Tray support inserts for chemical reactor vessels and methods of use

1. A tray support insert to support a tray within a reactor chamber of a hydrocarbon chemical reactor, the reactor chamber having an interior surface with a support shoulder formed thereon, the tray support insert comprising:

at least one annular member further comprising:

a support grid skirt which presents a first supporting surface for a first tray; and

a catalyst support grid ring which is seated upon the support grid skirt and which presents a second supporting surface for a second tray;

wherein the at least one annular member rests upon the support shoulder and presents a supporting surface for the first tray and the second tray;

wherein the support grid skirt further comprises an annular skirt frame and a plurality of support members which extend axially away from the annular skirt frame and upon which the first tray can be supported; and

wherein the catalyst support grid ring further comprises a vertical curved panel and

a tray support ledge which projects radially inwardly from the panel and upon which the second tray can be supported.

2. The tray support insert of claim 1 wherein the at least one annular member is formed of stainless steel.

3. The tray support insert of claim 1 wherein the at least one annular member is formed of a plurality of separate arcuate segments which can be assembled together to form a complete annular structure.

4. The tray support system of claim 1 wherein the catalyst support grid ring further comprises a rectangular box portion which projects radially inwardly from the panel and which presents a supporting surface for a catalyst bed.

5. A tray support insert to support a tray within a reactor chamber of a chemical reactor, the reactor chamber having an interior surface with a support shoulder formed thereon, the tray support insert comprising:

at least one annular member formed of stainless steel, the annular member comprising

a support grid skirt which presents a first supporting surface for a first tray; and

a catalyst support grid ring which is seated upon the support grid skirt and which presents a second supporting surface for a second tray;

wherein the at least one annular member rests upon the support shoulder and presents a supporting surface for the first tray and the second tray; and

wherein the support grid skirt comprises an annular skirt frame and a plurality of support members which extend axially away from the annular skirt frame and upon which the first tray can be supported; and

wherein the catalyst support grid ring comprises a vertical curved panel and a tray support ledge which projects radially inwardly from the panel and upon which the second tray can be supported.

6. The tray support insert of claim 5 wherein the at least one annular member is formed of a plurality of separate arcuate segments which can be assembled together to form a complete annular structure.

7. The tray support insert of claim 5 wherein the catalyst support grid ring further comprises:

a rectangular box portion which projects radially inwardly from the panel and which presents a supporting surface for a catalyst bed.

8. A method of supporting a tray upon a tray support insert within a reactor chamber of a chemical reactor vessel, the method comprising the steps of:

disposing the tray support insert into the reactor chamber;

disassembling the tray support insert into separate components after it is disposed into the reactor chamber;

assembling the tray support insert from the separate components within the reactor chamber;

disposing the assembled tray support insert upon a support shoulder that is formed within the

interior surface of the chemical reactor vessel, the tray support insert comprising at least

one annular member; and

supporting the tray upon the tray support insert;

wherein the step of disposing the tray support insert into the reactor chamber is carried out

prior to the step of disposing the tray support insert upon the support shoulder.

9. The method of claim 8 further comprising the step of flowing a chemical feed through the tray within the reactor chamber.

10. The method of claim 8 wherein the step of supporting the tray upon the tray support insert further comprises:

supporting trays of a quench section upon supporting surfaces of the tray support insert; and

wherein supporting the trays of the quench section upon supporting surfaces of the tray support insert will locate the quench section at a higher elevation within the reactor chamber than would supporting the quench section within the reactor chamber without the tray support insert.