Improve the quality of primaryreformer catalyst loadingby Unidense technology

UNIDENSETM catalyst loadingtechnology is used for filling primreformer tubes in ammonia, methhydrogen and other reformer bas

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UNIDENSETM catalyst loadingtechnology is used for filling primaryreformer tubes in ammonia, methanol,hydrogen and other reformer basedplants. It results in a high and uniformcatalyst density for efficient operationof the primary reformer.

UNIDENSETM is a simple and fastloading technology applicable to tubesizes from 3 to 10 internal diameter.UNIDENSETM requires no pre-socking ofcatalyst and no vibration of thereformer tubes.

UNIDENSETM combines being a highquality and fast loading technology.Reloading of tubes is normally avoided,and less catalyst is wasted.

UNIDENSETM principle: Catalyst is filled into the tube and theloading rope is gradually pulled out ofthe tube as the catalyst layer builds up.The brushes with flexible springsreduce the speed of the catalystparticles so that the breakage isavoided. The catalyst particles areloaded without bridges andunnecessary voids, hence there is noneed for vibration.

By applying the UNIDENSETM

technology the loading time of theprimary reformer can be substantiallyreduced whilst maintaining highquality loading. Typical loading timefor 4 tubes is 8 minutes.

UNIDENSETM technology ensures evengas flow in the tubes, and the pressuredrop variation is kept to a minimum.The density will normally be higherthan with the sock-method, resultingin slightly increased, but more evenpressure drop, due to better packing.

Since there are no extra voids, furthersettling of the catalyst, and thuspressure drop increase, will be minimal. UNIDENSETM gives high uniform densityalong the full length of the tube,decreasing the risk of hot spots andcontributing to lower tube walltemperatures and prolonged tube life.UNIDENSETM technology has been usedfor loading of all common catalysttypes and sizes. Reformer tube designswith varying internal diameter, narrowor wide top section, have successivelybeen loaded. Loading of catalyst

Primary reformer loading

Fast loading

No presocking of catalyst

No vibration of the tubes

Uniform pressure drop

Less waste of catalyst

No bridging or extra voids

High uniform density

UNIDENSE Technology GmbHAlexander-von-Humboldtstrasse 2D-01987 SchwarzheideTel.: +49-357-52 94 86 77Fax: +49-357-52 94 86 78 E-mail: info@unidense.comwww.unidense.com

Technology for primary reformer loading

Loading of catalyst by Unidense Technology

Reformer tubes

Inlet Y-piece

Loaded catalyst

Catalyst packing100 mm tube

Sock

load

ing

UN

IDEN

SETM

Delta pressure measurement

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Catalyst packing100 mm tube

Sock

load

ing

UN

IDEN

SETM

Manual loading using the UNIDENSE Technology

Reformer tubes

UNIDENSE is a simple and fast loading technology for loading reformer tubes with catalyst, applicable to tube internal diameter sizes from 3 and over. UNIDENSE requires no presocking of catalyst and no vibration of the reformer tubes. UNIDENSE combines a fast loa-ding technology with high quality perfor-mance. With this technology, reloading of tubes can be reduced tot a minimum and less catalyst is wasted.

UNIDENSE principle: catalyst is loaded into the tube and the loading rope is gradually pulled out of the tube as the catalyst layer builds up. The brushes with flexible springs reduce the speed of the catalyst particles so that breakage is avoided. The catalyst particles are loaded without bridging and unnecessary voids, hence there is no need for vibration.

The loading time of the primary reformer can be substantially reduced by applying the UNIDENSE technology, whilst main-taining high loading quality. UNIDENSE technology ensures a constant gas flow in flow in the tubes and the pressure drop variation is kept to a minimum. The density will normally be higher than with the sock method, resulting in a slightly increased, yet more constant pressure drop due to better packing. Since there are no extra voids, further settling of the catalyst, and thus pressure drop increase, will be minimal. UNIDENSE ensures a high uniform density along the full length of the tube, decreasing the risk of hot spots and contributing to lower tube wall temperatures and prolonged tube life.

Impression of the UNIDENSE principle

Automatic reformer loading by UNIDENSE Technology

178896_ENG - Uniloader.indd 1 05-05-2009 09:26:37

Unidense Technology GmbHAlexander-von-Humboldtstrasse 2D-01987 SchwarzheideTel.: +49-357 5294 8677Fax: +49-357 5294 8678E-mail: info@unidense.comwww.unidense.com

Automatic reformer loadingby UNIDENSE Technology

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UNILOADERThe UNILOADER is a machine for automatic loading of reformer tubes with catalyst by using the UNIDENSE principle. UNIDENSE is a leading and proven technology used within the syngas industry to load methanol, hydrogen and other reformers with catalyst.

The UNILOADER brings extra benefits to the UNIDENSE technology. The pos-sibility of human error is eliminated and the technology works more accurate, the result of which is an improved average pressure drop ( 3%). This improved performance is achieved in combination with faster loading speeds (up to two times faster) compared to the manual technique.

UNIDENSE technology is used for loa-ding all common catalyst types and sizes. Reformer tube designs with varying inter-nal diameter, narrow or wide top section, have successfully been loaded.

Advantages UNIDENSE Fast reformer loading No presocking of catalyst No vibration of the tubes Uniform pressure drop Less waste of catalyst No bridging or extra voids:

- Minimizes hot spots- Reduces catalyst settling

High uniform density: - Lower tube wall temperature- Prolonged tube life- Increased reforming capacity

Additonal advantages UNILOADER Human failures eliminated Improved uniform pressure drop variation 3% Faster reformer loading (up to 2x faster than manual loading) Higher uniform density

178896_ENG - Uniloader.indd 2 05-05-2009 09:26:38

UNIDENSE UNILOADERUNIDENSE isasimpleandfastloadingtechnology for loading reformer tubeswith catalyst,applicable to tubesizesfrom3to10internaldiameter.UNIDENSErequires nopresockingofcatalystandnovibrationofthereformertubes.UNIDENSEcombinesbeing ahighqualityandfastloadingtechnology Reloading of tubes is

TheUNILOADERisamachinetoautomaticallyloadreformertubeswithcatalystusingtheUNIDENSE principle.UNIDENSEisaleadingandproventechnologyusedwithintheSYNGASmarkettoloadprimaryreformerswithcatalyst.Th UNILOADER b i b fi

BENEFITSUNIDENSEFast reformer loading,No presocking of catalyst,No vibration of the tubes,Uniform pressure drop,technology.Reloading oftubesis

normallyavoided,andlesscatalyst iswasted.

UNIDENSEprinciple:Catalyst isloadedintothetubeandtheloadingropeisgraduallypulledoutofthetubeasthecatalystlayerbuildsup.Thebrusheswithflexiblespringsreducethespeed

The UNILOADERbrings new benefitsto theUNIDENSEtechnology.Thepossibilityforhumanerroriseliminatedasalltubesareloadedatexactlythesamemannerandspeed,resultinginhighuniformityandreducingthepressuredropvariationto3%(Fornewreformers,2%ispossible).Thisimproved performanceisachieved upt 20% f t l di Att h d

Uniform pressure drop,Less waste of catalyst,No bridging or extra voids:

Minimises hot spots, Reduces catalyst settling,

High uniform density: Lower tube wall temp., Prolonged tube life,

ofthecatalystparticlessothatbreakageisavoided.Thecatalystparticlesareloaded withoutbridgesandunnecessaryvoids,hencethereisnoneedforvibration.

to20%faster loading.Attachedvacuumcleanerandcarefullydesignedairflowensuresdustfreeloading.

Increased reforming,capacity.

EXTRABENEFITSUNILOADER

Human failure eliminated,Improved uniform pressurep pdrop variation 3%),

Faster reformer loading(up to 20% faster as manual),Highly uniform loading,Dustfree loading.

ByapplyingtheUNIDENSEtechnologytheloadingtimeoftheprimaryreformer can be substantially reducedreformercanbe substantially reducedwhilst maintaining highquality loading.UNIDENSEtechnology ensures evengasflowinthetubes,andthepressuredropvariationiskepttoaminimum.The densitywillnormallybehigherthanwiththesockmethod,resultinginslightlyincreased,butmoreeven

UNIDENSEtechnologyisusedforloadingofallcommoncatalysttypesandsizes.Reformertubedesignswithvaryinginternaldiameter,narrow

pressuredrop,duetobetterpacking.Since there arenoextravoids,furthersettlingofthecatalyst,andthuspressuredropincrease,willbeminimal.UNIDENSEgives highuniformdensityalongthefulllengthofthetube,decreasingtheriskofhotspotsandcontributingtolowertubewalltemperaturesandprolonged tubelife.

orwidetopsection,havesuccessivelybeenloaded. For further information,please directyour enquiry to:

.

p p gUNIDENSETechnology GmbHAlexandervonHumboldtStrae 2D01987SchwarzheideEmailrizalsalim@unidense.comEmail aidilizzat.hashim@unidense.comWeb www.unidense.com

Dieses Vorhaben wurde mit Mitteln des Ministeriums fr Wirtschaft des Landes Brandenburg und der EU gefrdert. Die Verantwortung fr den Inhalt der Verffentlichung liegt beim Autor.This project was funded by the Ministry of Economic Affairs of Brandenburg and the EU. The responsibility for the content of the publication is the author.

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