Improvements in or relating to catalyst carriers for tubular reactors

Abstract

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

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to tracking catalyst carrier usage in tubular reactors. Specifically, the present disclosure relates to a method and a catalyst carrier tracking system for tracking catalyst carrier usage in tubular reactors. [Background technology]

[0002] A conventional so-called fixed-bed tubular reactor comprises a reactor shell, usually cylindrical, containing a number of tubes that are 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; 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 can be easily managed. In some cases, the thermal effects are small enough that large diameter tubes may be used. This has the advantage of having a large amount of catalyst within the tube.

[0004] However, for larger exothermic or endothermic reactions, there needs to be efficient heat transfer through the tube wall to the heat transfer medium so that conditions within the reactor can be controlled to maintain a stable operating temperature and avoid deleterious effects. For exothermic reactions, such effects can include side reactions, damage to the catalyst, such as by sintering catalytic active sites, and, in the worst case, thermal runaway. For endothermic reactions, deleterious effects can 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 achieved in the past by installing a larger number of smaller diameter tubes. In some reactions, size limitations mean that the tubes have internal diameters of only 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 larger exothermic or endothermic reactions, in which the catalyst is not loaded directly into the reactor tubes, but instead is contained in a number of catalyst carriers configured to be located within the reactor tubes.

[0007] WO 2011 / 048361, WO 2012 / 136971, and WO 2016 / 050520 describe some examples of catalyst carriers configured for use in tubular reactors. WO 2022 / 064214, WO 2022 / 064210, WO 2022 / 064211, and co-pending GB Patent Applications Nos. 2202226.3 and 2203700.6 disclose methods and apparatus for loading, retaining, and removing catalyst carriers in such tubular reactors.

[0008] Catalyst carriers can be useful in a wide range of processes. Suitable applications include processes and reactors for exothermic reactions, such as those for the production of methanol, ammonia, methanation, shift reactions, oxidation reactions such as the formation of maleic anhydride, and ethylene oxide reactions. One specific example in which catalyst carriers can be used is in processes and reactors for carrying out Fischer-Tropsch reactions. Catalyst carriers can also be used in endothermic reactions, such as pre-reforming and dehydrogenation.

[0009] Each reactor tube may contain multiple catalyst carriers, and a single tubular reactor may contain multiple reactor tubes. Operating a tubular reactor for use may require the installation of a large number of catalyst carriers. After a period of operation of the tubular reactor, some or all of the catalyst carriers in the reactor tubes may need to be discharged and replaced, for example, due to deactivation of the catalyst contained in the catalyst carrier. The discharged catalyst carriers may be sent to post-treatment to regenerate or recycle the catalyst contents. Summary of the Invention

[0010] In a first aspect of the present disclosure, a method for tracking catalyst carrier usage in tubular reactors is provided, each tubular reactor comprising a plurality of reactor tubes, each reactor tube configured to receive a plurality of catalyst carriers, the method comprising, for each of at least some of the catalyst carriers: - marking the catalyst carrier with a carrier identifier; - reading a carrier identifier when installing the catalyst carrier in the reaction tube; - accessing a database to retrieve and / or record installation data associated with the identified catalyst carrier.

[0011] In some examples, the carrier identifier may be read when or just before the catalyst carrier is installed in the reactor tube.

[0012] Tracking catalyst carrier usage has many advantages. First, when a catalyst carrier is installed in a tubular reactor, installation data associated with that catalyst carrier can be retrieved from a database, and this data can be used to inform decisions regarding where to install the catalyst carrier, e.g., which reactor tube and / or which location within the reactor should be selected. This can be particularly beneficial when the catalyst carriers installed in the tubular reactor are not all identical but differ in one or more respects. For example, the amount and / or quality of catalyst in the catalyst carrier may differ. Using the installation data can enable informed decisions regarding installation placement. In some examples, catalyst carriers containing less active catalysts may be placed in the hottest zone of the tubular reactor near the top of each reactor tube, while catalyst carriers containing more active catalysts may be placed lower in the reactor tube.

[0013] Second, when a catalyst carrier is installed in a tubular reactor, the installation data associated with that catalyst carrier can be retrieved from a database and used to verify that the catalyst carrier is approved for use in the tubular reactor. For example, the installation data can be used to check that the catalyst is of the correct type and has the correct maturity.

[0014] Third, by recording installation data when catalyst carriers are installed in the reactor tube, the installation location of each catalyst carrier within the tubular reactor can be effectively tracked. This allows for analysis of catalyst carrier performance, individually and / or in groups, after the tubular reactor is operated. For example, diagnostic tests can be performed on used catalyst carriers, and the installation data can then be used to correlate the diagnostic results with known installation locations within the tubular reactor. For example, such diagnostic analysis can identify spatial trends and patterns in performance within a single tubular reactor and may also allow for the identification of performance differences between tubular reactors.

[0015] Fourth, by recording installation data when catalyst carriers are installed in the reactor tube, post-discharge treatment of the catalyst carriers can be performed more efficiently. For example, by being able to identify the installation location and duration of use of individual catalyst carriers and / or groups of catalyst carriers, recycling, regeneration, and / or reuse of catalyst carriers can be differentiated based on the operating conditions to which the catalyst carriers were exposed.

[0016] In some instances, the installation data -characteristic data of the catalyst carrier; - Current usage data of catalyst carriers, and - catalyst carrier usage history data.

[0017] Current usage data refers to data relating to the current installation of the catalyst carrier, i.e., the current or currently installed location of the catalyst carrier. Historical usage data refers to one or more previous installations of the catalyst carrier, e.g., previous uses of the catalyst carrier in either the same or different reactor tubes and / or tubular reactors.

[0018] The characteristic data of the catalyst carrier may be, for example, - the date of manufacture or regeneration of the catalyst carrier, the size and / or shape of the catalyst carrier, - the catalyst type contained in the catalyst carrier, e.g. batch number, - the amount of catalyst contained in the catalyst carrier, and - whether the catalyst carrier is configured to receive a thermocouple.

[0019] Preferably, each time a catalyst carrier is placed in a reactor tube, at least the current usage data is recorded in the database, so that the database can contain an up-to-date record of the current location of the catalyst carrier.

[0020] Current usage data for catalyst carriers can be found, e.g. - identification of the tubular reactor in which the catalyst carrier is currently installed; - identification of the reactor tube in which the catalyst carrier is currently installed; the position, optionally sequential position, of the catalyst carrier within the reactor tube in which it is currently installed, and - may represent one or more of the date and / or time of installation of the catalyst carrier into the reactor tube.

[0021] The catalyst carrier usage history data may be, for example, -Identification of one or more tubular reactors in which the catalyst carrier was previously installed; - identification of one or more reactor tubes in which the catalyst carrier was previously installed; the position, optionally sequential position, of the catalyst carrier within one or more reactor tubes in which the catalyst carrier was previously installed, and - may represent one or more of the dates and / or times of one or more previous installations of catalyst carriers into one or more reactor tubes, typically including the dates and / or times of the corresponding discharges.

[0022] The usage history data may include data for some or all of the catalyst carrier's previous operating life. In some examples, the usage history data may cover the period of the catalyst carrier's operating life since the catalyst carrier's most recent regeneration or reconditioning. The usage history data may also represent the pressure drop within the tubular reactor in which the catalyst carrier was previously installed during the catalyst carrier's operating period.

[0023] In some examples, the method further includes selecting an installation location when installing the catalyst carrier within the tubular reactor using the installation data retrieved from the database.

[0024] In some examples, selecting an installation location may include selecting a reactor tube to receive the identified catalyst carrier and / or selecting an ordinal position of the catalyst carrier within the reactor tube.

[0025] The method further comprises: - discharging the catalyst carrier from the reactor tubes following a period of operation of the tubular reactor; - reading a carrier identifier; - recording in a database the exposure time of the catalyst carrier relative to the operation period of the tubular reactor; Optionally, recording the pressure drop in the reactor tube before and after the operating period in a database.

[0026] The exposure time can be, for example, the period during which the catalyst carrier was installed, or the period during which the tubular reactor was operating while the catalyst carrier was installed, or the period during which one or more reactants actually flowed through the catalyst carrier.

[0027] In some examples, the method includes identifying one or more installation locations of catalyst carriers within one or more tubular reactors during one or more previous installations using installation data in the database.

[0028] In some examples, the method includes using the installation data to calculate a cumulative exposure time of the catalyst carrier over one or more previous installations.

[0029] Preferably, the method further comprises using the installation location to determine a treatment regime for the catalyst carrier.

[0030] Preferably, the method is carried out on most, and most preferably all, of the catalyst carriers installed in the tubular reactor.

[0031] In some examples, each catalyst carrier is marked with a unique carrier identifier representing a single catalyst carrier. This allows for the most granular tracking and analysis of catalyst carriers. In some alternative examples, catalyst carriers may be marked with carrier identifiers representing groups of catalyst carriers, optionally groups of catalyst carriers sharing a common characteristic. For example, catalyst carriers configured for installation in a particular zone of a tubular reactor may be marked with a common carrier identifier. A tubular reactor zone may be a vertical zone of the tubular reactor, such as the top third, middle third, or bottom third. A tubular reactor zone may be a radial region of the tubular reactor (e.g., the outer annular third region, the middle annular region, or the central region).

[0032] In some examples, the carrier identifier may include one or more of a serial number, a one-dimensional code such as a barcode, a two-dimensional code such as a QR code, a color code, a pictogram, a pattern code, a radio frequency code such as an RFID tag, and an etched or embossed pattern.

[0033] In some examples, the carrier identifier is visually readable by the human eye, but in preferred examples, the method further includes scanning the carrier identifier using a reader, which may include, for example, a barcode reader, a camera, or an RFID reader.

[0034] In some examples, the reader may comprise part of an installation tool for installing the catalyst carrier into the reactor tube. The reader may be configured to scan the catalyst carrier simultaneously as it is installed into the reactor tube.

[0035] In some other examples, the reader may include a handheld reader. For example, the reader may be part of a portable computing unit, such as a mobile phone, tablet computer, PDA, or laptop computer. The reader may allow the carrier identifier to be identified by a user positioned within the headspace of the tubular reactor, i.e., at the location for installing the catalyst carrier.

[0036] In some examples, the method may further include marking each of at least some of the reactor tubes with a tube identifier and reading the tube identifier when installing the catalyst carrier into the reactor tube.

[0037] In some examples, accessing the database may occur at or near the location of the tubular reactor, for example, the database may be hosted on a portable computing unit, such as a cell phone, tablet computer, PDA, or laptop computer, present in the tubular reactor, e.g., within the headspace during installation.

[0038] In other examples, accessing the database may involve communicating with a remote resource that is spatially separated from the tubular reactor. For example, the database may be hosted on a virtual or physical server located at another location. Access to the database may be by a suitable network connection, for example, via a wired or wireless network. Public data networks may be utilized for communication.

[0039] The database may be a manual, paper-based database. However, for reasons of operational efficiency, it is preferred that the database is a computerized database. The database may be operatively linked to a database user interface configured to enable input of data and queries into the database, and retrieval of results and data from the database.

[0040] In a second aspect of the present disclosure, a catalyst carrier tracking system is provided, the catalyst carrier tracking system comprising: a plurality of catalyst carriers, each of which is marked with a carrier identifier; one or more readers for reading carrier identifiers; a database containing installation data relating to a plurality of catalyst carriers.

[0041] The installation data is -characteristic data of the catalyst carrier; - Current usage data of catalyst carriers, and - catalyst carrier usage history data.

[0042] The characteristic data of the catalyst carrier are - the date of manufacture or regeneration of the catalyst carrier, the size and / or shape of the catalyst carrier, - the catalyst type contained in the catalyst carrier, e.g. batch number, - the amount of catalyst contained in the catalyst carrier, and - whether the catalyst carrier is configured to receive a thermocouple.

[0043] Current usage data for catalyst carriers is - identification of the tubular reactor in which the catalyst carrier is currently installed or will be installed, - identification of the reactor tube in which the catalyst carrier is currently installed or will be installed; the position, optionally sequential position, of the catalyst carrier within the reactor tube where it is currently installed or will be installed, and - may represent one or more of the date and / or time of installation of the catalyst carrier in the reactor tube.

[0044] The catalyst carrier usage history data is -Identification of one or more tubular reactors in which the catalyst carrier was previously installed; - identification of one or more reactor tubes in which the catalyst carrier was previously installed; the position, optionally sequential position, of the catalyst carrier within one or more reactor tubes in which the catalyst carrier was previously installed, and - may represent one or more of the dates and / or times of one or more previous installations of catalyst carriers into one or more reactor tubes, typically including the dates and / or times of the corresponding discharges.

[0045] The usage history data may also represent the pressure drop within the tubular reactor in which the catalyst carrier was previously installed during the operation of the catalyst carrier.

[0046] The catalyst carriers of the present disclosure may be filled or partially filled with any catalyst suitable for the intended reaction. For example, a Fischer-Tropsch catalyst may be used for the Fischer-Tropsch reaction. Cobalt-containing Fischer-Tropsch catalysts are preferred. 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.

[0047] The catalyst carriers of the present disclosure can be formed from any suitable material. Such materials are generally selected to withstand the operating conditions of the tubular reactor. The catalyst carriers can be made from carbon steel, aluminum, stainless steel, other alloys, or any material that can withstand the reaction conditions. [Brief explanation of the drawings]

[0048] 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 side view of a tubular reactor. [Figure 2] FIG. 2 is a schematic diagram of the upper part of the tubular reactor of FIG. 1. [Figure 3]1 is a schematic diagram of a catalyst carrier tracking system according to the present disclosure; [Figure 4] FIG. 1 is a flow diagram of a method according to the present disclosure. [Figure 5] FIG. 2 is a perspective view of a catalyst carrier for use in the tubular reactor of FIG. 1. [Figure 6] FIG. 6 is a cross-sectional view of the catalyst carrier of FIG. 5. [Figure 7] FIG. 6 is an exploded perspective view of the catalyst carrier of FIG. 5. DETAILED DESCRIPTION OF THE INVENTION

[0049] In the following, aspects and embodiments of the present disclosure will be described, by way of example only, with reference to a vertically oriented tubular reactor having a plurality of vertical reactor tubes extending between an upper tube sheet and a lower tube sheet, although it will be understood that the present disclosure may also be applied to other configurations of tubular reactors that may employ other orientations.

[0050] 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 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 vertically oriented may also be oriented horizontally.

[0051] 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 footer 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 footer space 5 from the heat exchange zone 4.

[0052] A plurality of reaction tubes 8 extend between the upper tube sheet 6 and the lower tube sheet 7. A large number of reaction tubes 8 may be provided, for example, 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.

[0053] Each reactor tube 8 is intended to be filled or substantially filled with a stacked arrangement of catalyst carriers 10. In particular, it is generally desirable for the catalyst carriers 10 to cover all or substantially all of the length of the reactor tubes 8 between the upper tube sheet 6 and the lower tube sheet 7, i.e., to cover all or substantially all of the length of the heat exchange zone 4.

[0054] The head space 3 may provide access to the upper ends of the reactor tubes 8 to allow loading of catalyst carriers 10 into the reactor tubes 8. An access opening 11 may be provided in the housing 2 to allow access to the head space 3. The access opening 11 may be, for example, a manhole or other access panel that can be selectively opened and closed.

[0055] The footer space 5 may provide access to the lower end of the reactor tube 8 to allow removal of the catalyst carrier 10 from the reactor tube 8 .

[0056] 2 shows an example of an installation tool 20 that can be used to install the catalyst carrier 10 in the reactor tube 8. The installation tool 20 can include an installation frame, a hydraulic ram attached to the installation frame, and one or more anchors for securing the installation frame to the upper tube sheet 6 of the tubular reactor 1. The anchors function to releasably engage the installation frame, and thus the installation tool 20, with the tubular reactor 1. The installation tool can form part of an installation system that additionally includes a power source. The power source can be located outside the tubular reactor 1 and configured to move the movable ram of the installation tool 20.

[0057] According to the present disclosure, a catalyst carrier tracking system and a method for tracking the use of catalyst carriers 10 in a tubular reactor 1 are provided. Generally, as shown in Fig. 3, the catalyst carrier tracking system includes a plurality of catalyst carriers 10, each marked with a carrier identifier 31, one or more readers 40 for reading the carrier identifiers 31, and a database 41 containing installation data associated with the plurality of catalyst carriers 10. As shown in Fig. 4, the method includes, in a first step S1, marking the catalyst carrier 10 with the carrier identifier 31 for one or more catalyst carriers 10. Next, in step S2, the method includes reading the carrier identifier 31 when installing the catalyst carrier 10 in the reactor tube 8. Next, in step S3, the method includes accessing the database 41 to retrieve and / or record installation data associated with the identified catalyst carriers 10.

[0058] Preferably, the method is carried out on most, and most preferably all, of the catalyst carriers 10 installed in the tubular reactor 1 .

[0059] To better understand the present disclosure, examples of the general configuration of the catalyst carrier 10 will first be described with reference to Figures 5-7. However, it will be understood that the catalyst carrier 10 can take a variety of forms. For example, as with the examples described herein, the catalyst carrier 10 may take other general configurations, including, but not limited to, those disclosed in International Publication Nos. 2011 / 048361, 2012 / 136971, and 2016 / 050520, the contents of which are incorporated herein by reference in their entireties.

[0060] Each catalyst carrier 10 may generally comprise a container sized to have dimensions smaller than the interior dimensions of the reactor tube 8 within which it will be placed during use. Typically, a seal is provided that is sized to interact with the interior wall of the reactor tube 8 when the catalyst carrier 10 is in place within the reactor tube 8. Parameters such as the length and diameter of the carrier may be selected to accommodate different reactions and configurations of the reactor tube 8.

[0061] 5-7, the container 100 may generally have a bottom surface 101 that closes the lower end of the container 100 and a top surface 102 at the upper end of the container 100. An outer carrier 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 outer carrier wall 103. The outer carrier wall 103 may have an opening 105 located below the seal 104.

[0062] As shown in FIG. 6 , the catalyst carrier 10 may more specifically comprise an annular vessel 110 for holding the catalyst during use. The annular vessel 110 may comprise a perforated inner vessel wall 111 defining an interior channel 112 and a perforated outer vessel wall 113 that may be concentrically disposed around the perforated inner vessel wall 111. An annular top surface 114 may close the upper end of the annular vessel 110, and an annular bottom surface 115 may close the lower end of the annular vessel 110. The lower end of the interior channel 112 may be closed by a channel end surface 116, except for one or more discharge openings (not shown) that may be provided at the lower end of the interior channel 112. The channel end surface 116 may be formed integrally with or separate from the inner vessel wall 111.

[0063] 7, the catalyst carrier 10 may be formed from several individual components that may be assembled together by any suitable means, such as, for example, welding. In some embodiments, such components may include a perforated inner tube 120, a perforated intermediate tube 121, an outer tube 122, a bottom cap 123, an annular top ring 124, a top cap 125, and an annular seal ring 126.

[0064] The catalyst carrier 10 may be formed from any suitable material. Such materials are generally selected to withstand the operating conditions of the reactor. Typically, the catalyst carrier is fabricated from carbon steel, aluminum, stainless steel, other alloys, or any material capable of withstanding the reaction conditions.

[0065] Suitable thicknesses of the components are on the order of about 0.1 mm to about 1.0 mm, preferably on the order of about 0.3 mm to about 1.0 mm.

[0066] 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 the opening 105. The bottom cap 123 may comprise the bottom surface 101 and / or the annular bottom surface 115. The bottom cap 123 may also extend across the perforated inner tube 120 to include the channel end face 116. The annular top ring 124 and the top cap 125 may include the 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.

[0067] 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 110. It will be appreciated that their size will therefore depend on the size of the catalyst particles used. In an alternative configuration, the holes may be larger but sized with a filter mesh covering the holes to ensure that the catalyst is maintained within the annular vessel 110.

[0068] 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.

[0069] The bottom surface 101, e.g., bottom cap 123, may be shaped to mate with the top end of another catalyst carrier 10. For example, the bottom surface 101 may include an annular recess 130 around the perforated inner tube 120. The top cap 125 may be shaped to mate with the annular recess 130 of another catalyst carrier 10. For example, the top cap 125 may include an annular ring 131 upstanding from an annular plug body 132. The annular ring 131 may be shaped and sized to be received within the annular recess 130.

[0070] The bottom surface 101, for example 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.

[0071] 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 the central opening of 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.

[0072] The top cap 125 may include a central inlet 134 in the annular plug body 132 to allow liquids and gases to enter the upper end of the interior channel 112. The annular ring 131 may include side openings 133 to allow liquids and gases to reach the central inlet 134.

[0073] The carrier outer wall 103 may be smooth or shaped. Suitable shapes include pleated, corrugated, and the like.

[0074] 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.

[0075] The carrier outer wall 103 may continue above the seal 104. Thus, the seal 104 may be located at the top of the catalyst support 10, optionally as part of the upper surface 102, or at a suitable point on the carrier outer wall 103, provided that it is located above an opening 105 in the carrier outer wall 103.

[0076] The seal 104 may be sufficiently compressible to accommodate the smallest diameter of the reactor tube 8. The seal 104 may generally be a flexible sliding seal. The seal 104 may engage with the inner surface of the reactor tube 8 so that liquids and gases passing along the reactor tube 8 are preferentially directed to flow through the interior of the catalyst carrier 10. The seal 104 may be configured, for example, to form a sliding seal that slides against the inner surface of the reactor tube 8.

[0077] In the example shown in FIGS. 5-7 , 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 deforms to fit inside and interact with the reactor tube 8 when the catalyst carrier 10 is inserted into the reactor tube 8. The deformable flange 140 includes an outer portion of the annular seal ring 126. An inner portion 141 of the annular seal 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 inclined relative to the inner portion 141. The deformable flange 140 may be inclined toward the top end of the catalyst carrier 10.

[0078] As mentioned above, according to the present disclosure, the catalyst carrier 10 is marked with a carrier identifier 31. In Figures 5-7, the carrier identifier 31 is shown in the form of a one-dimensional barcode, by way of example only. In other examples, the carrier identifier 31 may include one or more of another form of one-dimensional code: a serial number, a two-dimensional code such as a QR code, a color code, a pictogram, a pattern code, a radio frequency code such as an RFID tag, and an etched or embossed pattern.

[0079] The carrier identifier 31 may be located in any suitable location on the catalyst carrier 10. Preferably, the carrier identifier 31 is located on the carrier outer wall 103 so that the carrier identifier 31 can be easily read even in situations where the catalyst carrier 10 is joined end-to-end with other catalyst carriers 10.

[0080] The reader 40 may be a machine reader. Non-limiting examples of suitable readers include a barcode reader, a camera, and an RFID reader. The reader 40 may be a dedicated device or may be integrated as part of a device having other functions. In some examples, the reader 40 may include a handheld reader. For example, the reader 40 may include part of a portable computing unit, such as a mobile phone, a tablet computer, a PDA, or a laptop computer. In some examples, the reader 40 may comprise part of an installation tool 20 that may be used to install the catalyst carrier 10 in the reactor tube 8. The reader 40 may be configured to scan the carrier identifier 31 of the catalyst carrier 10 simultaneously with installing the catalyst carrier 10 in the reactor tube 8.

[0081] 3 , the method may further include marking each of at least some of the reactor tubes 8 with a tube identifier 32. The tube identifier 32 may be read when installing the catalyst carrier 10 into the reactor tubes 8 to identify the particular reactor tube 8 selected for installation and record it in a database 41. The tube identifier 32 may be located, for example, on the upper tube sheet of the tubular reactor 1 adjacent the top opening of each reactor tube 8. The tube identifier 32 may be read by the same reader 40 used to read the carrier identifier 31 or a different reader. For example, the installation tool 20 may include a first reader that may be oriented sideways to scan the carrier identifier 31 and a second reader that may be oriented downward to read the tube identifier 32.

[0082] The database 41 may preferably be a computerized database. The database 41 may be operatively linked to a database user interface configured to allow input of data and queries into the database 41 and retrieval of results and data from the database 41. The database 41 may be hosted on a portable device, such as a portable computing unit, e.g., a mobile phone, tablet computer, PDA, or laptop computer, which may also be the same portable device incorporating the reader 40. Alternatively, the database 41 may be hosted remotely, e.g., on a physical or virtual server located spatially separate from the tubular reactor 1. The database 41 or database functions may be distributed across multiple devices, e.g., some data hosting, data analysis, and / or data presentation may be performed on a portable device local to the tubular reactor 1 and some on a remote resource, e.g., a remote server.

[0083] If all or part of the database 41 is located remotely, accessing the database 41 may involve communicating via a suitable network connection 42, for example via a wired or wireless network. Public data networks may be used for communication.

[0084] The catalyst carrier 10 may be installed within the reactor tubes 8 of the tubular reactor 1 during use (during operation or refilling of the tubular reactor 1) or at other times as needed. In accordance with the present disclosure, catalyst carrier tracking systems and methods may be used to obtain, collate, and utilize installation data for the catalyst carrier 10. The installation data for the catalyst carrier 10 may be obtained and / or updated on the database 41 each time its carrier identifier 31 is read by the reader 40.

[0085] The carrier identifier 31 may be read at various times during the life cycle of the catalyst carrier 10. For example, the carrier identifier 31 may be read when it is initially manufactured, when it is installed in the reactor tube 8, when it is discharged from the reactor tube 8, when it is received at a new physical location, when it is subjected to a treatment regime (e.g., regeneration, refilling, repair, or recycling), and / or when it is taken out of service.

[0086] Each catalyst carrier 10 may be marked with a unique carrier identifier 31 that represents a single catalyst carrier 10. This allows for the most granular tracking and analysis of the catalyst carrier 10. Alternatively, the catalyst carrier 10 may be marked with a carrier identifier 31 that represents a group of catalyst carriers 10, optionally a group of catalyst carriers 10 that share a common characteristic, for example, having the same type or amount of catalyst, or the same length, or the same date of manufacture, etc.

[0087] The installation data is -characteristic data of the catalyst carrier 10, - current usage data of the catalyst carrier 10, and - may include one or more of the following: historical usage data of the catalyst carrier 10;

[0088] The characteristic data of the catalyst carrier 10 may be, for example, the date of manufacture or regeneration of the catalyst carrier 10; the size and / or shape of the catalyst carrier 10; the catalyst type contained in the catalyst carrier 10, e.g., the batch number, the amount of catalyst contained in the catalyst carrier 10, and - Whether the catalyst carrier 10 is configured to receive a thermocouple or not.

[0089] The current usage data may be data related to the current installation of the catalyst carrier 10, i.e., the current or currently installed location of the catalyst carrier 10. In some examples, the current usage data may be obtained at the time the catalyst carrier 10 is installed in its current reactor tube 8 and recorded in the database 41. The carrier identifier 31 may be read by the operator performing the installation at the time and location of installation.

[0090] In some examples, the current usage data in the database 41 may be considered to remain "current" until the next time the carrier identifier 31 of that catalyst carrier 10 is read. Preferably, at least the current usage data is recorded in the database 41 each time the catalyst carrier 10 is installed in the reactor tube 8, moved from one position to another, or otherwise undergoes a significant change. In this manner, the database 41 may contain an up-to-date record of the current location and / or status of the catalyst carrier 10.

[0091] The current usage status data of the catalyst carrier 10 may be, for example, - the identification of the tubular reactor 1 in which the catalyst carrier 10 is currently installed, - the identification of the reactor tube 8 in which the catalyst carrier 10 is currently installed, the position, optionally sequential position, of the catalyst carrier 10 within the reactor tube 8 in which it is currently installed, and - may represent one or more of the date and / or time of installation of the catalyst carrier 10 into the reactor tube 8.

[0092] The database 41 can utilize data read from the tube identifier 32 (if present) to determine the identity of the reactor tube 8 in which the catalyst carrier 10 is currently installed. Alternatively, the identity of the reactor tube 8 can be recorded in the database 41 manually by an operator, for example, by manual data entry using a portable device. Similarly, the identity of the tubular reactor 1 can be recorded in the database 41 manually by an operator, for example, by manual data entry using a portable device.

[0093] The "three-dimensional" position of each catalyst carrier 10 within the tubular reactor 1 can be identified and tracked, for example, by recording the identification information of the tubular reactor 1, the identification information of the reaction tube 8, and the ordinal position of the catalyst carrier 10 within the reaction tube 8.

[0094] The ordinal position may be recorded as the position of the catalyst carrier 10 within the stack of catalyst carriers 10, counting from either the top or bottom of the reactor tube 8. For example, the ordinal position may be recorded as the order number of placement on top of the reactor tube 8, such that the "first" catalyst carrier 10 is located at the bottom of the reactor tube, followed by the "second," "third," "fourth," and "nth" catalyst carriers 10 stacked on top, with the "nth" catalyst carrier located at the top of the reactor tube 8.

[0095] The database 41 can utilize the characteristic data of the catalyst carrier 10 (eg, the recorded length of the catalyst carrier 10) in conjunction with the ordinal position of the catalyst carrier 10 to derive the installation height of the catalyst carrier 10.

[0096] The usage history data may refer to one or more previous installations of the catalyst carrier 10, for example, previous uses of the catalyst carrier 10 in either the same or different reactor tubes 8 and / or tubular reactors 1. The usage history data for the catalyst carrier 10 may include, for example, - the identification of one or more tubular reactors 1 in which the catalyst carrier 10 was previously installed, - the identification of one or more reactor tubes 8 in which the catalyst carrier 10 was previously installed, the position, optionally sequential position, of the catalyst carrier 10 within one or more reactor tubes 8 in which it was previously installed, and - may represent one or more of the dates and / or times of one or more previous installations of the catalyst carrier 10 into one or more reactor tubes 8, typically the dates and / or times of the corresponding discharges.

[0097] The usage history data may also represent the pressure drop within the tubular reactor in which the catalyst carrier was previously installed during the operation of the catalyst carrier.

[0098] The installation data can be used to inform decisions by an operator when installing the catalyst carrier 10 within the tubular reactor 1. For example, installation data retrieved from a database can be used to select an installation location. For example, the installation data can indicate that the catalyst carrier 10 would be best located in a particular zone of the tubular reactor, e.g., the bottom third, middle third, or top third. The operator can then instruct the operator to install the catalyst carrier 10 accordingly (this instruction can occur on-site or off-site prior to delivery of the catalyst carrier to the tubular reactor 1). In another example, the installation data can indicate that the catalyst carrier 10 is specifically configured to accommodate the passage of a thermocouple. This allows the operator to ensure that only properly configured catalyst carriers 10 are installed for reactor tubes 8 that accept thermocouples.

[0099] The installation data can also be used to analyze the performance of the catalyst carrier 10. By allowing tracking and identification of groups of catalyst carriers 10 or individual catalyst carriers 10, the opportunities for post-operation analysis are greatly increased.

[0100] For example, the installation data may be used to track the installation location of the catalyst carriers 10 within the tubular reactor 1 during one or more previous installations.

[0101] For example, the installation data may be used to calculate the exposure time and / or cumulative exposure time of the catalyst carrier over one or more previous installations.

[0102] The installation data may also be used to determine the treatment regime of the catalyst carrier 10 after it has been discharged from the reactor tube 8. For example, this may be a determination that the catalyst carrier 10 can be immediately reused and reinstalled in the reactor tube 8. Alternatively, it may be a determination that the catalyst carrier 10 needs to be regenerated, recycled, or the like.

[0103] During operation, after the reaction tubes 8 are filled with catalyst carriers 10, the tubular reactor 1 is operated to pass one or more reactants through each reaction tube 8 from its inlet end to its outlet end. In the downward-flow tubular reactor 1 utilizing catalyst carriers 10 shown in Figures 5-7, the reactants flow downward through each reaction tube 8 and thus first contact the top surface 102 of the uppermost catalyst carrier 10. Seals 104 obstruct the passage of the reactants around the sides of the catalyst carrier 10. The top surface 102 thus directs the reactants inward through side openings 133 and into a central inlet 134 at the top end of an internal channel 112 in the inner vessel wall 111 defined by the perforated inner tube 120. The reactants then enter the annular vessel 110 through the perforated inner tube 120 and then radially pass through the catalyst bed toward the outer vessel wall 113 defined by the perforated intermediate tube 121. During this passage, the reactants contact the catalyst and react to form products. 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 reactor tube 8, where heat transfer occurs. The unreacted reactants and products can then contact the upper surface 102 of the underlying catalyst carrier 10 in the stacked formations, and the aforementioned process can be repeated. This pattern can be repeated as the reactants and products pass through the stacked formations until they are collected from the lower ends of the reactor tubes 8. A portion of the products, particularly liquid products, can be discharged from the inner channel 112 into the inner channel 112 of the underlying catalyst carrier 10 through discharge holes provided in the channel end face 116. Such products then continue to be discharged downward through the stacked formation of catalyst carriers 10 and can be collected from the lower end of the reaction tube 8.

Claims

1. A method for tracking the use of catalyst carriers in a tubular reactor, wherein each tubular reactor comprises a plurality of reaction tubes, each reaction tube configured to receive a plurality of catalyst carriers, and the method provides for each of at least a portion of the catalyst carriers. - A step of marking the catalyst carrier with a carrier identifier, - A step of reading the carrier identifier when the catalyst carrier is placed in the reaction tube, A method comprising the steps of accessing a database to retrieve and / or record installation data related to the identified catalyst carrier.

2. The installation data mentioned above is - Characteristic data of the catalyst carrier, - Current usage data of the catalyst carrier, and - The method according to claim 1, comprising one or more of the usage history data of the catalyst carrier.

3. The characteristic data of the catalyst carrier is - Manufacturing date or regeneration date of the catalyst carrier, - The size and / or shape of the catalyst carrier, - The catalyst type included in the catalyst carrier, - The amount of catalyst contained in the catalyst carrier, and The method according to claim 2, wherein one or more of the following are required: the catalyst carrier is configured to accept a thermocouple.

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

5. The current usage data of the catalyst carrier is - Identification information of the tubular reactor in which the catalyst carrier is currently installed, - Identification information of the reaction tube in which the catalyst carrier is currently installed, - The position of the catalyst carrier in the reaction tube where the catalyst carrier is currently installed, the arbitrarily selected sequential position, and - The method according to claim 2 or claim 3, which represents one or more of the date and / or time of the installation of the catalyst carrier into the reaction tube.

6. The usage history data of the catalyst carrier is - Identification information of one or more tubular reactors in which the catalyst carrier was previously installed, - Identification information of one or more reaction tubes in which the catalyst carrier was previously installed, - The position of the catalyst carrier in one or more reaction tubes where the catalyst carrier was previously installed, optionally in a sequential position, and - The method according to claim 2 or 3, which represents one or more of the dates and / or times of one or more previous installations of the catalyst carrier into one or more reaction tubes.

7. - The method according to claim 1 or 2, further comprising selecting the installation location using the installation data retrieved from the database when installing the catalyst carrier in a tubular reactor.

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

9. - Following the operating period of the tubular reactor, the catalyst carrier is discharged from the reaction tube, - Reading the aforementioned carrier identifier, The method according to claim 1 or claim 2, further comprising recording in the database the exposure time of the catalyst carrier related to the operating period of the tubular reactor.

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

11. The method according to claim 1 or 2, further comprising using the installation data in the database to identify one or more installation locations of the catalyst carriers in one or more tubular reactors during one or more previous installations.

12. The method according to claim 1 or 2, further comprising using the installation data to calculate the cumulative exposure time of the catalyst carrier over one or more previous installations.

13. The method according to claim 1 or 2, further comprising determining the treatment regime of the catalyst carrier using the installation position.

14. The method according to claim 1 or claim 2, wherein the method is carried out for most, preferably all, of the catalyst carriers installed in the tubular reactor.

15. The method according to claim 1 or 2, wherein each catalyst carrier is marked with a unique carrier identifier representing a single catalyst carrier.

16. The method according to claim 1 or claim 2, wherein the catalyst carrier is marked with a carrier identifier representing a group of catalyst carriers, or a group of catalyst carriers that optionally share common properties.

17. The method according to claim 1 or 2, wherein the carrier identifier includes one or more of the following: a serial number, a one-dimensional code, such as a barcode, a two-dimensional code, such as a QR code, a color code, a pictogram, a pattern code, a radio frequency code, such as an RFID tag, and an etched or embossed pattern.

18. The method according to claim 1 or 2, further comprising scanning the carrier identifier using a reader, wherein the reader includes a barcode reader, a camera, or an RFID reader.

19. The method according to claim 18, wherein the leader comprises part of an installation tool for installing the catalyst carrier inside the reaction tube.

20. The method according to claim 18, wherein the reader includes a handheld reader, and optionally the reader includes part of a portable computing unit, such as a mobile phone, tablet computer, PDA, or laptop computer.

21. The method according to claim 1 or claim 2, further comprising marking each of at least a portion of the reaction tubes with a tube identifier, and reading the tube identifier when the catalyst carrier is placed inside the reaction tube.

22. A catalyst carrier tracking system, - Multiple catalyst carriers, each marked with a carrier identifier, - One or more readers for reading the carrier identifier, A catalyst carrier tracking system comprising: a database containing installation data related to the aforementioned plurality of catalyst carriers.

23. The installation data mentioned above is - Characteristic data of the catalyst carrier, - Current usage data of the catalyst carrier, and - The catalyst carrier tracking system according to claim 22, comprising one or more of the catalyst carrier usage history data.

24. The characteristic data of the catalyst carrier is - Manufacturing date or regeneration date of the catalyst carrier, - The size and / or shape of the catalyst carrier, - The catalyst type included in the catalyst carrier, - The amount of catalyst contained in the catalyst carrier, and - The catalyst carrier tracking system according to claim 23, which represents one or more of the following: whether or not the catalyst carrier is configured to accept a thermocouple.

25. The current usage data of the catalyst carrier is - Identification information of the tubular reactor in which the catalyst carrier is currently installed or is currently installed. - Identification information of the reaction tube in which the catalyst carrier is currently installed or is currently installed. - The position of the catalyst carrier in the reaction tube where the catalyst carrier is currently installed or is installed, optionally in a sequential position, and - A catalyst carrier tracking system according to claim 23 or 24, which represents one or more of the date and / or time of the installation of the catalyst carrier into the reactor tube.

26. The usage history data of the catalyst carrier is - Identification information of one or more tubular reactors in which the catalyst carrier was previously installed, - Identification information of one or more reaction tubes in which the catalyst carrier was previously installed, - The position of the catalyst carrier in one or more reaction tubes where the catalyst carrier was previously installed, optionally in a sequential position, and - A catalyst carrier tracking system according to claim 23 or 24, which represents one or more dates and / or times of one or more previous installations of the catalyst carrier into one or more reaction tubes.

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