Method and apparatus for controlled ejection of components from a tube

Abstract

A conveyor (40), system, and method for controlled discharge of a stack of components from a tube, the conveyor (40) comprising: i) a frame (41) configured to be positioned proximate an outlet of the tube; and ii) a plurality of feeding elements (61) mounted to the frame (41). The feeding elements (61) are distributed around and along a feed path (80) extending through the frame (41) so as to contact components passing through the frame (41) along the feed path (80) in use. One or more of the feeding elements (61) comprise a tensioning mechanism for adjusting the level of friction between the one or more of the feeding elements (61) and components passing through the frame (41) along the feed path (80).

Description

[Technical Field]

[0001] The present disclosure relates to a method and apparatus for the controlled discharge of components from tubes, and in particular, for the controlled discharge of catalyst carriers from reactor tubes of 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 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 can be used. This has the advantage of having a large amount of catalyst within the tube.

[0004] However, for larger exothermic or endothermic reactions, efficient heat transfer through the tube walls to the heat transfer medium is necessary to allow for control of conditions within the reactor to maintain a stable operating temperature and avoid deleterious effects. For exothermic reactions, these effects may include side reactions, damage to the catalyst due to 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 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 tube, but instead is contained in a number of catalyst carriers configured to be located within the reactor tube.

[0007] WO 2011 / 048361, WO 2012 / 136971, and WO 2016 / 050520 describe several examples of catalyst carriers configured for use in 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 a process and reactor for carrying out the Fischer-Tropsch reaction. 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. Typically, each catalyst carrier includes a seal that engages the interior wall of the reactor tube. This seal may function to draw fluid through the interior of the catalyst carrier during use, and may also function to provide physical support to help maintain the vertical position of the catalyst carrier within the reactor tube.

[0010] From time to time, it may be necessary to evacuate the catalyst carrier from one or more of the reactor tubes. This may be for the purpose of, for example, tubular reactor maintenance or catalyst carrier replacement.

[0011] The present disclosure seeks to improve the discharge of components from the reactor tubes, as an example of improving the discharge of catalyst carriers from the tubes. Summary of the Invention

[0012] In a first aspect of the present disclosure, there is provided a conveyor for controlled discharge of a stack of components from a tube, comprising: i) a frame configured to be positioned proximate to the outlet of the tube; ii) a plurality of feed elements mounted to the frame, the feed elements being distributed around and along a feed path extending through the frame so as to contact components passing through the frame along the feed path in use; One or more of the feeding elements includes a tensioning mechanism for adjusting the level of friction between the one or more of the feeding elements and components passing through the frame along the feeding path.

[0013] Beneficially, the conveyor may assist in the controlled discharge of components. This has advantages both for the discharge of components from the tube outlet and, optionally, for the simultaneous insertion of components into the tube inlet. In particular, a feeding element having a tensioning mechanism may enable the controlled passage of components through the feeding path by providing controllable and adjustable frictional resistance to the component motion. The controlled passage of components through the feeding path may allow for control of the rate and timing of component discharge. Optionally, it may also allow for the simultaneous insertion of components into the tube inlet in a controlled manner. In particular, the conveyor may allow for the insertion of components into the tube inlet to be controlled by the action of discharging components from the tube outlet, rather than vice versa.

[0014] This can be particularly advantageous when the components are not self-supporting within the tube, i.e., when the components naturally slide down the tube toward the outlet under the action of gravity alone. Such non-self-supporting components can be damaged when inserted into an empty or partially empty tube by falling into the tube and by striking the base of the tube or the topmost component in the stack within the tube. For this reason, non-self-supporting components have typically been preferred over self-supporting components, e.g., by providing a seal on the catalyst carrier that frictionally engages against the inner wall of the tube, in the exemplary case of catalyst carriers within reactor tubes. However, this solution increases the force required to insert the components into the tube, and may require mechanical assistance, e.g., the use of a hydraulic ram, to insert the components. Beneficially, the present conveyor may enable the use of non-self-supporting components within the tube and may also enable a safe and controllable method of filling and / or emptying tubes with components and / or replacing components.

[0015] This beneficially reduces the likelihood of spontaneous or uncontrolled component ejection. This is particularly beneficial when components can each have a substantial mass, such as in the case of catalyst carriers, and when a stack of components includes a large number of components, potentially causing a high cumulative mass to act on the bottom component closest to the outlet. High cumulative mass within a stack of components can lead to uncontrolled ejection, particularly as a result of changes in the physical integrity of the components over time.

[0016] In some examples, each of the plurality of feeding elements includes a tensioning mechanism.

[0017] In some examples, the plurality of feeding elements comprises feeding elements at two levels along the feeding path, optionally at three levels, or more levels. Beneficially, increasing the number of levels of feeding elements present can reduce the risk of components flexing laterally during feeding by reducing the vertical spacing between adjacent levels. In some examples, components can be connected together, for example, by a frictional press fit, and reducing flexing laterally during ejection can reduce the risk of components spontaneously disconnecting from one another.

[0018] Preferably, the plurality of feeding elements comprises at least an upper feeding element and a lower feeding element.

[0019] In some examples, the spacing between the upper and lower feeding elements is substantially equal to the longitudinal length of each of the components. This can be particularly beneficial when the components each have a common external configuration and each include a feature, such as an enlarged portion, at a point along the length of the component that must be fed past the feeding element, e.g., a seal in the case of a catalyst carrier. Configuring the spacing between the upper and lower feeding elements to be substantially equal to the longitudinal length of the components can ensure that features, such as seals, of both adjacent components contact the feeding element simultaneously. This configuration can be used as a natural brake on component ejection and can help prevent spontaneous component ejection due to gravity alone. For example, the tensioning of the tensioning mechanism can be configured such that, when neither feeding element is externally driven, the stack of components stops and rests due to features, such as seals of adjacent components contacting the upper and lower feeding elements. In that case, an external input may be required to feed the enlarged portion, e.g., seal, past the feeding element.

[0020] In some examples, the plurality of feeding elements further includes an intermediate feeding element positioned between the upper and lower feeding elements. Beneficially, one or more of the intermediate feeding elements can be used to drive the component, i.e., to provide an external input to move the component along the feeding path. This can be particularly useful in the examples described above to allow an enlarged portion of the component, such as a seal, to be fed beyond the upper and lower feeding elements. One or more driven feeding elements can be provided at other levels. For example, one or more of the feeding elements at the upper and / or lower levels and / or at levels provided above the upper level or below the lower level can be driven feeding elements.

[0021] In some examples, the spacing between adjacent levels of the feed elements along the feed path is less than the longitudinal length of each of the components.

[0022] In some examples, each level of feeding elements along the feeding path includes at least three feeding elements. More than three, for example, four or five, feeding elements may be provided at each level. At least three feeding elements at each level, and preferably at least four feeding elements at each level, are preferred to help maintain the circularity of the components during feeding.

[0023] In some examples, the plurality of delivery elements are distributed circumferentially around the longitudinal axis of the delivery path at two, three, four, or more locations. The delivery elements may be regularly distributed around the circumference of the delivery path.

[0024] In a preferred example, the plurality of feeding elements comprises or consists of a plurality of feeding wheels, however, the present disclosure extends to feeding elements taking other forms as well, for example the feeding elements may comprise or consist of tracking elements such as caterpillar tracks, or reciprocating pads, or reciprocating fingers, etc.

[0025] In some examples, one or more of the feed wheels are driven wheels configured to be rotationally driven to feed the component along the feed path.

[0026] In some examples, one or more of the driven wheels are driven manually or by motor power.

[0027] In some examples, the conveyor further comprises one or more handles coupled to one or more of the driven wheels for rotating the driven wheels, the handles being, for example, capable of being rotated by hand.

[0028] Preferably, at least one driven wheel is provided at each of at least two levels along the feed path. For example, at least one driven wheel may be provided at each of the upper and middle levels, or at each of the middle and lower levels, or at each of the upper, middle, and lower levels. Beneficially, this can be configured so that at least one of the driven wheels is always spaced apart from an enlarged portion, e.g., a seal, of a component, thereby always applying a driving force to the body of at least one of the components along the feed path. For example, as described above, the enlarged portions, e.g., seals, of adjacent components may be configured to simultaneously contact the upper and lower feed elements, e.g., feed wheels. In such an example, it may be beneficial to provide at least one driven feed wheel (or other feed element) at an intermediate level of the feed element to ensure that drive is applied to the body of one of the components spaced apart from the enlarged portion, e.g., a seal.

[0029] In some examples, the tensioning mechanism comprises a tensioning spring that biases the delivery element inward toward the delivery path. Other tensioning mechanisms may also be used. For example, other resilient means or a tensioning screw mechanism may be provided.

[0030] In some examples, the tensioning mechanism further comprises a pre-compression mechanism for selectively setting the pre-compression of the tensioning spring.

[0031] In some examples, the frame includes connections for removably suspending the conveyor below the tube.

[0032] In some examples, the frame includes an opening at a first end of the frame that defines an entrance to the feed path for receiving components ejected from the tube.

[0033] In some examples, the frame includes an opening at the second end of the frame that defines an outlet for the delivery path.

[0034] In some examples, the delivery path is a straight path through the frame, optionally through the center of the frame.

[0035] In some examples, the component comprises a catalyst carrier, and the tube comprises a reactor tube of a tubular reactor. When applied to the field of tubular reactors, it will be recognized that the component may include components that may or may not include catalytic material. For example, the component may include a catalyst carrier that not only includes catalytic material, but may also include other components, such as spacer components provided within the stack of components to control the positioning of the catalyst carrier within the length of the reactor tube, and / or an ejector component that may be inserted into the upper end of the reactor tube to eject the catalyst carrier from the lower end of the reactor tube. Typically, such spacer and ejector components do not include any catalytic material, but still comprise a component within the meaning of this specification.

[0036] The component may be a tubular component. The component may be generally cylindrical in external shape (optionally including one or more protrusions, e.g., seals, as described above). The component may be generally right cylindrical in external shape.

[0037] In a second aspect of the present disclosure, there is provided a system, comprising: A conveyor according to any one of the preceding claims; a tubular reactor comprising a plurality of reactor tubes; a plurality of components; The conveyor provides a system, located proximate the outlet of the selected reactor tube, for controlling the discharge of multiple components from the selected reactor tube.

[0038] In some examples, the conveyor is removably attachable to the tubular reactor proximate the outlet of selected reactor tubes.

[0039] In some instances, the conveyor is removable and attachable by being suspended from the lower tube sheet of the tubular reactor.

[0040] Beneficially, the conveyor can be moved sequentially from under one reactor tube to another as needed, and the conveyor can be removed from the tubular reactor when not needed so as not to interfere with fluid flow during use of the tubular reactor.

[0041] In a third aspect, the present disclosure provides a method for controlled ejection of a stack of components from a tube, comprising: i) positioning a conveyor proximate to an outlet of the tube, the conveyor comprising a frame and a plurality of feeding elements mounted to the frame, the feeding elements being distributed around and along a feeding path extending through the frame; ii) discharging the components from the tube into a conveyor whereby the components pass along a feed path and, in so doing, contact a plurality of feed elements; A method is provided in which the level of friction between one or more of the feed elements and components passing along the feed path is selectively adjustable.

[0042] In some examples, locating the conveyor proximate to the outlet of the tube may include mounting the conveyor proximate to the outlet, optionally removably mounting the conveyor proximate to the outlet.

[0043] Preferably, the plurality of feeding elements comprises or consists of a plurality of feeding wheels, however, as mentioned above, other types of feeding elements may be provided.

[0044] In some examples, one or more of the feed wheels are driven wheels, and the rolling friction level is adjusted so that the component requires feeding through the feed path by rotation of the one or more driven wheels.

[0045] In some examples, the component comprises an enlarged portion having a larger diameter than the body of the component, and the friction level is adjusted such that rotation of one or more driven wheels is required for passage of the enlarged portion over the one or more driven wheels.

[0046] In some examples, one or more of the driven wheels are driven manually or by motor power.

[0047] In some examples, the level of rolling friction between each of the feed wheels and the components passing along the feed path is selectively adjustable.

[0048] In a preferred example, each component is contacted by the feed element at least at two levels along the feed path during at least a portion of its passage along the feed path.

[0049] In some examples, each component passing along the feed path is contacted by the feed element at two, three, four, or more locations around the longitudinal axis of the feed path.

[0050] In some examples, the friction level is adjusted by using a tensioning mechanism that includes a tensioning spring that biases the feed element inward toward the feed path.

[0051] In some examples, the tensioning mechanism further comprises a pre-compression mechanism for selectively setting the pre-compression of the tensioning spring.

[0052] In some examples, the method further includes inserting a component into an inlet of the tube, the insertion of the component into the inlet of the tube being controlled by the action of ejecting the component from an outlet of the tube.

[0053] In some examples, the frame is located proximate the outlet of the tube. In some examples, the frame is removably attachable proximate the outlet of the tube.

[0054] In a preferred example, the component comprises a catalyst carrier and the tube comprises a reactor tube of a tubular reactor. Typically, ejection of the catalyst carrier from the outlet of the reactor tube is accompanied by the simultaneous insertion of a replacement component (e.g., a catalyst carrier or ejector component) at the inlet of the reactor tube. Thus, the conveyors of the present disclosure can be used not only to empty reactor tubes, but also as part of a process to replace reactor tube components by simultaneously inserting and ejecting components until the reactor tube contains a new set of components and all previously inserted components have been ejected.

[0055] In some instances, the components are discharged from the conveyor into a container, such as a box or drum, for removal, for example, through the manway of the tubular reactor. In some instances, additional conveying means, such as a chute or hose, are connected to the frame of the conveyor to discharge the components from the conveyor, for example, to the outside of the tubular reactor or into a manway or opening in the tubular reactor, preferably through the bottom of the tubular reactor.

[0056] When components of the present disclosure are catalyst carriers, they can be filled or partially filled with any catalyst suitable for the intended reaction. For example, a Fischer-Tropsch catalyst can be used for the Fischer-Tropsch reaction. Cobalt-containing Fischer-Tropsch catalysts are preferred. The catalyst can be provided as catalyst particles or catalyst monoliths. The catalyst can be provided as a single catalyst bed or multiple catalyst beds. The catalyst carrier can be configured to promote axial and / or radial flow through the catalyst. In some embodiments, the catalyst carrier can be configured to preferentially promote radial flow through the catalyst.

[0057] The catalyst carrier can be formed of any suitable material. Such materials are generally selected to withstand the operating conditions of the tubular reactor. The catalyst carrier can be made of carbon steel, aluminum, stainless steel, other alloys, or any material that can withstand the reaction conditions. [Brief explanation of the drawings]

[0058] 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] Catalyst carrier is shown. [Figure 3] 1 shows a conveyor according to the present disclosure in conjunction with multiple catalyst carriers. [Figure 4] 4 shows the conveyor of FIG. 3 mounted on the lower tube sheet of a tubular reactor. [Figure 5] 4 shows an enlarged view of a portion of the conveyor of FIG. 3 during delivery of a plurality of catalyst carriers. [Figure 6] 4 is a top view of a portion of the conveyor of FIG. 3 showing the feed elements of the conveyor. [Figure 7] 4 shows the tensioning mechanism of the conveyor of FIG. 3 in a first state and a second state. [Figure 8] 4 shows a schematic cross-sectional view of the conveyor of FIG. 3 delivering a plurality of catalyst carriers. DETAILED DESCRIPTION OF THE INVENTION

[0059] In the following, aspects and embodiments of the present disclosure are described, by way of example only, with reference to components in the form of catalyst carriers for use with 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 components discharging in other directions and from other tubes.

[0060] Additionally, any reference herein to orientation, such as terms such as top, bottom, upper, lower, above, below, and the like, is used with respect to the orientation of parts shown in the referenced drawings, but should not be construed as limiting the potential orientation of such parts in actual use. For example, a part described as being vertically oriented may be oriented horizontally.

[0061] 1 shows a typical layout of a tubular reactor 1 of the present disclosure. The tubular reactor 1 comprises a housing 2. The interior of the housing can 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 zone 4. The lower tube sheet 7 separates the footer space 5 from the heat exchange zone 4.

[0062] A plurality of reactor tubes 8 extend between upper tube sheet 6 and lower tube sheet 7. A large number of reactor tubes 8 may be provided, for example, there may be 20 to 5000 reactor tubes 8. Each reactor 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.

[0063] Each reactor tube 8 is intended to be filled or substantially filled with catalyst carriers 10 in a stacked arrangement (e.g., as shown in FIG. 2). In particular, it is typically desired that the catalyst carriers 10 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., cover all or substantially all of the length of the heat exchange zone 4.

[0064] Head space 3 may provide access to the upper end of reactor tube 8 to allow loading of catalyst carriers 10 into reactor tube 8. Access opening 11 may be provided in housing 2 to allow access to head space 3. Access opening 11 may be, for example, a manhole or other access panel that can be selectively opened and closed.

[0065] 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 .

[0066] To better understand the present disclosure, one example of a general configuration of components in the form of a catalyst carrier 10 will be described with reference to Figure 2. However, it will be understood that the catalyst carrier 10 may take a variety of forms. For example, as with the embodiments described herein, the catalyst carrier 10 may take other general configurations, including, but not limited to, those disclosed in WO 2011 / 048361, WO 2012 / 136971, and WO 2016 / 050520, the contents of which are incorporated herein by reference in their entireties.

[0067] Each catalyst carrier 10 may generally comprise a container 20 sized to be smaller than the interior dimensions of the reactor tube 8 within which it will be placed in use. Typically, a seal 22 is provided 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.

[0068] 2, container 20 comprises an elongated body 21 having an outer wall 23 extending between a top end 24 and a bottom end 25. Top end 24 is provided with a lid portion 26 that at least partially closes elongated body 21 at top end 24. Bottom end 25 is provided with a skirt portion 27. Seal 22 is located toward top end 24, preferably near, e.g., directly below, lid portion 26.

[0069] Lid portion 26 is provided with a central aperture 28 which allows fluid to enter container 20 during use.

[0070] As shown in FIG. 2 , the outer wall 23 may be provided with a plurality of apertures configured to allow fluid transfer across the outer wall 23. At the bottom end 25 of the outer wall 23, the skirt portion 27 may include a plurality of bottom apertures 30. The bottom apertures 30 may be spaced apart around the periphery of the elongated body 21. Each bottom aperture 30 may be, for example, square-shaped or rectangular-shaped. Similarly, at the top end 24 of the outer wall 23, a plurality of upper apertures 31 may be provided. The upper apertures 31 may be spaced apart around the periphery of the elongated body 21. Each upper aperture 31 may be, for example, square-shaped or rectangular-shaped.

[0071] Catalyst carrier 10 may define an annular vessel for holding catalyst during use. The annular vessel may include a perforated inner vessel wall defining an inner channel and a perforated outer vessel wall that may be concentrically disposed around the perforated inner vessel wall and within outer wall 23. An annular top surface defined by a portion of lid portion 26 may close the upper end of the annular vessel, and an annular bottom surface may close the lower end of the annular vessel.

[0072] The seal 22 may be sufficiently compressible to accommodate the smallest diameter of the reactor tube 8. The seal 22 may generally be a flexible sliding seal. The seal 22 may engage against the inner surface of the reactor tube 8 such 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 22 may be configured, for example, to form a sliding seal against the inner surface of the reactor tube 8.

[0073] 2, the seal 22 may include a deformable flange extending from the outer wall 23. This flange 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.

[0074] Further details of the structure of such catalyst carriers 10 can be found in WO 2011 / 048361, WO 2012 / 136971, and WO 2016 / 050520, the contents of which are incorporated herein by reference in their entirety.

[0075] According to the present disclosure, a conveyor 40 is provided for the controlled discharge of stacks of components in the form of reactor tubes 8 from tubes in the form of catalyst carriers 10. An example of a conveyor 40 is shown in Figures 3-7 and schematically in Figure 8.

[0076] The conveyor of Figure 3 comprises a frame 41 which may comprise an upper plate 42, a lower ring 43 and a plurality of wheel subframes 46 which may extend therebetween. Optionally, an additional plate 44 may be provided above and spaced from the upper plate 42 and connected to the additional plate by connector bolts 45. The additional plate 44 may form a mounting plate for removably mounting the frame 41 to the lower tube sheet 7.

[0077] The additional plate 44 may include a central aperture 55. The upper plate 42 may also include a central aperture 50 that may be aligned with the central aperture 55. The central apertures 50, 55 may together define an entrance 81 to a feed path 80 that extends through the frame 41 to an exit 82, optionally defined by the lower ring 43. The feed path 80 is preferably a linear path, optionally coinciding with the central longitudinal axis of the frame 41. The wheel sub-frames 46 may optionally be distributed around the feed path 80 at regular intervals. In the example shown, four wheel sub-frames 46 are provided at 90-degree intervals.

[0078] Conveyor 40 further includes a plurality of feed elements mounted to frame 41. The feed elements may preferably be in the form of feed wheels 61. The feed wheels 61 may each be mounted to a wheel subframe 46. Each wheel subframe 46 may include two parallel, spaced apart plates defining a space therebetween for accommodating at least a portion of the feed wheel 61. As shown in FIG. 6, each feed wheel 61 may be rotatably mounted by a feed wheel axle 66 extending through an adjustment slot 67 in each of the spaced apart plates of the wheel subframe 46.

[0079] The feed wheels 61 may be divided into an upper feed wheel 63, an intermediate feed wheel 64, and a lower feed wheel 65, which may be located along the length of the frame 41, and in particular along the length of the wheel subframe 46. The upper feed wheel 63 may be located closest to the inlet 81, the lower feed wheel 65 may be located closest to the outlet 82, and the intermediate feed wheel 84 may be located therebetween. Preferably, the spacing between the upper feed wheel 63 and the lower feed wheel 65 is substantially equal to the longitudinal length of each of the catalyst carriers 10. Preferably, the spacing between adjacent levels of the feed wheels 61 along the feed path 80 is less than the longitudinal length of each of the catalyst carriers 10.

[0080] The feed wheels 61 are distributed around and along the feed path 80, as shown in Figures 6 and 8, so that, in use, the feed wheels 61 contact the catalyst carriers 10 passing through the frame 41 along the feed path 80.

[0081] Each level of feed wheels 61 along the feed path 80 may include at least three feed wheels, for example, four feed wheels 61 as shown in the example shown in FIG.

[0082] Preferably, one or more of the feed wheels 61 are driven wheels 62 configured to be driven in rotation to feed the catalyst carrier 10 along the feed path 80. The driven wheels 62 may be driven manually or by motor power. In the example shown in the figure, the driven wheels 62 may be rotated manually by using a drive crank 90 and a handle 91 connected to the driven wheels 62. Preferably, at least one driven wheel 62 is provided at each of at least two levels along the feed path 80. In the example shown, the first driven wheel 62 is one of the upper feed wheels 63, and the second driven wheel 62 is one of the intermediate feed wheels 64, as shown schematically in FIG. 8.

[0083] One or more of the feed wheels 61 of the conveyor 40 are provided with a tensioning mechanism for adjusting the level of friction between the or each feed wheel 61 and the catalyst carriers 10 passing through the frame 41 along the feed path 80. Optionally, each of the feed wheels 61 is provided with a tensioning mechanism.

[0084] The tensioning mechanism may include a tensioning spring 71 that biases the feed wheel 61 inward toward the feed path 80. The tensioning mechanism may further include a pre-compression mechanism for selectively setting the pre-compression of the tensioning spring 71. In the illustrated example, as most clearly shown in FIG. 7 , the pre-compression mechanism includes a mounting bar 73 fixedly attached to the wheel subframe 46 and a tensioning bolt 72. The tensioning spring 71 is located between the mounting bar 73 and the inner end of the tensioning bolt 72. The tensioning bolt 72 extends through the mounting bar 73 and can be rotated in both rotational directions to increase or decrease the pre-compression of the tensioning spring 71 by moving the inner end of the tensioning bolt (and therefore the outer end of the tensioning spring 71) inward or outward, respectively. The left portion of FIG. 6 shows a pre-compression mechanism with a relatively low level of pre-compression, and the right portion of FIG. 6 shows a pre-compression mechanism with a relatively high level of pre-compression.

[0085] As shown in FIG. 4 , the conveyor 40 can be configured to be located proximate the outlets of the reactor tubes 8, for example, by being attached to and optionally suspended from the lower tube sheet 7. The frame 41 can include connections for removably suspending the conveyor 40 below the reactor tubes 8. In the illustrative example, three mounting bosses 47 extend downwardly from the lower tube sheet 8, each having an enlarged distal end, such as the pivot disclosed in WO 2022 / 064211. The mounting plate 44 can be provided with three keyway apertures 56, as seen in FIGS. 3 and 6 , which can allow the conveyor 40 to be attached below the reactor tube outlets with a bayonet-style connection by engaging the enlarged heads of the mounting bosses 47 with the enlarged portions of the keyway apertures 56 and rotating the conveyor 40. Thus, the conveyor 40 can be configured to be located proximate the outlets of the reactor tubes 8.

[0086] In use, the controlled discharge of the catalyst carrier 10 is i) positioning, e.g., attaching, a conveyor 40 proximate to the outlet of the reactor tube 8; ii) discharging the catalyst carrier 10 from the reactor tube 8 into the conveyor 40, whereby the catalyst carrier passes along the feed path 80 and in the process comes into contact with a plurality of feed wheels 61.

[0087] As noted above, the level of friction between the feed wheel 61 and the catalyst carrier 10 passing along the feed path 80 is selectively adjustable, for example, by adjusting the tensioning mechanism.

[0088] As noted above, the catalyst carrier 10 may include an enlarged portion, e.g., a seal 22, having a larger diameter than the catalyst carrier body 21, and the friction level may be adjusted so that one or more rotations of the driven wheels 62 are required for passage of the enlarged portion over the driven wheels 62.

[0089] Preferably, each catalyst carrier 10 is contacted by the feed wheels 61 at least at two levels along the feed path 80 during at least a portion of its passage along the feed path 80 .

[0090] Discharge of catalyst carriers 10 from the outlet of reactor tube 8 into inlet 81 of feed path 80 may be accomplished or assisted by, or may involve, insertion of catalyst carriers 10 (or other components, e.g., ejector components) into the upper end of reactor tube 8, such that the stack of catalyst carriers 10 within the reactor tube is moved sequentially downward with or along with each insertion of a component at the upper end.

[0091] In some preferred examples, ejection of catalyst carriers 10 from the outlet of reactor tube 8 is accompanied by simultaneous insertion of catalyst carriers 10 into the inlet of reactor tube 8. In particular, ejection of catalyst carriers 10 may move the stack of catalyst carriers 10 down within reactor tube 8, allowing catalyst carriers 10 to be inserted into the inlet of reactor tube 8 to fill the space created at the upper end of reactor tube 8. In these and other examples, optionally, catalyst carriers 10 may be non-self-supporting catalyst carriers 10.

[0092] The conveyor 40 may allow for controlled insertion of the catalyst carrier 10 into the inlet of the reactor tube 8 by acting to eject the catalyst carrier 10 from the outlet of the reactor tube 8, rather than vice versa.

[0093] Optionally, the lower tube sheet 7 and / or the conveyor 40, e.g., the additional plate 44, may be provided with means for preventing the discharge of catalyst carriers 10 from the reactor tubes 8. For example, one or more shutters, e.g., moon-shaped disks (as described, for example, in WO 2022 / 064211, the contents of which are incorporated herein by reference in their entirety), may be pivoted at least partially across the outlets of the reactor tubes 8 or across the central aperture 55 of the additional plate 44 to prevent the passage of catalyst carriers 10. This may be beneficial by preventing the discharge of catalyst carriers 10 from the reactor tubes 8 while the conveyor 40 is mounted on the lower tube sheet 7. Once the conveyor 40 is properly mounted, the shutters may be withdrawn to clear the outlets of the reactor tubes 8 and the inlet 81 of the feed path 80.

[0094] Further aspects of the present disclosure are described in the following clauses.

[0095] Clause 1. A conveyor for controlled discharge of a stack of components from a tube, comprising: i) a frame configured to be positioned proximate to the outlet of the tube; ii) a plurality of feed elements mounted to the frame, the feed elements being distributed around and along a feed path extending through the frame so as to contact components passing through the frame along the feed path in use; A conveyor wherein one or more of the feeding elements includes a tensioning mechanism for adjusting a level of friction between the one or more of the feeding elements and components passing through the frame along the feeding path.

[0096] Clause 2. The conveyor of clause 1, wherein each of the plurality of feeding elements comprises a tensioning mechanism.

[0097] Clause 3. A conveyor as described in clause 1 or clause 2, wherein the plurality of feeding elements comprises feeding elements at two levels along the feeding path, optionally at three levels or more levels.

[0098] Clause 4. The conveyor of clause 3, wherein the plurality of feeding elements comprises an upper feeding element and a lower feeding element.

[0099] Clause 5. A conveyor as described in clause 4, wherein the spacing between the upper and lower feeding elements is substantially equal to the longitudinal length of each of the components.

[0100] Clause 6. A conveyor as described in clause 4 or clause 5, wherein the plurality of feeding elements further comprises an intermediate feeding element located between the upper feeding element and the lower feeding element.

[0101] Clause 7. A conveyor according to any one of clauses 3 to 6, wherein the spacing between adjacent levels of the feeding elements along the feeding path is less than the longitudinal length of each of the components.

[0102] Clause 8. A conveyor according to any one of clauses 3 to 7, wherein each level of feeding elements along the feeding path comprises at least three feeding elements.

[0103] Clause 9. A conveyor according to any one of clauses 1 to 8, wherein the plurality of feeding elements are distributed circumferentially around the longitudinal axis of the feeding path at two, three, four or more positions.

[0104] Clause 10. A conveyor according to any one of clauses 1 to 9, wherein the plurality of feed elements comprises or consists of a plurality of feed wheels.

[0105] Clause 11. The conveyor of clause 10, wherein one or more of the feed wheels is a driven wheel configured to be rotationally driven to feed the component along the feed path.

[0106] Clause 12. A conveyor as described in clause 11, wherein one or more driven wheels are driven manually or by motor power.

[0107] Clause 13. A conveyor as described in clause 11 or clause 12, further comprising one or more handles coupled to one or more of the driven wheels for rotating the driven wheels.

[0108] Clause 14. A conveyor as claimed in any one of clauses 11 to 13, wherein at least one driven wheel is provided at each of at least two levels along the feed path.

[0109] Clause 15. A conveyor as claimed in any one of clauses 1 to 14, wherein the tensioning mechanism comprises a tensioning spring that biases the feed elements inwardly towards the feed path.

[0110] Clause 16. The conveyor of clause 15, wherein the tensioning mechanism further comprises a pre-compression mechanism for selectively setting a pre-compression of the tensioning spring.

[0111] Clause 17. A conveyor as claimed in any one of clauses 1 to 16, wherein the frame comprises connections for removably suspending the conveyor below the tube.

[0112] Clause 18. A conveyor as claimed in clause 17, wherein the connection comprises a bayonet type connection.

[0113] Clause 19. A conveyor as claimed in any one of clauses 1 to 18, wherein the frame comprises an opening at a first end of the frame defining an entrance to the feed path for receiving components discharged from the tube.

[0114] Clause 20. A conveyor as claimed in any one of clauses 1 to 19, wherein the frame comprises an opening at the second end of the frame that defines an outlet for the feed path.

[0115] Clause 21. A conveyor according to any one of clauses 1 to 20, wherein the feed path is a straight path through the frame, optionally through the centre of the frame.

[0116] Clause 22. A conveyor according to any one of clauses 1 to 21, wherein the component comprises a catalyst carrier and the tube comprises a reactor tube of a tubular reactor.

[0117] Clause 23. A system comprising: A conveyor according to any one of clauses 1 to 22; a tubular reactor comprising a plurality of reactor tubes; a plurality of components; The system wherein a conveyor is positionable proximate to the outlet of a selected reactor tube for controlling the discharge of multiple components from the selected reactor tube.

[0118] Clause 24. The system of clause 23, wherein the conveyor is removably attachable adjacent the outlet of selected reactor tubes by being suspended from a lower tube sheet of the tubular reactor.

[0119] Clause 25. A method for controlled ejection of a stack of components from a tube, comprising: i) positioning a conveyor proximate to an outlet of the tube, the conveyor comprising a frame and a plurality of feeding elements mounted to the frame, the feeding elements being distributed around and along a feeding path extending through the frame; ii) discharging the components from the tube into a conveyor whereby the components pass along a feed path and, in so doing, contact a plurality of feed elements; A method wherein the level of friction between one or more of the feed elements and components passing along the feed path is selectively adjustable.

[0120] Clause 26. The method of clause 25, wherein positioning the conveyor proximate to the outlet of the tube comprises mounting the conveyor proximate to the outlet, optionally removably mounting the conveyor proximate to the outlet.

[0121] Clause 27. A method according to clause 25 or clause 26, wherein the plurality of feeding elements comprises or consists of a plurality of feeding wheels.

[0122] Clause 28. The method of clause 27, wherein one or more of the feed wheels are driven wheels and the rolling friction level is adjusted so that the component requires feeding through the feed path by rotation of the one or more driven wheels.

[0123] Clause 29. A method according to clause 28, wherein the component comprises an enlarged portion having a diameter greater than the body of the component, and the friction level is adjusted so that rotation of one or more driven wheels is required for passage of the enlarged portion over the one or more driven wheels.

[0124] Clause 30. A method according to any one of clauses 28 to 29, wherein one or more driven wheels are driven manually or by motor power.

[0125] Clause 31. A method according to any one of clauses 27 to 30, wherein the level of rolling friction between each of the feed wheels and the components passing along the feed path is selectively adjustable.

[0126] Clause 32. A method according to any one of clauses 26 to 31, wherein each component is contacted by the feed element at least at two levels along the feed path during at least a portion of its passage along the feed path.

[0127] Clause 33. A method according to any one of clauses 26 to 32, wherein each component passing along the feed path is contacted by the feed element at two, three, four or more locations around the longitudinal axis of the feed path.

[0128] Clause 34. The method of any one of clauses 26 to 33, wherein the friction level is adjusted by using a tensioning mechanism comprising a tensioning spring that biases the feed element inwardly towards the feed path.

[0129] Clause 35. The method of clause 34, wherein the tensioning mechanism further comprises a pre-compression mechanism for selectively setting a pre-compression of the tensioning spring.

[0130] Clause 36. The method of any one of clauses 26 to 35, further comprising inserting a component into an inlet of the tube, wherein the insertion of the component into the inlet of the tube is controlled by the action of ejecting the component from an outlet of the tube.

[0131] Clause 37. The method of any one of clauses 26 to 36, wherein the component comprises a catalyst carrier and the tube comprises a reactor tube of a tubular reactor.

Claims

1. A conveyor for controlled discharge of a stack of components from a tube, comprising: i) a frame configured to be positioned proximate to the outlet of the tube; ii) a plurality of feed elements mounted to the frame, the feed elements being distributed around and along a feed path extending through the frame so as to contact components passing through the frame along the feed path in use; a conveyor, wherein one or more of the feeding elements comprises a tensioning mechanism for adjusting a level of friction between the one or more of the feeding elements and components passing through the frame along the feeding path.

2. The conveyor of claim 1 , wherein the plurality of feeding elements comprises feeding elements at two levels, optionally at three levels, or more levels along the feeding path.

3. The conveyor of claim 2 , wherein the plurality of feeding elements comprises an upper feeding element and a lower feeding element.

4. 4. The conveyor of claim 3, wherein the spacing between said upper and lower feeding elements is substantially equal to the longitudinal length of each of said components.

5. 5. The conveyor of claim 3 or claim 4, wherein the plurality of feeding elements further comprises an intermediate feeding element located between the upper feeding element and the lower feeding element.

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

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

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

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

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

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

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

13. A conveyor according to any preceding claim, wherein the frame includes connections for removably suspending the conveyor below the tube.

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

15. 1. A system comprising: A conveyor according to any one of claims 1 to 14; a tubular reactor comprising a plurality of reactor tubes; a plurality of components; The system wherein the conveyor is located proximate to an outlet of a selected reactor tube for controlling discharge of the components from the selected reactor tube.

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

17. 1. A method for controlled ejection of a stack of components from a tube, comprising: i) positioning a conveyor proximate to an outlet of the tube, the conveyor comprising a frame and a plurality of feeding elements mounted to the frame, the feeding elements being distributed around and along a feeding path extending through the frame; ii) discharging components from the tube into the conveyor, whereby the components pass along the feed path and, in so doing, contact the plurality of feed elements; A method wherein a level of friction between one or more of the feed elements and the component passing along the feed path is selectively adjustable.

18. 18. The method of claim 17, wherein positioning the conveyor proximate the outlet of the tube comprises mounting the conveyor proximate the outlet, optionally removably mounting the conveyor proximate the outlet.

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

20. 20. The method of claim 19, wherein one or more of the feed wheels are driven wheels and a rolling friction level is adjusted such that the component requires feeding through the feed path by rotation of the one or more driven wheels.

21. 21. The method of claim 20, wherein the component comprises an enlarged portion having a diameter greater than a body of the component, and the friction level is adjusted such that rotation of the one or more driven wheels is required for passage of the enlarged portion over the one or more driven wheels.

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

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

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

25. 25. The method of any one of claims 18 to 24, further comprising inserting a component into an inlet of the tube, the insertion of the component into the inlet of the tube being controlled by the action of ejecting the component from the outlet of the tube.

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