart from the enlarged portion (e.g., seal).

[0032] In some examples, the tensioning mechanism includes a tensioning spring that biases the feed element inwardly toward the feed path. Other tensioning mechanisms may also be used. For example, other elastic devices or tensioning screw mechanisms may be provided.

[0033] In some examples, the tensioning mechanism further includes a pre-compression mechanism for selectively setting a pre-compression of the tensioning spring.

[0034] In some examples, the frame includes a connector for removably suspending the delivery device below the tube.

[0035] In some examples, the frame includes an opening at a first end of the frame, the opening defining an inlet to the feed path for receiving the component discharged from the tube.

[0036] In some examples, the frame includes an opening at the second end of the frame, the opening defining an outlet of the feed path.

[0037] In some examples, the feed path is a linear path through the frame, optionally through the center of the frame.

[0038] In some examples, the component includes a catalyst carrier, and the tube includes a reaction tube of a tubular reactor. It should be understood that when applied to the field of tubular reactors, the component may include a component containing or not containing a catalyst material. For example, the component may include a catalyst carrier containing a catalyst material, but may also include other components, such as a spacer component disposed in the stack of components to control the positioning of the catalyst carrier within the length of the reaction tube and / or an ejector component that can be inserted into the upper end of the reaction tube so that the catalyst carrier is discharged from the lower end of the reaction tube. Typically, such spacer components and ejector components do not contain any catalyst material, but still include components as intended in this specification.

[0039] The component may be a tubular component. The external shape of the component may be generally cylindrical (although as mentioned above, it may include one or more protrusions, such as seals). The external shape of the component may be generally right cylindrical.

[0040] In a second aspect, the present disclosure provides a system comprising:

[0041] A conveyor according to any preceding claim;

[0042] A tubular reactor comprising a plurality of reaction tubes; and

[0043] Multiple components;

[0044] The conveying device is positioned near the outlet of the selected reaction tube to control the discharge of the multiple components from the selected reaction tube.

[0045] In some examples, the delivery device can be removably attached to the tubular reactor near the outlet of a selected reaction tube.

[0046] In some examples, the transfer device can be removably attached by hanging from a lower tube sheet of the tubular reactor.

[0047] Advantageously, the conveyor can be moved successively from one reaction tube to another reaction tube as required. Moreover, when not required, the conveyor can be removed from the tubular reactor so as not to hinder the fluid flow during the use of the tubular reactor.

[0048] In a third aspect, the present disclosure provides a method for stacking a component for controlled discharge from a tube, the method comprising the steps of:

[0049] i) positioning a conveying device near the outlet of the tube, the conveying device comprising a frame and a plurality of feed elements mounted to the frame, the feed elements being distributed around and along a feed path extending through the frame; and

[0050] ii) discharging the component from the tube into the conveyor such that the component passes along the feed path and in doing so is contacted by the plurality of feed elements;

[0051] The friction level between one or more of the feed elements and the components passing along the feed path is selectively adjustable.

[0052] In some examples, positioning the delivery device proximate the outlet of the tube may include attaching the delivery device proximate the outlet, optionally removably attaching the delivery device proximate the outlet.

[0053] Preferably, the plurality of feed elements comprises or consists of a plurality of feed wheels. However, as mentioned above, other types of feed elements may be provided.

[0054] In some examples, one or more of the feed wheels are driven wheels, and the rolling friction level is adjusted such that the components are fed through the feed path by rotation of the one or more driven wheels.

[0055] In some examples, the component includes an enlarged portion having a larger diameter than a main body of the component, and the friction level is adjusted such that rotation of the one or more driven wheels is required for the enlarged portion to pass past the one or more driven wheels.

[0056] In some examples, the one or more driven wheels are driven by manual power or motor power.

[0057] In some examples, a level of rolling friction between each of the feed wheels and a component passing along the feed path is selectively adjustable.

[0058] In a preferred example, each component is contacted by the feed element at at least two levels along the feed path during at least a portion of its passage along the feed path.

[0059] In some examples, each component passing along the feed path is contacted by the feed element at two, three, four, or more locations around the longitudinal axis of the feed path.

[0060] In some examples, the friction level is adjusted using a tensioning mechanism that includes a tensioning spring that biases the feed element inwardly toward the feed path.

[0061] In some examples, the tensioning mechanism further includes a pre-compression mechanism for selectively setting a pre-compression of the tensioning spring.

[0062] In some examples, the method further includes inserting a component into an inlet of the tube, wherein the inserting of the component into the inlet of the tube is controlled by the act of discharging the component from an outlet of the tube.

[0063] In some examples, the frame is positioned near the outlet of the tube. In some examples, the frame can be removably attached near the outlet of the tube.

[0064] In a preferred example, the components include a catalyst support, and the tube includes a reaction tube of a tubular reactor. Typically, the discharge of the catalyst support from the outlet of the reaction tube will be accompanied by the insertion of a replacement component (e.g., a catalyst support or an ejector component) at the inlet of the reaction tube. Thus, the conveyor device of the present disclosure can be used not only to empty a reaction tube, but also as part of a process of replacing the components of a reaction tube by simultaneously inserting and discharging components until the reaction tube contains a new set of components and the previously installed components have been completely discharged.

[0065] In some examples, the components are discharged from the conveyor into a receiver (e.g., a grate or drum) for removal through, for example, a manhole in a tubular reactor. In some examples, an additional transport device (such as a chute or hose) is connected to the frame of the conveyor to discharge the components from the conveyor, for example, outside the tubular reactor or through a manhole or opening in the tubular reactor, preferably the bottom of the tubular reactor.

[0066] In the case where the components of the present disclosure are catalyst supports, these catalyst supports can be filled with or partially filled with any catalyst suitable for the intended reaction. For example, Fischer-Tropsch catalysts can be used for Fischer-Tropsch reactions. Cobalt-containing Fischer-Tropsch catalysts are preferred. The catalyst can be provided as catalyst particles or catalyst monoliths. The catalyst can be provided as a single catalyst bed or multiple catalyst beds. The catalyst support can be configured to promote axial and / or radial flow through the catalyst. In some embodiments, the catalyst support can be configured to preferentially promote radial flow through the catalyst.

[0067] The catalyst support 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

[0068] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0069] Figure 1is a schematic side view of a tubular reactor;

[0070] Figure 2 A catalyst support is shown;

[0071] Figure 3 A conveyor according to the present disclosure is shown together with a plurality of catalyst supports;

[0072] Figure 4 The lower tube plate of the tubular reactor is shown. Figure 3 The conveying device;

[0073] Figure 5 It shows that during the feeding of multiple catalyst supports Figure 3 an enlarged view of a portion of a conveyor device;

[0074] Figure 6 for Figure 3 A top view of a portion of a conveying device of the embodiment of the present invention, the top view showing a feed element of the conveying device;

[0075] Figure 7 shows the first state and the second state Figure 3 a tensioning mechanism of the conveyor; and

[0076] Figure 8 The feeding of multiple catalyst supports is shown Figure 3 A schematic cross-sectional view of a conveying device. DETAILED DESCRIPTION

[0077] Hereinafter, by way of example only, various aspects and embodiments of the present disclosure are described with reference to a component in the form of a catalyst support for use with 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 employ other orientations and other components discharged from other tubes.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] Each reaction tube 8 is intended to be filled or substantially filled with a stacked arrangement of catalyst supports 10 (e.g. Figure 2 In particular, it is generally desirable that the catalyst supports 10 cover the entire or substantially the entire length of the reaction tubes 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.

[0082] 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.

[0083] 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 .

[0084] In order to better understand the present disclosure, reference will be made to Figure 2 An example of a general configuration of a component in the form of a catalyst carrier 10 is described. However, it will be understood that the catalyst carrier 10 may take a variety of 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.

[0085] Each catalyst support 10 may typically include a container 20, the dimensions of which are set so that its dimensions are smaller than the internal dimensions of the reaction tube 8, in which the container will be placed in use. Typically, a seal 22 will be provided, the dimensions of which are set so that when the catalyst support 10 is in the appropriate 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.

[0086] like Figure 2As shown, the container 20 includes an elongated body 21 having an outer wall 23 extending between an upper end 24 and a bottom end 25. A cover portion 26 is provided at the upper end 24, which at least partially closes the elongated body 21 at the upper end 24. A skirt 27 is provided at the bottom end 25. The seal 22 is located toward the upper end 24 and is preferably proximate to the cover portion 26, such as just below the cover portion.

[0087] The lid portion 26 is provided with a central aperture 28 which allows fluid to enter the container 20 in use.

[0088] like Figure 2 As shown, the outer wall 23 can be provided with a plurality of holes configured to allow fluid to be transmitted across the outer wall 23. At the bottom end 25 of the outer wall 23, the skirt 27 can include a plurality of bottom holes 30. The bottom holes 30 can be spaced around the circumference of the elongated body 21. Each bottom hole 30 can have, for example, a square or rectangular shape. Similarly, at the upper end 24 of the outer wall 23, a plurality of upper holes 31 can be provided. The upper holes 31 can be spaced around the circumference of the elongated body 21. Each upper hole 31 can have, for example, a square or rectangular shape.

[0089] The catalyst carrier 10 may define an annular container for holding a catalyst in use. The annular container may include a perforated container inner wall defining an inner passage and a perforated container outer wall that may be arranged concentrically around the perforated container inner wall and within the outer wall 23. An annular top surface defined by a portion of the cover portion 26 may close the upper end of the annular container, and an annular bottom surface may close the lower end of the annular container.

[0090] The seal 22 can be sufficiently compressible to adapt to the minimum diameter of the reaction tube 8. The seal 22 can generally be a flexible sliding seal. The seal 22 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 22 can, for example, be configured to form a sliding seal against the inner surface of the reaction tube 8.

[0091] exist Figure 2 In the illustrated example, the seal 22 may include a deformable flange extending from the outer wall 23. The flange may be sized 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, the flange deforms to fit inside the reaction tube 8 and interact with the reaction tube.

[0092] Further details of the construction of such catalyst supports 10 may be found in WO2011 / 048361, WO2012 / 136971 and WO2016 / 050520, the contents of which are incorporated herein by reference in their entirety.

[0093] According to the present disclosure, a conveyor device 40 is provided for controlled discharge of a stack of components in the form of catalyst supports 10 from a tube in the form of a reaction tube 8. An example of a conveyor device 40 is shown in FIG. Figures 3 to 7 is shown in Figure 8 It is schematically shown in FIG.

[0094] Figure 3 The conveying device of the invention comprises a frame 41 which may include an upper plate 42, a lower ring 43 and a plurality of wheel set frames 46 which may extend therebetween. Optionally, an additional plate 44 may be disposed above the upper plate 42 and spaced apart from the upper plate and connected to the upper plate by connecting bolts 45. The additional plate 44 may form an attachment plate for removably attaching the frame 41 to the lower tube plate 7.

[0095] The additional plate 44 may include a central hole 55. The upper plate 42 may also include a central hole 50 that may be aligned with the central hole 55. The central holes 50, 55 may together define an inlet 81 leading to a feed path 80 that extends through the frame 41 to an outlet 82 that is optionally defined by the lower ring 43. The feed path 80 is preferably a linear path and optionally coincides with the central longitudinal axis of the frame 41. The wheel set frames 46 may be distributed around the feed path 80, optionally at regular intervals. In the illustrated example of the figures, four wheel set frames 46 are arranged at 90 degree intervals.

[0096] The conveyor 40 further includes a plurality of feed elements mounted to the frame 41. The feed elements may preferably be in the form of feed wheels 61. The feed wheels 61 may each be mounted to a wheel set frame 46. Each wheel set frame 46 may include two parallel spaced-apart plates defining a space therebetween for accommodating at least a portion of the feed wheel 61. Figure 6 As shown, each feed wheel 61 may be rotatably mounted using a feed wheel axle 66 that extends through an adjustment slot 67 in each of the spaced apart plates of the wheelset frame 46 .

[0097] The feed wheels 61 may be grouped into an upper feed wheel 63, a middle feed wheel 64, and a lower feed wheel 65, which may be positioned along the length of the frame 41, and in particular along the length of the wheel sub-frame 46. The upper feed wheel 63 may be positioned closest to the inlet 81, the lower feed wheel 65 is positioned closest to the outlet 82, and the middle feed wheel 84 is positioned therebetween. Preferably, the spacing between the upper feed wheel 63 and the lower feed wheel 65 is substantially equal to the longitudinal length of each catalyst carrier in the catalyst carrier 10. Preferably, the spacing between adjacent levels of the feed wheels 61 along the feed path 80 is less than the longitudinal length of each catalyst carrier in the catalyst carrier 10.

[0098] The feed wheel 61 is distributed around and along the feed path 80, such as Figure 6 and Figure 8 As shown, the feed wheel 61 is arranged, in use, to contact the catalyst carrier 10 passing through the frame 41 along the feed path 80 .

[0099] Each level of feed wheels 61 along the feed path 80 may include at least three feed wheels, for example four feed wheels 61, such as Figure 4 An example of an illustration is shown.

[0100] Preferably, one or more of the feed wheels 61 are driven wheels 62, which are configured to be driven to rotate to feed the catalyst carrier 10 along the feed path 80. The driven wheel 62 can be driven by manual power or motor power. In the illustrated example of these figures, the driven wheel 62 can be manually rotated by using a drive crank 90 and a handle 91 connected to the driven wheel 62. Preferably, at least one driven wheel 62 is set at each level of at least two levels along the feed path 80. In the illustrated example, and as Figure 8 Schematically shown, the first driven wheel 62 is one of the upper feed wheels 63 , and the second driven wheel 62 is one of the middle feed wheels 64 .

[0101] One or more of the feed wheels 61 of the conveyor 40 comprises a tensioning mechanism for adjusting the level of friction between the or each feed wheel 61 and the catalyst support 10 passing through the frame 41 along the feed path 80. Optionally, each of the feed wheels 61 comprises a tensioning mechanism.

[0102] The tensioning mechanism may include a tensioning spring 71 that biases the feed wheel 61 inwardly toward the feed path 80. The tensioning mechanism may further include a pre-compression mechanism for selectively setting the pre-compression of the tensioning spring 71. In the illustrated example, as in Figure 7 As best seen in the figure, the pre-compression mechanism comprises a mounting bar 73 and a tensioning bolt 72 fixedly attached to its wheelset frame 46. A tensioning spring 71 is positioned between the mounting bar 73 and the inner end of the tensioning bolt 72. The tensioning bolt 72 extends through the mounting bar 73 and can be rotated in two rotational directions to increase or decrease the pre-compression of the tensioning spring 71 by moving the inner end of the tensioning bolt (and thus the outer end of the tensioning spring 71) inwardly or outwardly, respectively. Figure 6 The left hand portion of shows a pre-compression mechanism with a relatively low level of pre-compression, and Figure 6 The right-hand part of shows a pre-compression mechanism with a relatively high level of pre-compression.

[0103] like Figure 4As shown, the conveyor 40 can be configured to be positioned near the outlet of the reaction tube 8, for example by being attached to the lower tube plate 7, optionally suspended from the lower tube plate. The frame 41 may include a connection for removably suspending the conveyor 40 below the reaction tube 8. In the illustrated example, three mounting punches 47 extend downwardly from the lower tube plate 8, each mounting punch having an enlarged distal end, such as a pivot disclosed in WO2022 / 064211. The attachment plate 44 may be provided with three keyway holes 56, such as Figure 3 and Figure 6 As can be seen in FIG. 5 , the three keyway holes enable the transfer device 40 to be attached below the outlet of the reaction tube in a bayonet-type connection by engaging the enlarged head of the mounting punch 47 in the enlarged portion of the keyway hole 56 and rotating the transfer device 40. The transfer device 40 can thus be configured to be positioned near the outlet of the reaction tube 8.

[0104] In use, controlled emissions of the catalyst support 10 may be achieved by the following steps:

[0105] i) positioning the conveyor 40 near, e.g., attached to, the outlet of the reaction tube 8; and ii) discharging the catalyst carrier 10 from the reaction tube 8 into the conveyor 40 such that the catalyst carrier passes along the feed path 80 and is contacted by the plurality of feed wheels 61 while doing so.

[0106] As described above, the level of friction between the feed wheel 61 and the catalyst carrier 10 passing along the feed path 80 is selectively adjustable, such as by adjusting a tensioning mechanism.

[0107] As described above, the catalyst carrier 10 may include an enlarged portion, such as a seal 22, having a larger diameter than the catalyst carrier body 21, and the friction level may be adjusted so that rotation of one or more of the driven wheels 62 is required to allow the enlarged portion to pass through the driven wheels 62.

[0108] Preferably, each catalyst support 10 is contacted by the feed wheel 61 at at least two levels along the feed path 80 during at least a portion of its passage along the feed path 80 .

[0109] The discharge of the catalyst carrier 10 out of the outlet of the reaction tube 8 into the inlet 81 of the feed path 80 can be achieved or assisted by, or accompanied by, inserting the catalyst carrier 10 (or other components, such as ejector components) into the upper end of the reaction tube 8 so that the stack of catalyst carriers 10 in the reaction tube moves downward successively at the upper end through or with each insertion of the component.

[0110] In some preferred examples, the discharge of the catalyst carrier 10 from the outlet of the reaction tube 8 is accompanied by the simultaneous insertion of the catalyst carrier 10 into the inlet of the reaction tube 8. In particular, the discharge of the catalyst carrier 10 can move the stack of catalyst carriers 10 downward within the reaction tube 8, thereby allowing the catalyst carrier 10 to be inserted into the inlet of the reaction tube 8 to fill the space formed at the upper end of the reaction tube 8. Optionally, the catalyst carrier 10 in these and other examples can be a non-self-supporting catalyst carrier 10.

[0111] The conveying device 40 may enable the insertion of the catalyst carrier 10 into the inlet of the reaction tube 8 to be controlled by the action of discharging the catalyst carrier 10 from the outlet of the reaction tube 8 , rather than in the opposite manner.

[0112] Optionally, the lower tube sheet 7 and / or the conveyor 40 (e.g., the additional plate 44) may be provided with means for preventing the discharge of the catalyst carrier 10 from the reaction tube 8. For example, one or more gates, such as a moon-shaped disc (e.g., as described in WO2022 / 064211, the contents of which are incorporated herein by reference in their entirety), may be at least partially pivoted across the outlet of the reaction tube 8 or across the center hole 55 of the additional plate 44 to prevent the passage of the catalyst carrier 10. This may be beneficial by preventing the catalyst carrier 10 from being discharged out of the reaction tube 8 while the conveyor 40 is mounted to the lower tube sheet 7. Once the conveyor 40 is correctly mounted, the gates may be retracted to clear the outlet of the reaction tube 8 and the inlet 81 of the feed path 80.

[0113] Other aspects of the disclosure are set out in the following clauses:

[0114] Clause 1. A conveyor for controlled discharge of a stack of components from a tube, the conveyor comprising:

[0115] i) a frame configured to be positioned adjacent an outlet of the tube; and

[0116] ii) a plurality of feed elements mounted to the frame, the feed elements being distributed about and along a feed path extending through the frame so as to contact, in use, a component passing through the frame along the feed path;

[0117] One or more of the feed elements include a tensioning mechanism for adjusting a level of friction between the one or more of the feed elements and a component passing through the frame along a feed path.

[0118] Clause 2. The conveying device of Clause 1, wherein each feed element of the plurality of feed elements comprises a tensioning mechanism.

[0119] Clause 3. The conveying device of Clause 1 or Clause 2, wherein the plurality of feed elements comprises feed elements at two, optionally three or more levels along the feed path.

[0120] Clause 4. The conveying device of Clause 3, wherein the plurality of feed elements include upper feed elements and lower feed elements.

[0121] Clause 5. The conveying device according to Clause 4, wherein the spacing between the upper feed element and the lower feed element is substantially equal to the longitudinal length of each of the components.

[0122] Clause 6. The conveying device of Clause 4 or Clause 5, wherein the plurality of feed elements further comprises a middle feed element positioned between the upper feed element and the lower feed element.

[0123] Clause 7. The conveying device of any one of Clauses 3 to 6, wherein the spacing of adjacent levels of feed elements along the feed path is less than the longitudinal length of each of the components.

[0124] Clause 8. The conveying device according to any of Clauses 3 to 7, wherein each level of feed elements along the feed path comprises at least three feed elements.

[0125] Clause 9. The conveying device of any preceding clause, wherein the plurality of feed elements are distributed circumferentially around the longitudinal axis of the feed path at two, three, four or more locations.

[0126] Clause 10. The conveying device according to any preceding clause, wherein the plurality of feed elements comprises or consists of a plurality of feed wheels.

[0127] Clause 11. The conveyor of Clause 10, wherein one or more of the feed wheels are driven wheels configured to be rotationally driven to feed the components along the feed path.

[0128] Clause 12. The conveyor according to clause 11, wherein the one or more driven wheels are driven by manual power or motor power.

[0129] Clause 13. The conveyor of clause 11 or clause 12, further comprising one or more handles coupled to the one or more driven wheels for rotating the driven wheels.

[0130] Clause 14. The conveying device according to any of clauses 11 to 13, wherein at least one driven wheel is provided at each of the at least two levels along the feed path.

[0131] Clause 15. The conveyor device of any preceding clause, wherein the tensioning mechanism comprises a tensioning spring that biases the feed element inwardly toward the feed path.

[0132] Clause 16. The delivery device of Clause 15, wherein the tensioning mechanism further comprises a pre-compression mechanism for selectively setting a pre-compression of the tensioning spring.

[0133] Clause 17. The delivery device of any preceding clause, wherein the frame includes a connection for removably suspending the delivery device beneath the tube.

[0134] Clause 18. The delivery device of Clause 17, wherein the connector comprises a bayonet connector.

[0135] Clause 19. The conveyor of any preceding clause, wherein the frame comprises an opening at a first end of the frame, the opening defining an inlet to the feed path for receiving a component discharged from the tube.

[0136] Clause 20. The conveyor of any preceding clause, wherein the frame includes an opening at the second end of the frame, the opening defining an outlet of the feed path.

[0137] Clause 21. A conveyor according to any preceding clause, wherein the feed path is a linear path through the frame, optionally through the centre of the frame.

[0138] Clause 22. The conveyor according to any preceding clause, wherein the component comprises a catalyst support and the tube comprises a reaction tube of a tubular reactor.

[0139] Clause 23. A system, comprising:

[0140] A transmission device as described in any of the preceding clauses;

[0141] A tubular reactor comprising a plurality of reaction tubes; and

[0142] Multiple components;

[0143] The conveying device can be positioned near the outlet of the selected reaction tube to control the discharge of the plurality of components from the selected reaction tube.

[0144] Clause 24. The system of Clause 23, wherein the conveyor device is removably attachable near the outlet of a selected reaction tube by being suspended from a lower tube sheet of the tubular reactor.

[0145] Clause 25. A method of controlled discharge of a stack of components from a pipe, the method comprising the steps of:

[0146] i) positioning a conveying device near the outlet of the tube, the conveying device comprising a frame and a plurality of feed elements mounted to the frame, the feed elements being distributed around and along a feed path extending through the frame; and

[0147] ii) discharging the component from the tube into the conveyor such that the component passes along the feed path and in doing so is contacted by the plurality of feed elements;

[0148] The friction level between one or more of the feed elements and the components passing along the feed path is selectively adjustable.

[0149] Clause 26. The method of Clause 25, wherein positioning the delivery device proximate the outlet of the tube comprises attaching the delivery device proximate the outlet, optionally removably attaching the delivery device proximate the outlet.

[0150] Clause 27. The method according to Clause 25 or Clause 26, wherein the plurality of feed elements comprises or consists of a plurality of feed wheels.

[0151] Clause 28. The method of Clause 27, wherein one or more of the feed wheels are driven wheels, and the rolling friction level is adjusted such that the components are fed through the feed path by rotation of the one or more driven wheels.

[0152] Clause 29. The method of clause 28, wherein the component includes an enlarged portion having a larger diameter than a main body of the component, and the friction level is adjusted so that rotation of the one or more driven wheels is required for the enlarged portion to pass past the one or more driven wheels.

[0153] Clause 30. The method of any one of clauses 28 to 29, wherein the one or more driven wheels are driven by manual power or motor power.

[0154] Clause 31. The method of any one of Clauses 27 to 30, wherein a level of rolling friction between each of the feed wheels and a component passing along the feed path is selectively adjustable.

[0155] Clause 32. The method according to any one of Clauses 26 to 31, wherein each component is contacted by a feed element at at least two levels along the feed path during at least a portion of its passage along the feed path.

[0156] Clause 33. The method of any one of Clauses 26 to 32, wherein each component passing along the feed path is contacted by the feed element at two, three, four or more locations around the longitudinal axis of the feed path.

[0157] Clause 34. The method of any one of Clauses 26 to 33, wherein the friction level is adjusted by using a tensioning mechanism comprising a tensioning spring that biases the feed element inwardly toward the feed path.

[0158] Clause 35. The method of clause 34, wherein the tensioning mechanism further comprises a pre-compression mechanism for selectively setting a pre-compression of the tensioning spring.

[0159] Clause 36. The method of any one of clauses 26 to 35, further comprising inserting a component into the inlet of the tube, wherein the inserting of the component into the inlet of the tube is controlled by the act of discharging the component from the outlet of the tube.

[0160] Clause 37. The method according to any one of Clauses 26 to 36, wherein the component comprises a catalyst support and the tube comprises a reaction tube of a tubular reactor.

Claims

1. A conveying device for controlled discharge of a stack of components from a tube, the conveying device comprising: i) a frame configured to be positioned adjacent an outlet of the tube; as well as ii) a plurality of feed elements mounted to the frame, the feed elements being distributed about and along a feed path extending through the frame so as to contact, in use, a component passing through the frame along the feed path; One or more of the feed elements include a tensioning mechanism for adjusting a level of friction between the one or more of the feed elements and the component passing through the frame along the feed path. 2 . The conveying device of claim 1 , wherein the plurality of feed elements comprises feed elements at two, optionally three or more levels along the feed path.

3. The conveying device according to claim 2, wherein the plurality of feed elements include upper feed elements and lower feed elements.

4. The conveying device according to claim 3, wherein the spacing between the upper feed element and the lower feed element is substantially equal to the longitudinal length of each of the components.

5. The conveying device according to claim 3 or claim 4, wherein the plurality of feed elements further comprises a middle feed element positioned between the upper feed element and the lower feed element.

6. A conveying device according to any one of claims 2 to 5, wherein the spacing of adjacent levels of the feed elements along the feed path is less than the longitudinal length of each of the components.

7. A conveying device according to any preceding claim, wherein the plurality of feed elements comprises or consists of a plurality of feed wheels.

8. The conveying device of claim 7, wherein one or more of the feed wheels are driven wheels configured to be rotationally driven to feed the components along the feed path.

9. A conveyor according to claim 7 or claim 8, further comprising one or more handles coupled to the one or more driven wheels for rotating the driven wheels.

10. A conveying device according to any one of claims 7 to 9, wherein at least one driven wheel is provided at each of at least two levels along the feed path.

11. A conveyor according to any preceding claim, wherein the tensioning mechanism comprises a tensioning spring biasing the feed element inwardly towards the feed path.

12. The delivery device of claim 11, wherein the tensioning mechanism further comprises a pre-compression mechanism for selectively setting a pre-compression of the tensioning spring.

13. A delivery device according to any preceding claim, wherein the frame includes connections for removably suspending the delivery device beneath the tube.

14. A conveyor according to any preceding claim, wherein the component comprises a catalyst support and the tube comprises a reaction tube of a tubular reactor.

15. A system, comprising: A conveyor according to any preceding claim; A tubular reactor, the tubular reactor comprising a plurality of reaction tubes; as well as Multiple components; The conveying device is positioned near the outlet of the selected reaction tube to control the discharge of the plurality of components from the selected reaction tube.

16. The system of claim 15, wherein the conveying device is removably attachable near the outlet of a selected reaction tube by being suspended from a lower tube sheet of the tubular reactor.

17. A method for controlled discharge of a stack of components from a pipe, the method comprising the steps of: i) positioning a conveying device near the outlet of the tube, the conveying device comprising a frame and a plurality of feed elements mounted to the frame, the feed elements being distributed around and along a feed path extending through the frame; as well as ii) discharging a component from the tube into the conveying device such that the component passes along the feed path and in doing so is contacted by the plurality of feed elements; The level of friction between one or more of the feed elements and the component passing along the feed path is selectively adjustable.

18. The method of claim 17, wherein positioning the delivery device proximate the outlet of the tube comprises: The delivery device is attached proximate the outlet, optionally the delivery device is removably attached proximate the outlet.

19. The method of claim 18, wherein the plurality of feed elements comprises or consists of a plurality of feed wheels.

20. The method of claim 19, wherein one or more of the feed wheels are driven wheels, and the rolling friction level is adjusted so that the components need to be fed through the feed path by rotation of the one or more driven wheels.

21. A method according to claim 20, wherein the component includes an enlarged portion having a larger diameter than the main body of the component, and the friction level is adjusted so that rotation of the one or more driven wheels is required for the enlarged portion to pass past the one or more driven wheels.

22. A method according to any one of claims 18 to 21 wherein each component is contacted by feed elements at at least two levels along the feed path during at least a portion of its passage along the feed path.

23. A method according to any one of claims 18 to 22, wherein the friction level is adjusted by using a tensioning mechanism comprising a tensioning spring biasing the feed element inwardly towards the feed path.

24. The method of claim 23, wherein the tensioning mechanism further comprises a pre-compression mechanism for selectively setting a pre-compression of the tensioning spring.

25. A method according to any one of claims 18 to 24, further comprising inserting a component into an inlet of the tube, wherein the insertion of the component into the inlet of the tube is controlled by the act of discharging the component from the outlet of the tube.

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