Apparatus and method for installing and removing catalyst supports

Abstract

An apparatus and method for installation and removal of catalyst supports (10) in a tubular reactor is described utilizing a support unit (20). The support unit (20) is installable in a reactor tube (8) along with a plurality of catalyst supports (10). The support unit (20) includes at least one engagement portion for engaging an inner surface of the reactor tube (8) to create a frictional engagement between the support unit (20) and the reactor tube (8). The magnitude of the frictional engagement is sufficient to support the static load of two or more catalyst supports (10) such that the support unit (20) holds the two or more catalyst supports (10) in place within the reactor tube (8).

Description

[Technical field]

[0001] The present disclosure relates to an apparatus and method for the installation and removal of catalyst supports in a tubular reactor. [Background technology]

[0002] A conventional so-called fixed-bed tubular reactor comprises a reactor shell, usually cylindrical, containing a number of tubes, usually directly packed with catalyst particles. In use, a heat transfer medium flows through the reactor shell outside these tubes, thereby regulating the temperature of the catalyst within the tubes by heat exchange across the tube walls. Thus, if the reaction is exothermic, the heat transfer medium allows heat to be removed from the catalyst, and if the reaction is endothermic, the heat transfer medium provides heat to the catalyst.

[0003] For some reactions, the thermal effects of the reaction are so mild that they are either not a problem or they can be easily managed. In some cases, the thermal effects are small enough that a large diameter tube may be used. This has the advantage that there is a large amount of catalyst in the tube.

[0004] However, for more exothermic or endothermic reactions, it is necessary that there is efficient heat transfer through the tube walls to the heat transfer medium to maintain a stable operating temperature so that conditions within the reactor can be controlled 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 of catalytic active sites, and in the worst case, thermal runaway. For endothermic reactions, deleterious effects may include quenching of the reaction.

[0005] To achieve the desired efficiency, the surface area of ​​the tube wall per unit length must be maximized. This has been accomplished in the past by installing a larger number of smaller diameter tubes. In some reactions, size limitations dictate that the tubes only have internal diameters on the order of about 15-40 mm. However, the use of this large number of tubes increases the cost and complexity of the reactor.

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

[0007] A first type of such catalyst carrier is described in WO 2011 / 048361. This arrangement seeks to optimize heat transfer at the tube walls so that larger tubes and a larger volume of smaller catalyst particles can be used for more exothermic or even endothermic reactions. The catalyst carrier described in WO 2011 / 048361 comprises an annular container for holding the catalyst in use. The container has a perforated inner wall defining the tube, a perforated outer wall, a top surface closing the annular container, and a bottom surface closing the annular container. The bottom closing surface of the tube is formed by the inner wall of the annular container. A skirt extends upwardly from the perforated outer wall of the annular container from a position at or near the bottom surface of the container to a position below the location of the seal. The seal is located at or near the top surface and extends from the container a distance that extends beyond the outer surface of the skirt.

[0008] A second type of such catalyst support is described in WO 2012 / 136971. In this arrangement, the catalyst support includes a container for holding a monolith catalyst in use, the container having a base closing the container and a skirt extending upwardly from the base of the container to a position below the position of the seal and spaced therefrom, the skirt being arranged such that there is a space between an outer surface of the monolith catalyst and the skirt, and the seal is located at or near an upper surface of the monolith catalyst and extends a distance from the monolith catalyst extending beyond the outer surface of the skirt.

[0009] A third type of such catalyst support is described in WO 2016 / 050520. In this configuration, the catalyst support includes a container for holding the catalyst during use. The container has a bottom surface closing the container and a top surface. The carrier outer wall extends from the bottom surface to the top surface, and the seal extends from the container a distance that extends beyond the carrier outer wall. The carrier outer wall has an opening located below the seal.

[0010] For example, in a catalyst carrier of the type described above, the seal extending beyond the vessel serves at least two functions.

[0011] First, the seals function to guide the reactants correctly to the catalyst supports, substantially preventing bypass flow of the reactants. For example, in a tubular reactor with downflow, the reactants flow downward through the reactor tube and thus first contact the top surface of the uppermost catalyst support in the stacked arrangement of catalyst supports. The seals of each catalyst support extend outwardly from the vessel and are sized to make sealing contact with the inner surface of the reactor tube bore. This sealing contact substantially prevents the passage of reactants around the sides of the catalyst support. As a result, the reactants are guided to flow through the interior of the vessel of catalyst supports, where the reactants come into contact with the catalyst contained in that vessel.

[0012] Second, the seals function to physically support the catalyst support within the reactor tube bore. For example, the seals of each catalyst support extend outwardly from the vessel and are large enough to deform when inserted into the reactor tube, resulting in a residual frictional engagement of the catalyst support with the inner surface of the reactor tube. The use of such seals makes the catalyst support self-supporting, i.e., the residual frictional engagement is strong enough to maintain the position of the catalyst support within the reactor tube without external support.

[0013] There may be hundreds, even thousands, of such catalyst supports in a tubular reactor, and each reactor tube may accommodate many catalyst supports, for example up to 80 or more, in a stacked configuration. As a result, the insertion force required to install the catalyst supports into each reactor tube may be large. In particular, the insertion force required is proportional to the number of catalyst supports already inserted into the reactor tube, since inserting each catalyst support requires all of the already inserted catalyst supports to be pushed further along the reactor tube. Therefore, the catalyst supports must be carefully designed in terms of material and dimensions to withstand high crushing forces to ensure that they are not damaged during installation into the reactor tube.

[0014] Furthermore, for optimal performance of the catalyst support and reactor, the loading should ensure proper alignment of the catalyst support within the reactor tube. In heat exchange tubular reactors, it is also desirable to position the catalyst support in the heat exchange zone so that uncontrolled heating or cooling is prevented.

[0015] It is an object of the present disclosure to provide an apparatus and method for loading and unloading catalyst supports that addresses these issues. Summary of the Invention

[0016] In a first aspect of the present disclosure, a method for installing a catalyst support in a reaction tube of a tubular reactor is provided, the tubular reactor being of a type comprising a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, a heat exchange zone being provided between the upper tube plate and the lower tube plate, The method is: i) providing a plurality of catalyst supports; ii) providing a support unit including at least one engagement portion for engaging an inner surface of the reaction tube; iii) inserting a support unit into a first end, preferably an upper end, of the reaction tube to create a frictional engagement between at least one engagement portion of the support unit and an inner surface of the reaction tube; iv) inserting the catalyst support into the first end of the reactor tube and pushing the support unit along the reactor tube into an installed position towards the second end, preferably the lower end, of the reactor tube; The magnitude of frictional engagement of at least one engaging portion of the support unit is such that the support unit can support a static load of two or more catalyst supports to hold the two or more catalyst supports in place within the reactor tube when no additional catalyst supports are inserted into the first end of the reactor tube.

[0017] Advantageously, the support unit functions to provide physical support to the catalyst support within the reactor tube, particularly during the process of installing the catalyst support within the reactor tube. The support provided by the support unit means that the seal of each catalyst support is no longer required to support most or part of the weight of the catalyst support and therefore may be made from a thinner and / or more flexible material. This further means that the insertion force required to insert each catalyst support into the reactor tube and then to push the catalyst support along the reactor tube into its installed position can be reduced.

[0018] The use of the support unit may also allow the use of non-self-supporting catalyst supports, i.e. catalyst supports that simply slide down the reactor tube under the action of gravity without the application of any additional external force.

[0019] Advantageously, the reduced insertion force of each individual catalyst support also means that the maximum total insertion force required to push a stack of catalyst supports along a reactor tube during filling of the reactor tube can be reduced compared to inserting a stack of catalyst supports having self-supporting seals.

[0020] The reduced force required to insert the catalyst support into the reactor tube may allow the use of catalyst supports with reduced crush strength compared to known catalyst supports. As a result, the catalyst support may be formed with reduced component thickness, for example with reduced plate thickness for the walls and tubular elements of the catalyst support vessel. Advantageously, the use of reduced component thickness may reduce the weight and cost of the catalyst support while at the same time increasing the internal volume that can accommodate the catalyst. Furthermore, fewer resources may be required to manufacture the catalyst support, increasing the sustainability of the process.

[0021] The physical support provided by the support unit may allow the configuration of the seal to be altered so that the seal design is focused on obtaining the required quality of fluid seal to prevent or limit bypass of reactants around the catalyst vessel body, for example, the seal diameter may be reduced, and / or the seal stiffness may be reduced, and / or the seal material thickness may be reduced, and / or the seal material may be changed.

[0022] Additionally, a more flexible seal may be less susceptible to damage, such as impact damage that may occur during manual handling of the catalyst support prior to installation.

[0023] Advantageously, the use of the support unit may allow the individual reactor tubes to be filled and / or emptied of catalyst supports more easily than tubular reactors of conventional design, for example, the catalyst supports may be configured to slide out of the reactor tubes under the action of gravity when the support unit is removed.

[0024] The support unit and / or catalyst support may be inserted into the first end of the reactor tube by hand force or by using a tool, such as a mechanical ram, which helps push the support unit and / or catalyst support into the reactor tube.

[0025] The magnitude of the frictional engagement may be selected to enable the support unit to support a static load of 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports such that 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports are held in place within the reactor tube when no additional catalyst supports are inserted into the first end of the reactor tube.

[0026] The magnitude of the frictional engagement can be selected to allow the support unit to slide along the reactor tube under dynamic loads imparted to the support unit through the catalyst support when the additional catalyst support is inserted into the first end of the reactor tube.

[0027] The amount of frictional engagement of each individual catalyst support with the reactor tube when inserted therein can be less than the weight of the catalyst support such that the catalyst support will slide down the reactor tube under its own weight unless supported by an external object.

[0028] The support unit may be pushed along the reactor tube into a mounting position that may be adjacent to the second end of the reactor tube, preferably flush with the lower tube plate.

[0029] The method may include inserting a single support unit into the reactor tube and pushing the single support unit toward the second end of the reactor tube using a single stack of catalyst supports that are inserted individually or in sets into the first end of the reactor tube. Optionally, the single stack of catalyst supports may extend from the single support unit to or adjacent the first end of the reactor tube.

[0030] The support unit can support an entire tube filled with catalyst supports. For example, a single support unit can be installed at or towards the bottom of the reactor tube, and the catalyst supports can be supported on top of the support unit in a single stack. For example, 60, 70, 80 or more catalyst supports can be supported on top of one support unit.

[0031] Alternatively, the method comprises: a) inserting a first support unit into a reactor tube and pushing the first support unit toward a second end of the reactor tube using a first stack of one or more catalyst supports that are inserted individually or in sets into a first end of the reactor tube; b) inserting a second support unit into the reaction tube and using a second stack of one or more catalyst supports inserted individually or in a set into the first end of the reaction tube, pushing the second support unit, the first stack of one or more catalyst supports, and the first support unit towards the second end of the reaction tube.

[0032] The method may further include inserting a third, fourth or more support units by using a third, fourth or more stacks of one or more catalyst supports, similar to step b).

[0033] Each support unit can support catalyst supports equivalent to a partial tube, for example, each support unit can support a set of 10 catalyst supports arranged on top of the support unit, and a reactor tube can include 2 to 8 or more support units.

[0034] The magnitude of frictional engagement between the at least one engaging portion of the support unit and the inner surface of the reaction tube can be varied by adjusting the at least one engaging portion of the support unit.

[0035] The adjustment of the at least one engagement portion of the support unit may be performed before or during insertion of the support into the reaction tube. Optionally, the at least one engagement portion may be adjusted to calibrate the magnitude of the frictional engagement to the characteristics of the reaction tube.

[0036] Additionally or alternatively, the adjustment of the at least one engagement portion of the support unit may be performed when the support unit is installed in its installation position in the reaction tube. Optionally, the at least one engagement portion may be adjusted to calibrate the magnitude of the frictional engagement to the characteristics of the reaction tube.

[0037] The reaction tube characteristic may be one or more of an inner diameter of the reaction tube, a surface roughness of the reaction tube, and an ovality of the reaction tube.

[0038] Varying the amount of frictional engagement may be performed from positions above and / or below the support unit.

[0039] Varying the magnitude of frictional engagement may be accomplished using an adjustment tool applied to the support unit via the first end and / or the second end of the reaction tube.

[0040] The method may further include varying a magnitude of frictional engagement between the support unit and an inner surface of the reaction tube to lock the support unit to the reaction tube.

[0041] Advantageously, the adjustment of at least one engagement portion of the support unit allows the support unit to be adapted to the requirements of the individual reactor tubes. It also allows the support unit to have different levels of frictional engagement with the reactor tubes at different times.

[0042] The or each support unit preferably does not contain any catalytic material.

[0043] The method is: v) removing the or each support unit from the reaction tube; vi) removing the catalyst support from the reactor tube by sliding the catalyst support out of the reactor tube, preferably solely under the action of gravity.

[0044] The or each support unit may be removed from one end of the reactor tube by pushing it out using one or more additional catalyst supports which are inserted into the other end of the reactor tube.

[0045] Alternatively, the or each support unit may be removed from the reaction tube by reducing the magnitude of frictional engagement between at least one engagement portion of the support unit and the inner surface of the reaction tube, preferably allowing the support unit to slide out of the reaction tube simply under the action of gravity.

[0046] In a second aspect of the present disclosure, a support unit for reaction tubes of a tubular reactor is provided, the tubular reactor being of a type comprising a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, a heat exchange zone being provided between the upper tube plate and the second tube plate, The support unit can be installed in the reaction tube together with a plurality of catalyst supports, the support unit includes at least one engagement portion for engaging an inner surface of the reaction tube to create a frictional engagement between the support unit and the reaction tube; The amount of frictional engagement is sufficient to support the static load of two or more catalyst supports such that the support unit holds the two or more catalyst supports in place within the reactor tube.

[0047] The amount of frictional engagement may be sufficient for the support unit to support a static load of 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports such that 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports are held in place within the reactor tube.

[0048] The support unit may be configured to support a plurality of catalyst supports stacked above and / or below the support unit. Optionally, the plurality of catalyst supports may form a stack of catalyst supports that directly engages the upper or lower end of the support unit.

[0049] At least one engagement portion may be "self-locking," such that frictional engagement with the reactor tube bore increases when a force is applied tending to urge the support unit downwardly within the reactor tube bore.

[0050] At least one engagement portion may be adjustable to vary the amount of frictional engagement between the support unit and the inner surface of the reaction tube.

[0051] At least one engagement portion may be reversibly adjustable to selectively increase or decrease the frictional engagement between the support unit and the inner surface of the reaction tube.

[0052] At least one engagement portion may be configured to be adjustable before or during insertion of the support unit into the reaction tube.

[0053] At least one engagement portion may be configured to be adjustable when the support unit is installed in its installed position within the reaction tube.

[0054] The at least one engagement portion may be configured to be adjustable from a position above and / or below the support unit.

[0055] The at least one engagement portion may include an adjustment mechanism configured to be operated by an adjustment tool applied to the support unit via an end of the reaction tube.

[0056] The at least one engagement portion may be configured to press against an inner surface of the reaction tube.

[0057] The at least one engagement portion may include one or more, optionally two or more, optionally four or more, optionally six or more engagement portions. The at least one engagement portion may include one or more pairs of engagement portions. Each pair may include opposing engagement portions extending outwardly from opposite sides of the support unit. The support unit may include two, four, six, or more pairs of engagement portions.

[0058] The at least one engagement portion may include an adjustment mechanism operable to adjust a length of the at least one engagement portion, an angle of the protrusions, and / or a length of the protrusions, and / or to adjust a force applied by the at least one engagement portion against an inner surface of the reaction tube, and / or to adjust a surface area of ​​engagement of the at least one engagement portion against an inner surface of the reaction tube.

[0059] The at least one engagement portion may include one or more arms, wings, flanges, rims, protrusions, or skirts that protrude from the body of the support unit, hi some embodiments, the at least one engagement portion may include an extensible or inflatable (e.g., hydraulic or pneumatic) device.

[0060] The support unit may include an elastic body for pressing one or more arms, wings, flanges, rims, protrusions, or skirts against the inner surface of the bore of the reaction tube, optionally the elastic body being a variable resistance body, and optionally the elastic body including one or more spring elements.

[0061] The support unit may include a mechanical or electrical mechanism for moving the at least one engagement portion. The mechanical or electrical mechanism may be configured to convert a linear or rotational movement of the adjustment tool into a linear and / or radial and / or angular movement of the at least one engagement portion.

[0062] Additionally or alternatively, the support unit may include a hydraulic or pneumatic mechanism for moving the at least one engagement portion, for example, the at least one engagement portion may be moved radially inward and outward by changing a pressurized state of a hydraulic or pneumatic bladder associated with the at least one engagement portion.

[0063] At least one end of the support unit may be configured to engage one of the catalyst supports to maintain alignment of the catalyst support within the reactor tube.

[0064] The or each support unit preferably does not contain any catalytic material.

[0065] The support unit may comprise an internal channel for transporting liquids and gases through the support unit. Suitably, the internal channel may be such that the presence of the support unit does not impede the flow of liquids and gases during operation of the reactor tube.

[0066] The material and any contents of the support unit may be selected to be non-reactive to the intended process conditions of the tubular reactor.

[0067] In a third aspect of the present disclosure, a support unit for reaction tubes of a tubular reactor is provided, the tubular reactor being of a type comprising a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, a heat exchange zone being provided between the upper tube plate and the second tube plate, The support unit can be installed in the reaction tube together with a plurality of catalyst supports, the support unit includes at least one engagement portion for engaging an inner surface of the reaction tube to create a frictional engagement between the support unit and the reaction tube; At least one engagement portion is adjustable to vary the amount of frictional engagement between the support unit and the inner surface of the reaction tube.

[0068] At least one engagement portion may be reversibly adjustable to selectively increase or decrease the frictional engagement between the support unit and the inner surface of the reaction tube.

[0069] The at least one engagement portion may be configured to press against an inner surface of the reaction tube.

[0070] The at least one engagement portion may include an adjustment mechanism operable to adjust a length of the at least one engagement portion, an angle of the protrusions, and / or a length of the protrusions, and / or to adjust a force applied by the at least one engagement portion against an inner surface of the reaction tube, and / or to adjust a surface area of ​​engagement of the at least one engagement portion against an inner surface of the reaction tube.

[0071] The at least one engagement portion may include one or more arms, wings, flanges, rims, protrusions, or skirts that protrude from the body of the support unit.

[0072] The support unit may include an elastic body for pressing one or more arms, wings, flanges, rims, protrusions, or skirts against the inner surface of the bore of the reaction tube. The elastic body may be a variable resistance body. The elastic body may include one or more spring elements.

[0073] The support unit may include a mechanical or electrical mechanism for moving the at least one engagement portion, and optionally the mechanical or electrical mechanism may be configured to convert a linear or rotational movement of the adjustment tool into linear and / or radial and / or angular movement of the at least one engagement portion.

[0074] In a fourth aspect of the present disclosure, a tubular reactor is provided comprising a plurality of reaction tubes extending between an upper tube sheet and a lower tube sheet, a heat exchange zone being provided between the upper tube sheet and the lower tube sheet, and the or each reaction tube is provided with: i) one or more support units, each of which includes at least one engagement portion that frictionally engages with an inner surface of the reaction tube; and iii) one or more stacks of catalyst supports supported in position by one or more support units.

[0075] Each support unit may support two or more catalyst supports, optionally three or more, optionally five or more, optionally ten or more, optionally twenty or more, optionally fifty or more catalyst supports.

[0076] The frictional engagement between each individual catalyst support and the reactor tube in which it is housed can be less than the weight of the catalyst support.

[0077] The or each reactor tube may contain two or more support units.

[0078] At least one engagement portion of the one or more support units may be adjustable to vary the amount of frictional engagement with the inner surface of the reaction tube in which it is housed.

[0079] At least one engaging portion of the one or more support units can be adjusted to calibrate the magnitude of the frictional engagement to the characteristics of the reactor tube, such as the inner diameter of the reactor tube, the surface roughness of the reactor tube, and / or the ovality of the reactor tube.

[0080] The or each support unit may be as described in any of the aspects above.

[0081] Advantageously, the use of the support unit within the reactor tube may eliminate the need for a support such as a grid, mesh or plate at the bottom of the reactor tube as part of the tubular reactor, however the support unit may also be used in combination with a support such as a grid, mesh or plate at the bottom of the reactor tube.

[0082] Advantageously, the support unit may also serve to prevent the catalyst carriers containing catalyst from being located at the level of the lower tube plate. Instead, all catalyst carriers containing catalyst may be located within the heat exchange zone. This may facilitate heat exchange with all catalyst carriers, thereby better optimizing the performance of the tubular reactor.

[0083] In a fifth aspect of the present disclosure, a kit of parts for installation in a tubular reactor of the type comprising a plurality of reaction tubes extending between an upper tube sheet and a lower tube sheet, with a heat exchange zone being provided between the upper tube sheet and the lower tube sheet, the kit of parts comprising one or more support units and a plurality of catalyst supports, One or more support units are positionable within the reactor tube, each support unit including at least one engagement portion for engaging an inner surface of the reactor tube to create a frictional engagement between the support unit and the reactor tube sufficient to support the weight of two or more catalyst supports; The catalyst supports are mountable within the reactor tubes, with each catalyst support including a seal for engaging an inner surface of the reactor tube to create a frictional engagement between the catalyst support and the reactor tube that is insufficient to support the weight of the catalyst support within the reactor tube.

[0084] At least one engagement portion of each support unit may create a frictional engagement between the support unit and the reactor tube large enough to support the weight of 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports.

[0085] The one or more support units preferably do not contain a catalytic material, and the catalyst support preferably contains a catalytic material.

[0086] The kit of parts may include 1 to 20 support units and 20 to 200 catalyst supports.

[0087] The present support units, tubular reactors, methods, and kits of parts can be usefully used in a wide range of processes. Examples of suitable applications include processes and reactors for reactions for the production of methanol, reactions for the production of ammonia, methanation reactions, hydrogenation reactions, shift reactions, oxidation reactions such as the formation of maleic anhydride, and exothermic reactions such as ethylene oxide reactions. A particularly preferred use is in processes and reactors for carrying out Fischer-Tropsch reactions.

[0088] Endothermic reactions such as pre-reforming, dehydrogenation, etc. may also be carried out in conjunction with the present support unit, tubular reactor, and method.

[0089] The catalyst carriers of the present disclosure may be loaded or partially loaded with any catalyst suitable for the intended reaction. The catalyst may be provided as catalyst particles or catalyst monoliths. The catalyst may be provided as a single catalyst bed or multiple catalyst beds. The catalyst carrier may be configured to promote axial and / or radial flow through the catalyst. In some embodiments, the catalyst carrier may be configured to preferentially promote radial flow through the catalyst.

[0090] The support units and catalyst supports of the present disclosure may be formed from any suitable material. Such materials are generally selected to withstand the operating conditions of the tubular reactor. The support units and catalyst supports may be manufactured from carbon steel, aluminum, stainless steel, other alloys, or any material capable of withstanding the reaction conditions.

[0091] The catalyst supports of the present disclosure may advantageously allow the catalyst to be used in highly exothermic or endothermic reactions in the medium. The catalyst supports may allow the use of larger reactor tubes leading to significant weight and cost reductions for a given volume of reactor. [Brief description of the drawings]

[0092] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] FIG. 1 is a schematic diagram of a tubular reactor. [Diagram 2] FIG. 2 is a schematic diagram of a first arrangement including a support unit and multiple catalyst supports within a reactor tube. [Diagram 3] FIG. 13 is a schematic diagram of a second arrangement including multiple support units and multiple catalyst supports within a reactor tube. [Figure 4] FIG. 2 is a cross-sectional view of a support unit installed in a reaction tube. [Diagram 5] FIG. 5 is a bottom view of the support unit and the reaction tube of FIG. 4. [Figure 6] FIG. 11 is a cross-sectional view of another support unit installed in a reaction tube. [Figure 7] FIG. 11 is a cross-sectional view of another support unit installed in a reaction tube. [Figure 8] FIG. 11 is a cross-sectional view of another support unit installed in a reaction tube. [Figure 9] FIG. [Figure 10] FIG. 10 is a perspective view of the catalyst carrier of FIG. [Figure 11] FIG. 11 is a cross-sectional view of the catalyst carrier of FIGS. 9 and 10. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0093] In the following, aspects and embodiments of the present disclosure are described by way of example only with reference to a vertically oriented tubular reactor having a plurality of vertical reaction tubes extending between an upper tube sheet and a lower tube sheet, however, it will be understood that the present disclosure may also be applied to other configurations of tubular reactors that may employ other orientations.

[0094] Additionally, any references to orientation herein, such as terms such as top, bottom, upper, lower, above, below, and the like, are used with respect to the orientation of the 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 part described as being oriented vertically may also be oriented horizontally in use.

[0095] 1 shows a typical layout of a tubular reactor 1 of the present disclosure. The tubular reactor 1 includes a housing 2. The interior of the housing may be divided into a head space 3, a heat exchange zone 4, and a foot 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 section 4. The lower tube sheet 7 separates the foot space 5 from the heat exchange zone 4.

[0096] 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 20 to 5000 reaction tubes 8. Each reaction tube 8 may have an inner diameter of, for example, 20 to 150 mm. In some embodiments, the inner diameter may be about 85 mm.

[0097] Each reactor tube 8 is intended to be filled or substantially filled with a stacked arrangement of catalyst supports 10. The head space 3 may provide access to the upper ends of the reactor tubes 8 to allow loading of the catalyst supports 10 into the reactor tubes 8. An access opening may be provided in the housing 2 to allow access to the head space 3. The access opening may be, for example, a manhole or other access panel that can be selectively opened and closed. The foot space 5 may provide access to the lower ends of the reactor tubes 8 to allow removal of the catalyst supports 10 from the reactor tubes 8.

[0098] According to the present disclosure, one or more support units 20 may be utilized in at least one reactor tube 8 to support and retain the catalyst support 10 within the bore of the reactor tube 8. Optionally, each of the reactor tubes 8 present in the tubular reactor 1 utilizes one or more support units 20 to support and retain the catalyst support 10 within each reactor tube 8.

[0099] In the following, the support unit 20 will be described in detail. It will be understood that a single tubular reactor 1 may use many such support units 20.

[0100] The support unit 20 can be installed inside the reaction tube 8. The support unit 20 can be completely contained within the reaction tube, i.e., no part of the support unit 20 can protrude from the reaction tube. Alternatively, a part of the support unit 20 can protrude from the reaction tube.

[0101] As will be further described below with reference to Figures 4 and 5, the support unit 20 includes at least one engagement portion 24 for engaging an inner surface of the reaction tube 8 to create a frictional engagement between the support unit 20 and the reaction tube 8.

[0102] The support unit 20 is installed by inserting the support unit 20 into a first end, preferably the upper end, of the reaction tube 8 to create a frictional engagement between at least one engagement portion 24 and the inner surface of the reaction tube 8. One or more catalyst supports 10 may then be inserted into the first end of the reaction tube 8 and the support unit 20 may be forced along the reaction tube 8 toward a second end, preferably the lower end, of the reaction tube 8 into its installed position.

[0103] The amount of frictional engagement is sufficient to support a static load of two or more catalyst supports 10 such that the support unit 20 holds the two or more catalyst supports 10 in place within the reactor tube 8. Optionally, the amount of frictional engagement can be sufficient to support a greater number of catalyst supports 10, for example, three or more, five or more, ten or more, twenty or more, or fifty or more catalyst supports.

[0104] The support units 20 may be installed at various positions within the reactor tube 8 to create various arrangements of stacks of catalyst supports 10 within the reactor tube 8. For example, the support units 20 support the catalyst supports 10 stacked above and / or below the support units 20. The catalyst supports 10 may form a stack that directly engages the upper or lower ends of the support units 20.

[0105] Schematic diagrams of two exemplary arrangements are shown in Figures 2 and 3. For simplicity, the figures show only a small number of catalyst supports 10. In reality, the reactor tube 8 will contain many more catalyst supports 10.

[0106] In a first arrangement shown in FIG. 2, the support unit 20 is configured to support a plurality of catalyst supports 10 stacked above the support unit 20 in a single stack. The catalyst supports 10 may form a stack of catalyst supports 10 directly engaged with the upper end of the support unit 20. Thus, in this example, each reactor tube 8 may only accommodate a single support unit 20. Thus, a complete stack of catalyst supports 10 may be stacked on one support unit 20. For example, 60, 70, 80 or more catalyst supports 10 may be supported on top of one support unit 20. The support unit 20 may be located at the height of the lower tube sheet 7 to ensure that the lowest catalyst support 10 in the bore is retained within the heat exchange zone 4.

[0107] In a second arrangement shown in FIG. 3, a plurality of support units 20a-20c are provided within the reactor tube 8 with a stack of catalyst supports 10 between them. For example, a first support unit 20a may be provided at the level of the lower tube plate 7 to ensure that the lowest catalyst supports 10 in the bore are retained within the heat exchange zone 4. A first subset of catalyst supports 10 may be supported on the first support unit 20a. A second support unit 20b may be provided above the first subset of catalyst supports 10, on which a second subset of catalyst supports 10 are supported. A third support unit 20c may be provided above the second subset of catalyst supports 10, and so on. It will be appreciated that the first support unit 20a may be provided in the position shown in FIG. 3 by first inserting the first support unit 20a into the top end of the reactor tube 8, and then pushing the first support unit 20a partway down the reactor tube 8 by inserting and pushing the first subset of catalyst supports 10 into the reactor tube. The insertion and pushing of the second support unit 20b and the second subset of catalyst supports 10, and then the third support unit 20c, into the reactor tube acts to successively push the first support unit 20a further down the reactor tube 8. It is important to note that during this process, the support units 20a-20c continuously support the catalyst supports 10 that have been inserted into the reactor tube 8 up to that point.

[0108] The support unit 20 may be inserted into the reactor tube 8 alone or together with one or more catalyst supports 10 .

[0109] Each subset of catalyst supports 10 may contain up to 5, 10, 15 or more catalyst supports 10. A reactor tube 8 may, for example, include 2 to 8 or more subsets of support units 20 and catalyst supports.

[0110] At least one end of the support unit 20 may be configured to engage one of the catalyst supports 10 to maintain alignment of the catalyst support 10 within the bore of the reactor tube 8. For example, the upper and / or lower ends of the support unit 20 may be shaped to mate with the lower and / or upper ends, respectively, of the catalyst support 10 to center the catalyst support 10 within the bore.

[0111] At least one engagement portion 24 may be adjustable to vary the magnitude of frictional engagement between the support unit 20 and the inner surface of the reaction tube 8. Preferably, at least one engagement portion 24 may be reversibly adjustable to selectively increase or decrease the frictional engagement between the support unit 20 and the inner surface of the reaction tube 8.

[0112] Adjustment of the at least one engagement portion 24 allows the support unit 20 to be adapted, e.g. calibrated, to the requirements of the individual reaction tube 8. An example would be calibrating the frictional engagement to the inner diameter or ovality of the reaction tube 8. This calibration step can be performed before or when the support unit 20 is first inserted into the reaction tube 8.

[0113] Additionally or alternatively, adjustment of the at least one engagement portion also allows the support unit 20 to have different levels of frictional engagement with the reaction tube 8 at different times throughout the operation of the tubular reactor 1. For example, the frictional engagement may be reduced to allow easier insertion or removal of the support unit 20 into / from the reaction tube 8, or may be increased to increase safety at the installation site when the tubular reactor 1 is in operation.

[0114] To facilitate this, the at least one engagement portion 24 may be adjusted when the support unit 20 is installed in its installation position within the reaction tube 8. The at least one engagement portion 24 may be adjusted from a position above and / or below the support unit 20. The at least one engagement portion 24 may be adjusted using an adjustment tool applied to the support unit 20 via the end of the reaction tube 8.

[0115] At least one engagement portion 24 may be configured to press against an inner surface of the reaction tube 8 .

[0116] The at least one engagement portion 24 may include one, two, three, four, five, six, or more engagement portions 24. It may include one or more pairs of engagement portions 24. Each pair may include opposing engagement portions 24 extending outwardly from opposite sides of the support unit 20. The support unit 20 may include two, four, six, or more pairs of engagement portions 24.

[0117] The support unit 20 may include an adjustment mechanism for adjusting the length, the angle of the protrusion, and / or the length of the protrusion of the at least one engagement portion 24, and / or for adjusting the force applied by the at least one engagement portion 24 against the inner surface of the reaction tube 8, and / or for adjusting the surface area of ​​engagement of the at least one engagement portion 24 against the inner surface of the reaction tube 8.

[0118] The at least one engagement portion 24 may include one or more arms, wings, flanges, rims, protrusions, or skirts that protrude from the body of the support unit 20.

[0119] The support unit 20 may include an elastic body for pressing one or more arms, wings, flanges, rims, or skirts against the inner surface of the reaction tube 8. The elastic body may be a variable resistance body, for example one or more spring elements.

[0120] The support unit 20 may include a mechanical or electrical mechanism for moving the at least one engagement portion 24. The mechanical or electrical mechanism may be configured to convert a linear or rotational movement of the adjustment tool into a linear and / or radial and / or angular movement of the at least one engagement portion 24. The adjustment mechanism may include or consist of a mechanical mechanism.

[0121] Additionally or alternatively, the support unit 20 may include a hydraulic or pneumatic mechanism for moving the at least one engagement portion 24 .

[0122] Each engagement portion 24 may include one or more arms, wings, flanges, rims, protrusions, or skirts that protrude from the body of the support unit 20.

[0123] Examples of support units 20 having one or more engagement portions 24 are shown in Figures 4 and 5. The support unit 20 may include a body 21, which may be cylindrical or tubular. The upper end of the support unit 20 may include a socket 22 for receiving and centering the lower end of another catalyst support 10 located just above the stack. The support unit 20 preferably does not have its own fluid seal with the reaction tube 8. Rather, it is contemplated that reactants may preferably pass freely around and / or through the support unit 20 when placed within the bore of the reaction tube 8.

[0124] The support unit 20 of Fig. 4 includes a plurality of engagement portions 24 located at the lower end of the main body 21. The engagement portions 24 include a plurality of arms 25 extending outwardly of the main body 21. The distal ends of the arms are configured to engage with the inner surface of the reaction tube 8. In the illustrated example, four arms 25 are provided, optionally spaced at 90° intervals from each other.

[0125] The pair of arms 25 may be provided by a single elastic element. For example, a strip of elastic material may be attached at or near the center of the body 21 such that each end of the strip forms an arm 25.

[0126] The arm 25 may be formed from a resilient material having suitable strength, such as carbon steel, aluminum, stainless steel, or other such alloys.

[0127] In the illustrated example, the two strips are attached to the body 21 by bolts 26 that are fitted through openings located in the longitudinal centres of each strip. The bolts 26 are connected to nuts 27 secured to the lower end of the body 21.

[0128] The bolt 26 and nut 27 form an adjustment mechanism. Clockwise rotation of the bolt 26 relative to the nut 27 forces the centre of the strip upwards towards the body 21. This movement causes the arms 25 to flex outwards, forcing the distal ends to press more firmly against the inner surface of the reactor tube 8, increasing the amount of frictional engagement between the support unit 20 and the inner surface.

[0129] The bolts 26 may be rotated using an adjustment tool in the form of a spanner or socket wrench, which may be attached to an extension arm if necessary to allow access to the bolts 26 mounted within the bore of the reactor tube 8.

[0130] It will be appreciated that the resistance mechanism is reversibly adjustable, i.e., the bolt 26 can be rotated counterclockwise to draw the arm 25 inwardly and reduce the frictional engagement between the support unit 20 and the inner surface of the reaction tube 8.

[0131] Another example of a support unit 20 having one or more engagement portions 24 is shown in FIG. 6. The support unit 20 includes engagement portions 24 in the form of arms 30, 31 pivotally connected to the body 21 at a pivot point 34. Each arm 30, 31 may have a shoe 32 at its distal end for engaging against the inner surface of the reaction tube 8. In the illustrated example, two arms 30, 31 are provided, which extend in opposite directions to form a scissors-type arrangement. Each shoe 32, or each arm 30, 31, may be biased to engage the shoe 32 against the inner surface of the reaction tube 8. For example, as shown, the shoe 32 may be connected to the body 21 of the support unit 20 by a spring 33. The spring 33 may act to pull the arms 30, 31 upwards towards the body 21, causing the shoe 32 to engage against the inner surface due to the angle and length of the arms 30, 31. A release mechanism 35 may be provided to disengage (wholly or partially) the shoe 32 from the inner surface. For example, the release mechanism 35 may include a pull wire extending between the shoes 32 or between the distal ends of the arms 30, 31. A tool may be coupled to the pull wire and the wire may be pulled downward to release the support unit 20.

[0132] Another example of a support unit 20 with one or more engagement portions 24 is shown in FIG. 7. The support unit 20 is similar to that of FIG. 6 and includes an engagement portion 24 in the form of arms 30, 31, bearing shoes 32 pivotally connected to the body 21 at a pivot point 34. The differences are, firstly, that an additional pair or arms 36, 37 are provided which are pivotally connected to each other and to the two shoes 32 (or to the distal ends of the arms 30, 31). Thus, a scissors-type arrangement is again achieved. Secondly, no spring is provided to bias the movement of the arms 30, 31. Rather, a rotatable mechanism 39 is provided to adjust the mutual angle of the arms 36, 37 relative to the arms 30, 31. In the illustrated example, a bolt-nut device is coupled to the arms 30, 31 and the arms 36, 37. Manipulation of the bolts allows arms 36, 37 to be moved up and down, towards and away from arms 30, 31 respectively, which facilitates movement of shoe 32 into and out of engagement with the inner surface of reaction tube 8.

[0133] Another example of a support unit 20 having one or more engagement portions 24 is shown in FIG. 8. The support unit 20 is similar to that of FIG. 6 and includes engagement portions 24 in the form of arms 40, 41 and bearing shoes 42 pivotally connected to the body 21 at pivot points 44. The differences are, first, that this arrangement is located at the upper end of the body 21. An additional pair of arms 46, 47 is provided to provide standoffs for the pivot points 49 of the arms 40, 41. Second, each spring 43 extends from the shoe 42 of one of the arms 40, 41 to the opposite end of the other arm 40, 41. The release mechanism 45 functions in much the same way as the support unit of FIG. 6, except that it is accessed by a tool from above and the pull wire is pulled upward to release the support unit 20.

[0134] The support unit 20 of the present disclosure may be used to support catalyst supports 10 of various configurations. The catalyst support may generally comprise a container sized to have dimensions smaller than the interior dimensions of the reactor tube 8 in which it will be placed during use. Typically, a seal is provided that is sized to interact to some degree with the inner wall of the reactor tube 8 bore when the catalyst support is in place within the reactor tube 8. Parameters such as the length and diameter of the container may be selected to accommodate different reactions and configurations of the reactor tube 8.

[0135] Examples of general types of catalyst supports 10 that may be used with the support unit 20 in the tubular reactor 1 are shown, by way of example, in Figures 9, 10 and 11. However, it will be appreciated that the catalyst support 10 may take a variety of forms. For example, as with the embodiments described herein, the catalyst support 10 may take other general forms, including but not limited to those general forms disclosed in WO 2011 / 048361, WO 2012 / 136971 and WO 2016 / 050520, the contents of which are incorporated herein by reference in their entirety. Known catalyst supports, such as those described in WO 2011 / 048361, WO 2012 / 136971 and WO 2016 / 050520, are typically configured to be self-supporting within the bore of the reactor tube. This was made possible by configuring the catalyst support seal to create sufficient residual frictional engagement between the catalyst support and the inner surface of the reactor tube to maintain the position of the catalyst support within the reactor tube without external support.

[0136] In accordance with the present disclosure, the use of support unit 20 allows seals of the catalyst support, such as those described in WO 2011 / 048361, WO 2012 / 136971 and WO 2016 / 050520 or elsewhere, to be modified to provide a non-self-supporting catalyst support with reduced residual frictional engagement with the inner surface of the bore of the reactor tube 8. However, support unit 20 may also be used with self-supporting catalyst supports.

[0137] As shown in Figures 9, 10 and 11, the catalyst support 10 may include a container 100 for holding the catalyst during use. The container 100 may generally have a bottom surface 101 closing the lower end of the container 100 and a top surface 102 at the upper end of the container 100. A support 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 support outer wall 103. The support outer wall 103 may have an opening 105 located below the seal 104.

[0138] In at least some embodiments, the catalyst support 10 may more specifically comprise an annular vessel for holding the catalyst during use. The annular vessel may comprise a perforated inner vessel wall 111 defining an inner channel and a perforated outer vessel wall 113 that may be concentrically disposed around the perforated inner vessel wall 111. An annular top surface may close an upper end of the annular vessel, and an annular bottom surface may close a lower end of the annular vessel. The lower end of the inner channel may be closed by a channel end surface 116, except for one or more discharge openings that may be provided at the lower end of the inner channel. The channel end surface 116 may be formed integrally with or separately from the inner vessel wall 111.

[0139] 9, the catalyst support 10 may be formed from several individual components that may be assembled together by any suitable means including, for example, welding. In some embodiments, such components may include a perforated inner tube 120, a perforated middle tube 121, an outer tube 122, a bottom cap 123, an annular top ring 124, a top cap 125, and an annular seal ring 126.

[0140] The catalyst support 10 may be formed from any suitable material. Such materials are generally selected to withstand the operating conditions of the reactor. Typically, the catalyst support is fabricated from carbon steel, aluminum, stainless steel, other alloys, or any material capable of withstanding the reaction conditions.

[0141] The preferred thickness of the component is generally about 0.1 mm to about 1.0 mm, preferably about 0.3 mm to about 1.0 mm. In particular, the use of the support unit 20 may enable the use of a catalyst support 10 having a reduced crush strength, in which the thickness of the component is generally about 0.5 mm or less.

[0142] The perforated inner tube 120 may comprise a perforated inner vessel wall 111. The perforated intermediate tube 121 may comprise a perforated outer vessel wall 113. The outer tube 122 may comprise the carrier outer wall 103 and may define an opening 105. The bottom cap 123 may comprise a bottom surface 101 and / or an annular bottom surface. The bottom cap 123 may also extend across the perforated inner tube 120 to include the channel end surface 116. The annular top ring 124 and the top cap 125 may include an annular top surface 114 and may include at least a portion of the top surface 102. The annular seal ring 126 may include the seal 104.

[0143] The size of the holes in the perforated inner tube 120 and the perforated intermediate tube 121 are selected to allow uniform flow of reactants and products through the catalyst while maintaining the catalyst within the annular vessel. It will be appreciated that their size will therefore depend on the size of the catalyst particles used. In an alternative configuration, the perforations may be sized larger but with a filter mesh covering the perforations to ensure that the catalyst is maintained within the annular vessel.

[0144] It will be understood that the holes may be of any suitable configuration, and indeed where a wall or tube is described as being perforated, all that is required is that there be a means to allow reactants and products to pass through the wall or tube.

[0145] The bottom surface 101, e.g., bottom cap 123, may be shaped to engage with the top end of another catalyst support 10 and / or the top end of the support unit 20. For example, the bottom surface 101 may include an annular recess about the perforated inner tube 120. The top cap 125 may be shaped to engage with the annular recess of another catalyst support 10. For example, the top cap 125 may include an annular ring upstanding from the annular plug body 132. The annular ring may be shaped and sized to be received within the annular recess.

[0146] The bottom surface 101, such as the bottom cap 123 and / or the channel end surface 116, may include one or more drain holes. If one or more drain holes are present, they may be covered by a filter mesh.

[0147] The annular top ring 124 may be shaped and sized to engage 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 a central opening in the annular top ring 124. The engagement between the top cap 125 and the annular top ring 124 may function to sandwich the annular seal ring 126 and hold it in place.

[0148] The top cap 125 may include a central inlet 134 in an annular plug body 132 to allow liquids and gases to enter the upper end of the inner channel. The annular ring may include side openings 133 to allow liquids and gases to reach the central inlet 134.

[0149] The carrier outer wall 103 may be smooth or shaped. Suitable shapes include pleated, corrugated, and the like.

[0150] 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.

[0151] The seal 104 may be formed in any suitable manner. However, it is generally sufficiently compressible to accommodate the smallest diameter of the reactor tube 8. The seal 104 is generally a flexible sliding seal. In some embodiments, 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 flange 140 may be sized larger than the inner diameter of the reactor tube 8 so that it is deformed to fit inside and interact with the reactor tube 8 when the catalyst carrier 10 is inserted into the reactor tube 8. The deformation of the seal 104 may facilitate a liquid-tight and / or gas-tight seal between the top end of the catalyst carrier 10 and the inner surface of the reactor tube 8. The seal 104 may create a fluid-tight seal with the inner surface of the bore of the reactor tube 8. Alternatively, it may be configured to allow a small percentage of liquid and / or gas reactants to bypass the seal 104. Optionally, the seal 104 may not provide substantial physical support to maintain the axial position of the catalyst support 10 within the bore.

[0152] 11 , the deformable flange 140 includes an outer portion of the annular sealing ring 126. An inner portion 141 of the annular sealing ring 126 may define a clamping surface that is sandwiched and held between the top cap 125 and the annular top ring 124. The deformable flange 140 may be angled relative to the inner portion 141. The deformable flange 140 may be angled toward the top end of the catalyst support 10.

[0153] 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 upper surface 102, or at any suitable point on the carrier outer wall 103, provided that it is located above an opening 105 in the carrier outer wall 103.

[0154] The catalyst supports 10 may be configured to allow them to be attached together in a stacked arrangement. For example, adjacent catalyst supports 10 may be engaged together by engagement of one or more cooperating formations.

[0155] In some embodiments, each catalyst support 10 may have an upper cooperating formation provided on or toward the upper end of the vessel 100 and a lower cooperating formation provided on or toward the lower end of the vessel 100.

[0156] Adjacent catalyst supports 10 may be engaged together by engagement of a lower cooperating formation on one catalyst support 10 with an upper cooperating formation on the adjacent catalyst support 10 .

[0157] The upper and lower cooperating formations may be configured to be engaged and disengaged by relative rotational movement of the adjacent catalyst supports 10. For example, the upper and lower cooperating formations may take the form of a bayonet fitting.

[0158] In some embodiments, the upper cooperating formation is provided above the seal 104. For example, the upper cooperating formation may be provided on or as part of the annular ring and / or the carrier outer wall 103.

[0159] In use, the catalyst support 10 may be placed in the reactor tube 8 with the aid of the support unit 20 .

[0160] The first positioning as shown diagrammatically in FIG. 2 may be achieved, for example, by first inserting the support unit 20 into a first end, preferably the upper end, of the reaction tube 8 to create a frictional engagement between the engagement portion 24 of the support unit 20 and the inner surface of the reaction tube 8. The support unit 20 may be inserted manually or by machine. The insertion may be performed or assisted by the use of a ram. The ram may be a manual ram operated by hand or a powered ram operated, for example, by a power source or by electrical, hydraulic or pneumatic power.

[0161] The frictional engagement with the reaction tube 8 prevents the support unit 20 from moving uncontrolled downwards on the reaction tube 8. The magnitude of the frictional engagement can be adjusted before or when inserting the support unit 20 into the reaction tube 8 by adjusting the engagement portion 24.

[0162] Such adjustment of the engagement portion 24 can be used to calibrate the support unit 20 to characteristics of the reaction tube 8, such as one or more of the inner diameter of the reaction tube 8, the surface roughness of the reaction tube 8, and the ellipticity of the reaction tube 8.

[0163] In addition, this adjustment can be used to calibrate the support unit 20 to the number of catalyst supports 10 that will need to be supported in the reactor tube 8 during use. For example, if the number of "stacks" of catalyst supports 10 is 80, the engagement portion 24 can be adjusted to create sufficient friction to support at least 80W (plus any necessary safety margins and the weight of the support unit), where W is the weight of one catalyst support 10. This example assumes that the catalyst supports 10 are completely non-self-supporting, i.e., the support unit 20 supports the entire weight of the stack. Alternatively, the catalyst supports 10 may be partially self-supporting, with some friction achieved by the engagement of the seal 104 with the reactor tube 8. In this case, the frictional engagement of the support unit 20 needs to support less than 80W (but taking into account any necessary safety margins).

[0164] 2, the catalyst supports 10, either individually or in sets, may be inserted into a first end of the reactor tube 8 and the support units 20 gradually pushed along the reactor tube 8 toward the second end, preferably the lower end, of the reactor tube 8 into an installed position. As with the support units 20, the catalyst supports 10 may be inserted manually and / or with the aid of a tool such as a ram. Preferably, the same ram may be used for both functions.

[0165] The engagement portion 24 of the support unit 20 may also be adjusted while the support unit 20 is installed in its installed position within the reaction tube 8. For example, in the arrangement of Figure 2, a tool may be inserted from below the support unit 20 (i.e., through the bottom end of the reaction tube 8) to adjust the frictional engagement. This may be advantageous to increase the frictional engagement, for example, when the reaction tube 8 is being filled and the support unit 20 is being pushed down to the bottom end to "lock" the support unit 20 in place.

[0166] The second arrangement as shown diagrammatically in FIG. 3 can be achieved, for example, by first inserting the first support unit 20a into the first end, preferably the upper end, of the reactor tube 8 and creating a frictional engagement in the same manner as above. As above, the magnitude of the frictional engagement can be adjusted to calibrate the first support unit 20a to the characteristics of the reactor tube 8. Also, the engagement portion 24 can be adjusted to calibrate the first support unit 20a to the number of catalyst supports 10 that will need to be supported in the reactor tube 8 in use. In this case, the number of catalyst supports 10 supported is not the entire stack, but only those immediately above the first support unit 20a and immediately below the second support unit 20b, which in the illustrated example is two catalyst supports 10. Thus, the magnitude of the frictional engagement of the first support unit 20a only needs to be 2W (plus any necessary safety margin and the weight of the first support unit), where W is the weight of one catalyst support 10.

[0167] Next, two catalyst supports 10 can be inserted, either individually or as a pair, to push the first support unit 20 a part way along the reactor tube 8 .

[0168] The process is then repeated with a second support unit 20b, another pair of catalyst supports 10, and a third support unit 20c.

[0169] As each subset of support units 20a-20c and its associated catalyst supports 10 are inserted, the total force required to push the entire stack along the reactor tube 8 increases. However, the use of multiple support units 20 on a single reactor tube 8 can be used to reduce the comparative maximum insertion force required to fill the reactor tube 8, as compared to the use of a single support unit 20 as shown in FIG.

[0170] Once all the reaction tubes 8 are filled, the tubular reactor 1 can be put into operation. During operation, for example in downflow, the reactants flow downward through each reaction tube 8. The reactants are directed to flow through the catalyst support 10 and into contact with the catalyst contained therein. Because the support unit 20 does not have a fluid seal, the reactants can flow substantially unimpeded through and / or around the support unit 20. The support unit 20 preferably does not contain a catalyst.

[0171] In one example of this flow, using the exemplary catalyst support 10 shown in Figures 9 and 10, the reactants first contact the top surface 102 of the topmost catalyst support 10 in the stacked configuration. Seals 104 of the catalyst support 10 prevent the passage of the reactants around the sides of the catalyst support 10. The top surface 102 thus directs the reactants inwardly through side openings 133 to a central inlet 134 at the top of an inner channel in the inner vessel wall 111 defined by the perforated inner tube 120.

[0172] The reactants then enter the annular vessel 110 through a perforated inner tube 120 and then pass radially through the catalyst bed toward the outer vessel wall 113 defined by a perforated middle tube 121. During this passage, the reactants contact the catalyst and react to form products.

[0173] The unreacted reactants and products then exit the annular vessel 110 through the perforated intermediate tube 121. The carrier outer wall 103 defined by the outer tube 122 then directs the reactants and products upward between the inner surface of the carrier outer wall 103 and the perforated intermediate tube 121 until they reach the openings 105 in the carrier outer wall 103. The reactants and products are then directed through the openings 105 and flow downward between the outer surface of the carrier outer wall 103 and the inner surface of the reaction tube 8 where heat transfer occurs.

[0174] The unreacted reactants and products can then contact the upper surface 102 of the underlying catalyst support 10 in the stacking formation, and the aforementioned process can be repeated. This pattern can be repeated as the reactants and products pass through the stacking formation until they are collected from the lower end of the reactor tube 8.

[0175] A portion of the products, particularly liquid products, may be discharged from the inner channel through discharge holes provided in the channel end face 116 into the inner channel of the underlying catalyst support 10. Such products then continue to discharge the stacked formation of the catalyst support 10 and may be collected from the lower end of the reactor tube 8.

[0176] When the catalyst support 10 needs to be removed, for example for maintenance of the tubular reactor 1 or replacement of the catalyst support 10, the support units 20 can be removed from the reactor tube 8 by pushing them out together with the catalyst support 10. Optionally, the magnitude of resistance of the engagement portions 24 can be first reduced to allow easier removal. For example, in the arrangement of FIG. 2, a tool can be inserted through the lower end of the reactor tube 8 to operate the adjustment mechanism to reduce the frictional engagement, e.g., between the arm 25 and the inner surface of the reactor tube 8. The support units 20 and the catalyst support 10 can then be removed.

[0177] The catalyst supports 10 may be removed from the lower end of each reactor tube 8. If they are non-self-supporting, the catalyst supports 10 may slide freely out of the reactor tube 8 under the action of gravity. Alternatively, they may be pushed out, for example by inserting an additional element into the upper end of the reactor tube 8.

[0178] Further aspects and embodiments of the present disclosure are described in the following sections.

[0179] Terms: A1. A method for installing a catalyst carrier in a reaction tube of a tubular reactor, the tubular reactor being of a type having a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, and a heat exchange zone being provided between the upper tube plate and the lower tube plate; The method is: i) providing a plurality of catalyst supports; ii) providing a support unit including at least one engagement portion for engaging an inner surface of the reaction tube; iii) inserting a support unit into a first end, preferably an upper end, of the reaction tube to create a frictional engagement between at least one engagement portion of the support unit and an inner surface of the reaction tube; iv) inserting the catalyst support into the first end of the reactor tube and pushing the support unit along the reactor tube into an installed position towards the second end, preferably the lower end, of the reactor tube; The method, wherein a magnitude of frictional engagement of at least one engaging portion of the support unit enables the support unit to support a static load of two or more catalyst supports such that the two or more catalyst supports are held in place within the reactor tube when additional catalyst supports are not inserted into the first end of the reactor tube. A2. The method of claim A1, wherein the magnitude of frictional engagement is selected to enable the support unit to support a static load of 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports such that 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports are held in place within the reactor tube when no additional catalyst supports are inserted into the first end of the reactor tube. A3. The method according to paragraph A1 or A2, wherein the magnitude of the frictional engagement is selected to allow the support unit to slide along the reaction tube under a dynamic load imparted to the support unit through the catalyst support when the additional catalyst support is inserted into the first end of the reaction tube. A4. The method according to any one of paragraphs A1 to A3, wherein the magnitude of frictional engagement of each individual catalyst support with the reaction tube when inserted into the reaction tube is less than the weight of the catalyst support such that the catalyst support slides down the reaction tube under its own weight unless supported by an external object. A5. The method according to any one of paragraphs A1 to A4, wherein the support unit is pushed along the reaction tube into an installation position that may be adjacent to the second end of the reaction tube, preferably at the same height as the lower tube plate. A6. The method of any one of paragraphs A1-A5, wherein the method includes inserting a single support unit into the reactor tube and pushing the single support unit toward the second end of the reactor tube using a single stack of catalyst supports that are inserted individually or in sets into the first end of the reactor tube, and optionally, the single stack of catalyst supports extends from the single support unit to or adjacent the first end of the reactor tube. A7. The method is a) inserting a first support unit into a reactor tube and pushing the first support unit toward a second end of the reactor tube using a first stack of one or more catalyst supports that are inserted individually or in sets into a first end of the reactor tube; b) inserting a second support unit into the reaction tube and using a second stack of one or more catalyst supports inserted individually or in a set into the first end of the reaction tube, pushing the second support unit, the first stack of one or more catalyst supports, and the first support unit toward the second end of the reaction tube. The method according to any one of paragraphs A1 to A5. A8. The method of claim A7, further comprising inserting a third, fourth, or more support units by using a third, fourth, or more stacks of one or more catalyst supports, similar to step b). A9. The method according to any one of paragraphs A1 to A8, wherein the magnitude of frictional engagement between at least one engagement portion of the support unit and the inner surface of the reaction tube can be changed by adjusting at least one engagement portion of the support unit. A10. The method according to paragraph A9, wherein the adjustment of at least one engagement portion of the support unit is performed before or during insertion of the support into the reaction tube, and optionally the at least one engagement portion is adjusted to calibrate the magnitude of the frictional engagement to the characteristics of the reaction tube. A11. The method according to paragraph A9, wherein the adjustment of at least one engagement portion of the support unit is performed when the support unit is installed in its installation position in the reaction tube, and optionally the at least one engagement portion is adjusted to calibrate the magnitude of the frictional engagement to the characteristics of the reaction tube. A12. The method according to item A9 or A10, wherein the reaction tube characteristics are one or more of the inner diameter of the reaction tube, the surface roughness of the reaction tube, and the ellipticity of the reaction tube. A13. The method of any one of paragraphs A9-A12, wherein varying the magnitude of frictional engagement is performed from a position above and / or below the support unit. A14. The method according to any one of paragraphs A9 to A13, wherein varying the magnitude of frictional engagement is performed using an adjustment tool applied to the support unit via the first end and / or the second end of the reaction tube. A15. The method according to any one of paragraphs A1 to A14, further comprising a step of changing a magnitude of frictional engagement between the support unit and the inner surface of the reaction tube to lock the support unit to the reaction tube. A16. The method according to any one of paragraphs A1 to A15, wherein the or each support unit does not contain a catalytic material. A17. v) removing the or each support unit from the reaction tube; The method of any one of paragraphs A1-A16, further comprising removing the catalyst support from the reaction tube by: vi) sliding the catalyst support out of the reaction tube, preferably solely under the action of gravity. A18. The method according to paragraph A17, wherein the or each support unit is removed from one end of the reactor tube by pushing it out using one or more additional catalyst supports which are inserted into the other end of the reactor tube. A19. The method according to paragraph A17, wherein the or each support unit is removed from the reaction tube by reducing the magnitude of frictional engagement between at least one engagement portion of the support unit and the inner surface of the reaction tube, and allowing the support unit to slide out of the reaction tube, preferably solely under the action of gravity. B1. A support unit for reaction tubes of a tubular reactor, the tubular reactor being of the type comprising a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, a heat exchange zone being provided between the upper tube plate and the second tube plate; The support unit can be installed in the reaction tube together with a plurality of catalyst supports, the support unit includes at least one engagement portion for engaging an inner surface of the reaction tube to create a frictional engagement between the support unit and the reaction tube; The amount of frictional engagement is sufficient to support the static load of the two or more catalyst supports such that the support unit holds the two or more catalyst supports in place within the reactor tube, the support unit. B2. The support unit of paragraph B1, wherein the magnitude of frictional engagement is sufficient for the support unit to support a static load of 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports such that 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports are held in place within the reactor tube. B3. The support unit described in paragraph B1 or paragraph B2, wherein the support unit is configured to support a plurality of catalyst supports stacked above and / or below the support unit, optionally forming a stack of catalyst supports that directly engage the upper or lower ends of the support unit. B4. The support unit according to any one of paragraphs B1 to B3, wherein at least one engagement portion is adjustable to change the magnitude of frictional engagement between the support unit and the inner surface of the reaction tube. B5. The support unit according to any one of paragraphs B1 to B4, wherein at least one engagement portion is reversibly adjustable to selectively increase or decrease the frictional engagement between the support unit and the inner surface of the reaction tube. B6. The support unit according to any one of paragraphs B1 to B5, wherein at least one engagement portion is configured to be adjustable before or during insertion of the support unit into the reaction tube. B7. The support unit according to any one of paragraphs B1 to B5, wherein at least one engagement portion is configured to be adjustable when the support unit is installed at its installation position in the reaction tube. B8. A support unit according to any one of paragraphs B1 to B7, wherein at least one engagement portion is configured to be adjustable from a position above and / or below the support unit. B9. A support unit according to any one of paragraphs B1 to B8, wherein at least one engagement portion includes an adjustment mechanism configured to be operated by an adjustment tool applied to the support unit via an end of the reaction tube. B10. The support unit according to any one of paragraphs B1 to B9, wherein at least one engagement portion is configured to be pressed against the inner surface of the reaction tube. B11. The support unit according to any one of clauses B1 to B10, wherein at least one engagement portion includes an adjustment mechanism operable to adjust the length of at least one engagement portion, the angle of the protrusion, and / or the length of the protrusion, and / or to adjust the force applied by at least one engagement portion to the inner surface of the reaction tube, and / or to adjust the surface area of ​​engagement of at least one engagement portion to the inner surface of the reaction tube. B12. The support unit according to any one of paragraphs B1 to B11, wherein at least one engagement portion includes one or more arms, wings, flanges, rims, protrusions, or skirts that protrude from a body of the support unit. B13. The support unit according to paragraph B12, wherein the support unit includes an elastic body for pressing one or more arms, wings, flanges, rims, protrusions, or skirts against an inner surface of the bore of the reaction tube, optionally the elastic body being a variable resistance body, and optionally the elastic body including one or more spring elements. B14. A support unit described in any one of clauses B1 to B13, wherein the support unit includes a mechanical mechanism for moving at least one engagement portion, and optionally the mechanical mechanism is configured to convert a linear or rotational movement of the adjustment tool into a linear and / or radial and / or angular movement of the at least one engagement portion. B15. The support unit of any one of paragraphs B1-B14, wherein at least one end of the support unit is configured to engage one of the catalyst supports to maintain alignment of the catalyst support within the reactor tube. B16. A support unit according to any one of paragraphs B1 to B15, wherein the or each support unit does not contain a catalytic material. C1. A support unit for reaction tubes of a tubular reactor, the tubular reactor being of the type comprising a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, a heat exchange zone being provided between the upper tube plate and the second tube plate; The support unit can be installed in the reaction tube together with a plurality of catalyst supports, the support unit includes at least one engagement portion for engaging an inner surface of the reaction tube to create a frictional engagement between the support unit and the reaction tube; A support unit, wherein at least one engagement portion is adjustable to vary a magnitude of frictional engagement between the support unit and an inner surface of the reaction tube. C2. The support unit of paragraph C1, wherein at least one engagement portion is reversibly adjustable to selectively increase or decrease frictional engagement between the support unit and the inner surface of the reaction tube. C3. The support unit according to paragraph C1 or C2, wherein at least one engagement portion is configured to be pressed against the inner surface of the reaction tube. C4. The support unit according to any one of clauses C1 to C3, wherein at least one engagement portion includes an adjustment mechanism operable to adjust the length of at least one engagement portion, the angle of the protrusion, and / or the length of the protrusion, and / or to adjust the force applied by at least one engagement portion to the inner surface of the reaction tube, and / or to adjust the surface area of ​​engagement of at least one engagement portion to the inner surface of the reaction tube. C5. The support unit of any one of paragraphs C1 to C4, wherein at least one engagement portion includes one or more arms, wings, flanges, rims, protrusions, or skirts that protrude from the body of the support unit. C6. The support unit according to paragraph C5, wherein the support unit includes an elastic body for pressing one or more arms, wings, flanges, rims, protrusions, or skirts against an inner surface of the bore of the reaction tube, optionally the elastic body being a variable resistance body, and optionally the elastic body including one or more spring elements. C7. A support unit described in any one of clauses C1 to C6, wherein the support unit includes a mechanical mechanism for moving at least one engagement portion, and optionally the mechanical mechanism is configured to convert linear or rotational motion of the adjustment tool into linear and / or radial and / or angular motion of the at least one engagement portion. D1. A tubular reactor comprising a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, wherein a heat exchange zone is provided between the upper tube plate and the lower tube plate, and the or each reaction tube is provided with: i) one or more support units, each of which includes at least one engagement portion that frictionally engages with an inner surface of the reaction tube; iii) one or more stacks of catalyst supports supported in position by one or more support units. D2. The tubular reactor of paragraph D1, wherein each support unit supports two or more catalyst supports, optionally three or more, optionally five or more, optionally ten or more, optionally twenty or more, and optionally fifty or more catalyst supports. D3. The tubular reactor of paragraph D1 or paragraph D2, wherein the frictional engagement between each individual catalyst support and the reactor tube in which it is housed is less than the weight of that catalyst support. D4. The tubular reactor according to any one of paragraphs D1 to D3, wherein the or each reaction tube contains two or more support units. D5. The tubular reactor according to any one of paragraphs D1 to D4, wherein at least one engagement portion of one or more support units is adjusted to change the magnitude of frictional engagement with the inner surface of the reaction tube in which it is contained. D6. The tubular reactor according to paragraph D5, wherein at least one engagement portion of the one or more support units is adjusted to calibrate the magnitude of the frictional engagement to the characteristics of the reaction tube, such as the inner diameter of the reaction tube, the surface roughness of the reaction tube, and / or the ellipticity of the reaction tube. D7. The tubular reactor according to any one of paragraphs D1 to D6, wherein the or each support unit is as described in any one of paragraphs B1 to B16 or C1 to C7. E1. A kit of parts for installation in a tubular reactor of the type having a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, wherein a heat exchange zone is provided between the upper tube plate and the lower tube plate, the kit of parts including one or more support units and a plurality of catalyst supports; One or more support units are positionable within the reactor tube, each support unit including at least one engagement portion for engaging an inner surface of the reactor tube to create a frictional engagement between the support unit and the reactor tube sufficient to support the weight of two or more catalyst supports; The catalyst supports are positionable within the reactor tubes, each catalyst support including a seal for engaging an inner surface of the reactor tube to create a frictional engagement between the catalyst support and the reactor tube that is insufficient to support the weight of the catalyst support within the reactor tube. E2. The kit of parts described in paragraph E1, wherein at least one engagement portion of each support unit creates a frictional engagement between the support unit and the reactor tube large enough to support the weight of 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports. E3. The kit of parts according to paragraph E1 or paragraph E2, wherein the one or more support units do not contain the catalytic material, and the catalytic material is contained in a catalyst support. E4. A kit of parts according to any one of paragraphs E1 to E3, comprising 1 to 20 support units and 20 to 200 catalyst supports.

Claims

1. A method for installing a catalyst support in a reaction tube of a tubular reactor, the tubular reactor being of a type having a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, and a heat exchange zone being provided between the upper tube plate and the lower tube plate, The method comprises: i) providing a plurality of catalyst supports; ii) providing a support unit including at least one engagement portion for engaging with an inner surface of the reaction tube; iii) inserting the support unit into a first end, preferably an upper end, of the reaction tube to create a frictional engagement between the at least one engagement portion of the support unit and an inner surface of the reaction tube; iv) inserting a catalyst support into the first end of the reactor tube and pushing the support unit along the reactor tube towards the second end, preferably the lower end, of the reactor tube into an installed position; the magnitude of the frictional engagement of the at least one engaging portion of the support unit is such that the support unit can support a static load of two or more catalyst supports so as to hold the two or more catalyst supports in place within the reactor tube when no additional catalyst supports are inserted into the first end of the reactor tube.

2. 10. The method of claim 1, wherein the magnitude of the frictional engagement is selected to enable the support unit to support a static load of 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports such that 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports are held in place within the reactor tube when no additional catalyst supports are inserted into the first end of the reactor tube.

3. 10. The method of claim 1, wherein the magnitude of frictional engagement of each individual catalyst support with the reactor tube when inserted therein is less than the weight of that catalyst support such that the catalyst support will slide down the reactor tube under its own weight unless supported by an external object.

4. The method comprises: i) inserting a single support unit into the reactor tube and pushing the single support unit toward the second end of the reactor tube using a single stack of catalyst supports inserted individually or in a set into the first end of the reactor tube, optionally wherein the single stack of catalyst supports extends from the single support unit to or adjacent to the first end of the reactor tube; or ii) a) inserting a first support unit into the reactor tube and pushing the first support unit toward the second end of the reactor tube using a first stack of one or more catalyst supports inserted individually or in sets into the first end of the reactor tube; b) inserting a second support unit into the reaction tube and using a second stack of one or more catalyst supports inserted individually or in a set into the first end of the reaction tube, pushing the second support unit, the first stack of one or more catalyst supports, and the first support unit toward the second end of the reaction tube.

5. 10. The method of claim 1, wherein the magnitude of the frictional engagement between the at least one engaging portion of the support unit and the inner surface of the reaction tube can be varied by adjusting the at least one engaging portion of the support unit.

6. the adjustment of the at least one engagement portion of the support unit is performed before or during insertion of the support into the reaction tube, and optionally the at least one engagement portion is adjusted to calibrate the magnitude of the frictional engagement to the characteristics of the reaction tube; or or 6. The method of claim 5, wherein the adjustment of the at least one engagement portion of the support unit is performed when the support unit is installed in its installation position within the reaction tube, and optionally the at least one engagement portion is adjusted to calibrate the magnitude of the frictional engagement to characteristics of the reaction tube.

7. 6. The method of claim 5, wherein varying the magnitude of the frictional engagement is performed using an adjustment tool applied to the support unit via the first end and / or the second end of the reactor tube.

8. The method of claim 1 , wherein the or each support unit does not contain a catalytic material.

9. v) removing the or each support unit from the reaction tube; vi) sliding the catalyst support out of the reactor tube, preferably solely under the action of gravity.

10. the or each support unit is removed by pushing it out from one end of the reactor tube using one or more additional catalyst supports inserted into the other end of the reactor tube; or 10. The method according to claim 9, wherein the or each support unit is removed from the reaction tube by reducing the magnitude of the frictional engagement between the at least one engaging portion of the support unit and the inner surface of the reaction tube, and allowing the support unit to slide out of the reaction tube, preferably solely under the action of gravity.

11. A support unit for reaction tubes of a tubular reactor, the tubular reactor being of a type comprising a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, a heat exchange zone being provided between the upper tube plate and a second tube plate, the support unit can be installed in the reaction tube together with a plurality of catalyst supports, the support unit includes at least one engagement portion for engaging an inner surface of the reaction tube to create a frictional engagement between the support unit and the reaction tube; The support unit, wherein the magnitude of the frictional engagement is sufficient to support the static load of two or more catalyst supports such that the support unit holds the two or more catalyst supports in place within the reactor tube.

12. 12. The support unit of claim 11, wherein the magnitude of the frictional engagement is sufficient for the support unit to support a static load of 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports such that 3 or more, optionally 5 or more, optionally 10 or more, optionally 20 or more, optionally 50 or more catalyst supports are held in place within the reactor tube.

13. 12. The support unit of claim 11, wherein the at least one engagement portion is reversibly adjustable to selectively increase or decrease the frictional engagement between the support unit and the inner surface of the reaction tube.

14. 12. The support unit according to claim 11, wherein the at least one engaging portion comprises an adjustment mechanism operable to adjust a length of the at least one engaging portion, an angle of a protrusion, and / or a length of a protrusion, and / or to adjust a force applied by the at least one engaging portion against the inner surface of the reaction tube, and / or to adjust a surface area of ​​engagement of the at least one engaging portion with the inner surface of the reaction tube.

15. The support unit of claim 11 , wherein the at least one engagement portion comprises one or more arms, wings, flanges, rims, protrusions, or skirts that protrude from a body of the support unit.

16. 12. A support unit according to claim 11, wherein the or each support unit does not contain catalytic material.

17. A support unit for reaction tubes of a tubular reactor, the tubular reactor being of a type comprising a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, a heat exchange zone being provided between the upper tube plate and a second tube plate, the support unit can be installed in the reaction tube together with a plurality of catalyst supports, the support unit includes at least one engagement portion for engaging an inner surface of the reaction tube to create a frictional engagement between the support unit and the reaction tube; A support unit, wherein the at least one engagement portion is adjustable to vary the magnitude of the frictional engagement between the support unit and the inner surface of the reaction tube.

18. 18. The support unit of claim 17, wherein the at least one engagement portion is reversibly adjustable to selectively increase or decrease the frictional engagement between the support unit and the inner surface of the reaction tube.

19. A tubular reactor comprising a plurality of reaction tubes extending between an upper tube plate and a lower tube plate, wherein a heat exchange zone is provided between the upper tube plate and the lower tube plate, and the or each reaction tube has: i) one or more support units each including at least one engagement portion that frictionally engages with the inner surface of the reaction tube; and iii) one or more stacks of catalyst supports supported in position by said one or more support units.

20. 20. The tubular reactor of claim 19, wherein each support unit supports two or more catalyst supports, optionally three or more, optionally five or more, optionally ten or more, optionally twenty or more, optionally fifty or more catalyst supports.

21. 20. The tubular reactor of claim 19, wherein the frictional engagement between each individual catalyst support and the reactor tube in which it is housed is less than the weight of that catalyst support.

22. 20. The tubular reactor of claim 19, wherein the or each reactor tube contains two or more support units.

23. 20. The tubular reactor of claim 19, wherein the at least one engaging portion of the one or more support units is adjusted to vary the magnitude of the frictional engagement with the inner surface of the reactor tube in which it is housed.

24. 1. A kit of parts for installation within a tubular reactor of the type comprising a plurality of reaction tubes extending between an upper tube sheet and a lower tube sheet, wherein a heat exchange zone is provided between the upper tube sheet and the lower tube sheet, the kit of parts comprising one or more support units and a plurality of catalyst supports, the one or more support units are installable within the reactor tube, each support unit including at least one engaging portion for engaging an inner surface of the reactor tube to create a frictional engagement between the support unit and the reactor tube sufficient to support the weight of two or more of the catalyst supports; the catalyst supports are installable within the reactor tubes, each catalyst support including a seal for engaging the interior surface of the reactor tube to create a frictional engagement between the catalyst support and the reactor tube that is insufficient to support the weight of the catalyst support within the reactor tube.

25. 25. The kit of parts of claim 24, wherein the one or more support units do not contain a catalytic material, and the catalyst carrier contains a catalytic material.

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