Unidense Services Brochure

UNIDENSE™ UNILOADER™ UNIDENSE™ is a simple and fast loadingtechnology for loading reformer tubes with catalyst, applicable to tube sizes from 3 to 10” internal diameter. UNIDENSE™ requires no pre‐socking of catalyst and no vibration of the reformer tubes. UNIDENSE™ combines being a high quality and fast loading technology Reloading of tubes is

The UNILOADER™ is a machine to automatically load reformer tubes with catalyst using the UNIDENSE ™principle. UNIDENSE™ is a leading and proven technology used within the SYNGAS market to load primary reformers with catalyst.

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BENEFITS UNIDENSE™Fast reformer loading,No presocking of catalyst,No vibration of the tubes,Uniform pressure drop,technology. Reloading of tubes is

normally avoided, 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

The UNILOADER™ brings new benefitsto the UNIDENSE™ technology. The possibility for human error is eliminated as all tubes are loaded at exactly the same manner and speed, resulting in high uniformity and reducing the pressure drop variation to ≤ 3% (For new reformers, ≤ 2% is possible). Thisimproved performance is achieved up

20% f l di A 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,

of the catalyst particles so that breakage is avoided. The catalyst particles are loaded without bridgesand unnecessary voids, hence thereis no need for vibration.

to 20% faster loading. Attached vacuum cleaner and carefully designed air flow ensures dust‐free loading.

‐ Increased reforming,capacity.

EXTRA BENEFITS UNILOADER™

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

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

By applying the UNIDENSE™ technology the loading time of the primary reformer can be substantially reducedreformer can be substantially reducedwhilst maintaining high quality loading.

UNIDENSE™ technology ensures even gas 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 slightly increased, but more even

UNIDENSE™ technology is used for loading of all common catalyst typesand sizes. Reformer tube designs with varying internal diameter, narrow

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™ gives 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.

or wide top section, have successivelybeen loaded. For further information, please direct your enquiry to:

.

UNIDENSE™ Technology GmbHl d b ld ß

p p gAlexander‐von‐Humboldt‐Straße 2D‐01987 SchwarzheideTel + 6012 – 907 3528Fax + 603 – 7660 9393Email [email protected] Web www.unidense.com

Dieses Vorhaben wurde mit Mitteln des Ministeriums für Wirtschaft des Landes Brandenburg und der EU gefördert. Die Verantwortung für den Inhalt der Veröffentlichung 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.

DOSSIER System correctly, restriction orifice to achieve EXTRA BENEFITSDOSSIER System

The DOSSIER system is the latest technology innovation by UNIDENSE™as an added value to the client when combined together with the UNILOADER™. It is a machine that ensures achieving the enhanced safe & healthy working environment, catalyst

y,critical air‐flow during dP measurement test.

The UNIDENSE™ dP Equipment is very user‐friendly with its light weight design and digital reading up to three (3) decimal points. This increases the

EXTRA BENEFITS DOSSIER SYSTEM

Further elimination of human error,Further reduces the number of workers required,Fast & accurate catalyst

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weighing accuracy, minimum attrition, de‐dusting of catalyst, further minimizing the requirement of manpower hence avoiding human error. Ultimately it also achieves a more efficient schedule duration as compared to conventional method of

accuracy of the measurement and reduces the time consumed without compromising the quality if the data obtained.

UNIDENSE™ VideoscopeUNIDENSE™ Videoscope is the most

weighing,Minimum attrition,De‐dusting capability

BENEFITS UNIDENSE™ DP EQUIPMENT &

VIDEOSCOPEmanual handling.

Not only does the DOSSIER System applies to catalyst weighing for reformer tube loading, it is also widely use for bulk catalyst repacking.

important equipment required before any catalyst loading activity commence. It helps client to inspect the tube internal to ensure that it is completely empty with no debris, used catalyst or other obstructions remaining. It is also used to determine condition of the

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AccurateUser‐FriendlySimple & FastConsistentReliable

outlet catalyst support grid. This camera inspection gives the UNIDENSE™ supervisor and client confidence in the tube condition and cleanliness prior to any loading.

Any irregularities observed during the inspection must be corrected

DOSSIER System principle: Catalyst is poured into the top funnel and then weighed according to the desired mass selection. This is controlled via special designed control panel where the

inspection must be corrected immediately and prior to any loadings. Such irregularities are, for example, poor tube cleaning and/or damage to tube or support grid (mouse trap).

designed control panel where the parameters are being set to achieve optimum result. The weighed catalyst is then conveyed to the outlet distributor directly into buckets or any other type of packaging material; i.e. drums, etc.

UNIDENSE™ dP Equipment

.

q pUNIDENSE™ Technology provides anaccurate and reliable equipment for reputable accuracy of pressure drop measurement. The dP equipment comes complete with a variety of inflatable bladder to cater the clients reformer tube internal diameter size

For further information, please direct your enquiry to:

UNIDENSE™ Technology GmbHAl d H b ld S ß 2Alexander‐von‐Humboldt‐Straße 2D‐01987 SchwarzheideTel + 6012 – 907 3528Fax + 603 – 7660 9393Email [email protected] Web www.unidense.com


OUTTUBE™ CLEANER

BENEFITS OUTTUBE™ CLEANER

Fast reformer tube cleaning,Reduce overall shutdown schedule

OUTTUBE CLEANEROutTube ™ Cleaner is the latest technology advancement to safe and efficient method for external cleaning of reformer tubes and/or furnaceheater’ tubes , applicable to tube sizes from 3” to 10” nominal diameter. OutTube™ Cleaner incorporates the

A suction device is also designed to the OutTube™ Cleaner to prevent the dispersion of any contaminant particles into the environment and provides a cleaner and hygienic workspace.

schedule,Optimize overall cost and potential cost savingNo scaffolding required,No working at height required,Reduction of manpower requirement,

OutTube Cleaner incorporates the highest regards towards safety. With the OutTube™ Cleaner, it is proven that working in height is eliminated and confined space entry is minimize to essential personnel only. Ultimately time saving is also achieved as the need for scaffolding is no longer required. requirement,

Dust‐free cleaning,High cleaning efficiency:‐ improved heat transfer,‐ Prolonged tube life

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By applying the OutTube™ Cleaner technology the overall cleaning duration for the tube external can be substantially reduced whilst achievingdesired cleaning requirement. It is moreefficient than the conventional cleaning method with higher capability

.

cleaning method with higher capability to cover more area which are difficult to access. With consideration of “safety” above any other factor, OutTube™ Cleaner is the leading technology in ensuring safe and healthy work environment. It decreases the risk of potential hazards related to working

OutTube™ Cleaner principle: It consists of two air‐driven motors; responsible for the rotation of a head with steel brushes for cleaning the tubes and to drive the vertical movement on the tubes for optimum contamination

of potential hazards related to working at height and reduces the number of people required to work in a confined space condition.

Our references for OutTube™ Cleaner includes Agrium in Canada, Shell Stanlow in UK Yara Sluiskil in


tubes for optimum contamination removal such as dust, carbon deposit and scale. The OutTube™ Cleaner is also equiped with an automatic limit switch on the upper part of the machine in order to drive down the unit upon reaching the complete height of the tube.

Stanlow in UK, Yara Sluiskil in Netherlands and much more. For further information, please direct your enquiry to:

Alexander‐von‐Humboldt‐Straße2D‐01987 SchwarzheideTel + 6012 – 907 3528Fax + 603 – 7660 9393Email [email protected] Web www.unidense.com


INTUBE™ CLEANER

BENEFITS INTUBE™ CLEANER

Fast reformer tube cleaning,Reduce overall shutdown schedule

INTUBE CLEANERInTube ™ Cleaner is the latest technology advancement to safe and efficient method for internal cleaning of reformer tubes and/or furnaceheater’ tubes , applicable to tube sizes from 3” to 8” nominal diameter. InTube™ Cleaner incorporates the

A suction device is also designed to the InTube™ Cleaner to extract the scales, coked deposit and other contaminant particles which has been dislodged by the cleaning brushes.

Diagram ‐ Before & After Results Cleaning with the InTubeTM Cleaner schedule,

Optimize overall cost and potential cost savingDust‐free cleaning,High cleaning efficiency:‐ Improved heat transfer,‐ Prolonged tube life,‐ 100% contact on cleaning

InTube Cleaner incorporates the highest regards towards safety. With the InTube™ Cleaner, it is the first ever invention specifically built to cater the cleaning requirement for reformer tubes. The InTubeTM Cleaner also has undergone rigorous testing to ensure its functionality is effective and at the

Cleaning with the InTube Cleaner

100% contact on cleaning surface area

ysame time does not comprimise the tube internal metallurgy. ZOOM IN

.

By applying the InTube™ Cleaner technology the overall cleaning duration for the tube internal can be substantially reduced whilst achievingdesired cleaning requirement. It is moreefficient than the conventional cleaning method with higher capability

InTube™ Cleaner principle: It consists of an air‐driven motor; responsible for the rotation of a head with steel

cleaning method with higher capability to cover more area which are difficult to access. With consideration of “safety” above any other factor, InTube™ Cleaner is the leading technology in ensuring safe and healthy work environment.


the rotation of a head with steel brushes for cleaning the tubes and at the same time to drive the vertical movement on the tubes for optimum contamination removal such as dust, carbon deposit and scale.

Our references for InTube™ Cleaner includes Eiffel Industries in France and much more. For further information, please direct your enquiry to:

Alexander‐von‐Humboldt‐Straße2D‐01987 SchwarzheideTel + 6012 – 907 3528Fax + 603 – 7660 9393Email [email protected] Web www.unidense.com


CALYDENSCALYDENS is a simple and fast loading technology for loading fixed bed reactors, applicable to axial flow and/or radial flow reactor design. CALYDENS loading method also canbe applied to multiple bed reactors as well.CALYDENS combines being a high quality and fast loading technology.

CALYDENS technology ensures even liquid/gas flow in the reactors, and the pressure drop variation is kept to a minimum. The density will normally be higher than with the “sock” loading method, due to better packing. CALYDENS gives high uniform density along the full height of the reactor, decreasing the risk of channeling

BENEFITS CALYDENSFast reactor loading,Optimal catalyst particledispersion,Efficient distribution,

CALYDENS principle: Catalyst is loaded into the reactor and the loading machine shall ensure full control of the loading parameters for maximum catalyst protection. CALYDENS also is designed to achieve optimal particle dispersion and efficient catalyst distribution across the reactor internal di

decreasing the risk of channeling. Efficient distribution,Uniform pressure drop,No channeling,‐ Reduces catalyst settling,

High uniform density,Easy to handle & install,Easy to operate,“Plug & Play” machine.

diameter.

The CALYDENS machine is easy to operate and features a unique user‐friendly equipment setup and

COMPARISON:

CALYDENS A B

Rotating & Reversible

Dust Control Capability

friendly equipment setup and installation. The operation of the machine is simple and will fit easily to most reactor internal configuration. The CALYDENS is also equipped with a fail‐safe mechanism to stop the catalyst flow in case of any interruption to the pnuematic air supply driving the motor.

Bed Profile Viewing

Loading around Transfer Pipe

Loading without obstruction to Center of

By applying the CALYDENS technology the loading time of the fixed bed reactor can be substantially reducedwhilst maintaining high quality loading.

.

Sock Loading CALYDENS Loading Catalyst Bed

Loading to the maximum height beneath the Distributor

CALYDENS technology is used forCALYDENS technology is used for loading of all common catalyst typesand sizes. Reactor designs with varying internal diameter, have successivelybeen loaded. For further information, please direct your enquiry to:

UNIDENSE™ Technology GmbHAl d H b ld S ß 2Alexander‐von‐Humboldt‐Straße 2D‐01987 SchwarzheideTel + 6012 – 907 3528Fax + 603 – 7660 9393Email [email protected] Web www.unidense.com


UOP Dense Loading Service

Catalyst Refining

Application

Research backed by years of refinery experience hasestablished that reducing void fraction and control-ling catalyst particle orientation helps to preventreactor flow maldistribution. UOP’s proprietarycatalyst dense loading system increases catalyst beddensity and uniformity by means of the unique wayin which the catalyst bed is loaded. As a result ofthis increased density and uniformity, producersoperating a fixed bed catalytic process unit gain theability to increase operating severity, run longercycles and/or process more fresh charge stock intheir process units.

Typical density improvements

Percent Increase Percent Increase

Type of Over Manufacturer’s Over Sock

Particle Bulk Density Loading

Sphere 3-5 % ~10 %

Extrudate 8-10 % ~25 %

Pills 7-9 % ~15 %

UOP’s catalyst loading service offers three keyadvantages:

� High capacity loading� Improved loading machine design� Experienced advisors on-site

Process improvements resulting from improved density include:

� More uniform reactant distribution� Longer cycle length or higher throughput, or both� Better selectivity� Lower reactor temperatures

The average catalyst particle orientation will alsoaffect liquid distribution depending on how the catalyst particles are oriented. Liquid flows over acatalyst particle in a packed bed and tends to collectat the low points of the individual particles. In a bedof extruded catalyst, liquid will tend to be redistrib-uted to the sides of the reactor if the catalyst bed ismounded, or to the center of the reactor if the cata-lyst bed is dished. While liquid redistribution in abed of spheres is not as significant as in a bed of

extrudates, dense loading has been shown toimprove the liquid distribution by orienting thespheres closer to the ideal rhombohedral packing.

High-capacity loading

With dramatically increased loading rates of up to45,000 lb/hr (20T/hr), refiners can make significantreductions in the time spent reloading reactors. UOPcan provide one or more machines to load reactors in parallel for a more efficient loading.

Improved machine design

After identifying keyvariables in adetailed statisticalanalysis, UOPimproved the designof the dense loadingmachine to deliverconsistently flat cat-alyst bed profiles,which translate intoimproved unit performance.

The new dense load-ing machine hasbeen designed tohandle increased catalyst flow while streamlinedinternal passages minimize catalyst breakage.

The new distributor rotor has also been designed toload faster while maintaining better control of cata-lyst bed profiles. Dimensional control has beenimproved, resulting in more consistency in loading.

Loaders are maintained at our full-service facilitiesby dedicated machinists with decades of combinedexperience. All equipment is put through a series ofperformance tests to ensure its operating conditionbefore it is shipped to your facility.

Experienced advisors on-site

UOP is unique in the quality of personnel that wedeploy to customer facilities as part of the denseloading service. Trained process advisors overseeevery aspect of the loading operation with an eye

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efin

ing

UOP dense loading machine in place.

towards maximizing the performance of processunits. UOP can work with the customer’s staff orcontractor to ensure that the loading goes assmoothly and quickly as possible.

Having an experienced advisor supervising the cata-lyst loading will provide an additional measure ofcontrol over the loading operation. Catalyst densityis, in part, a factor of catalyst properties and bed levelness during the dense loading process. UOP’syears of research and development have resulted ina good understanding of exactly what settings touse for a wide range of catalyst and reactor types.The combination of years of experience and theUOP advisor’s attention to detail help ensure a uniform catalyst bed and maximum catalyst performance.

Quality program instituted

We have applied statistical regression to the denseloading process. UOP’s position as a catalyst manu-facturer and process licensor has allowed us to setup a data base of catalyst loading information. Usingthis data, we have developed statistical models thatgive us better than 95% confidence in our expecteddensity results.

Licensed suppliers

UOP’s catalyst loading technology is also availablefrom select, licensed industrial service companies.Contact UOP for service options in your area.

For more information

For more information, contact your local UOP representative or our Des Plaines sales office:

e-mail: [email protected]: +1-847-391-2253phone: +1-847-391-2000

Machines are maintained atfacilities around the globe.

UOP advisors have experiencewith all aspects of catalyst loading.

© 2006 UOP LLC. All rights reserved.The information in this document should not be construed as a representation for which UOP assumes legal responsibility, or an authorization or recommendation to practice a patented invention without a license.

UOP LLC25 East Algonquin RoadDes Plaines, IL 60017-5017, U.S.A.www.uop.comUOP 4520-5 0306CREF0E

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Unidense Services Brochure