Particle loading method and apparatus for a radial flow vessel

1. A particle loading assembly for loading particles into a vessel to form a particle bed comprising an inner layer of particles and an outer layer of particles, the inner layer of particles arranged radially and concentric with the outer layer of particles, the inner layer containing at least a first type of particle of different granulometry or range of composition or both granulometry and range of composition from a second type of particle contained in the outer layer, the assembly comprising:

a sliding barrier for segregating particles for the inner layer from the particles for the outer layer during loading, the sliding barrier having a top end and a bottom end;

an inner particle distributor for distributing particles for the inner layer, the inner particle distributor in fixed spaced relation to the sliding barrier, the inner particle distributor having a lowermost particle discharge position, wherein a horizontal plane passing through the lowermost particle discharge position of the inner particle distributor passes through the sliding barrier at a position between the top end and the bottom end of the sliding barrier;

an outer particle distributor for distributing particles for the outer layer, the outer particle distributor in fixed spaced relation to the sliding barrier, the outer particle distributor having a lowermost particle discharge position, wherein a horizontal plane passing through the lowermost particle discharge position of the outer particle distributor passes through the sliding barrier at a position between the top end and the bottom end of the sliding barrier; and

a hoist for lifting the sliding barrier, the inner particle distributor, and the outer particle distributor during loading of the particles for the inner and outer layers;

wherein a first vertical height, h 1 , is defined between the lowermost particle discharge position of the inner particle distributor and the bottom end of the sliding barrier, wherein the first vertical height, h 1 , is at least 100 mm; and

wherein a second vertical height, h 2 , is defined between the lowermost particle discharge position of the outer particle distributor and the bottom end of the sliding barrier, wherein the second vertical height, h 2 , is at least 100 mm.

2. The particle loading assembly according to claim 1 , wherein the inner particle distributor comprises a means for dispersing particles, wherein the means for dispersing particles comprises at least one of a perforated plate, a wire mesh, an expanded metal, or a plate defining a plurality of orifices with an accompanying particle dispersal assembly associated with each orifice of the plurality of orifices.

3. The particle loading assembly according to claim 2 , wherein the means for dispersing particles comprises the plate defining the plurality of orifices with the accompanying particle dispersal assembly associated with each orifice of the plurality of orifices, wherein each particle dispersal assembly is disposed adjacent to a respective orifice of the plurality of orifices in the plate, wherein each particle dispersal assembly comprises a deflecting surface disposed relative to its respective orifice such that particles can flow vertically from the respective orifice and be dispersed by the deflecting surface.

4. The particle loading assembly according to claim 2 , wherein the inner particle distributor comprises a spreader, wherein the spreader comprises at least one of a perforated plate, a wire mesh, an expanded metal, a particle loading arm, or a plate defining a plurality of orifices with the accompanying particle dispersal assembly associated with each orifice of the plurality of orifices, wherein the spreader of the inner particle distributor is positioned at an elevation above the means for dispersing particles of the inner particle distributor.

5. The particle loading assembly according to claim 4 wherein the spreader of the inner particle distributor comprises the particle loading arm, wherein the particle loading arm comprises

a conduit section having a first end and a second end, wherein the first end is in particle flow communication with a supply of particles for the inner layer of particles, and wherein the conduit section has a plurality of orifices disposed between the first end and the second end; and

a plurality of particle dispersal assemblies, each particle dispersal assembly being disposed adjacent to a respective orifice in the conduit section, wherein each particle dispersal assembly comprises a deflecting surface disposed relative to its respective orifice such that particles can flow vertically from the respective orifice and be dispersed by the deflecting surface.

6. The particle loading assembly according to claim 1 , wherein the inner particle distributor comprises a particle loading arm, wherein the particle loading arm comprises

a conduit section having a first end and a second end, wherein the first end is in particle flow communication with a supply of particles for the inner layer of particles, and wherein the conduit section has a plurality of orifices disposed between the first end and the second end; and

a plurality of particle dispersal assemblies, each particle dispersal assembly being disposed adjacent to a respective orifice in the conduit section, wherein each particle dispersal assembly comprises a deflecting surface disposed relative to its respective orifice such that particles can flow vertically from the respective orifice and be dispersed by the deflecting surface.

7. The particle loading assembly according to claim 6 , wherein each particle dispersal assembly of the particle loading arm of the inner particle distributor further comprises a dispersing surface disposed adjacent to the orifice, wherein a plane tangent to any point on the deflecting surface and a plane tangent to any point on the dispersing surface intersect at an included angle of between about 30 and about 60 degrees, whereby particles can be deflected by the deflecting surface, impinge upon the dispersing surface, and be further dispersed by the dispersing surface.

8. The particle loading assembly according to claim 1 , wherein the outer particle distributor comprises a means for dispersing particles, wherein the means for dispersing particles of the outer particle distributor comprises at least one of a perforated plate, a wire mesh, an expanded metal, or a plate defining a plurality of orifices with an accompanying particle dispersal assembly associated with each orifice of the plurality of orifices.

9. The particle loading assembly according to claim 8 , wherein the means for dispersing particles of the outer particle distributor comprises the plate defining the plurality of orifices with the accompanying particle dispersal assembly associated with each orifice of the plurality of orifices, wherein each particle dispersal assembly is disposed adjacent to a respective orifice of the plurality of orifices in the plate, wherein each particle dispersal assembly comprises a deflecting surface disposed relative to its respective orifice such that particles can flow vertically from the respective orifice and be dispersed by the deflecting surface.

10. The particle loading assembly according to claim 9 , wherein each particle dispersal assembly of the accompanying particle dispersal assemblies of the means for dispersing particles of the outer particle distributor comprises a dispersing surface disposed adjacent each respective orifice of the plurality of orifices, wherein a plane tangent to any point on the deflecting surface and a plane tangent to any point on the dispersing surface intersect at an included angle of between about 30 and about 60 degrees, whereby particles can be deflected by the deflecting surface, impinge upon the dispersing surface, and be further dispersed by the dispersing surface.

11. The particle loading assembly according to claim 8 , wherein the outer particle distributor comprises a spreader, wherein the spreader of the outer particle distributor comprises at least one of a perforated plate, a wire mesh, an expanded metal, a particle loading arm, or a plate defining a plurality of orifices with the accompanying particle dispersal assembly associated with each orifice of the plurality of orifices, wherein the spreader of the outer particle distributor is positioned at an elevation above the means for dispersing particles of the outer particle distributor.

12. The particle loading assembly according to claim 11 wherein the spreader of the outer particle distributor comprises the particle loading arm, wherein the particle loading arm of the outer distributor comprises

a conduit section having a first end and a second end, wherein the first end is in particle flow communication with a supply of particles for the outer layer of particles, and wherein the conduit section has a plurality of orifices disposed between the first end and the second end; and

a plurality of particle dispersal assemblies, each particle dispersal assembly being disposed adjacent to a respective orifice in the conduit section of the particle loading arm of the outer particle distributor, wherein each particle dispersal assembly comprises a deflecting surface disposed relative to its respective orifice such that particles can flow vertically from the respective orifice and be dispersed by the deflecting surface.

13. The particle loading assembly according to claim 1 , wherein the outer particle distributor comprises a particle loading arm ( 56 ), wherein the particle loading arm ( 56 ) of the outer particle distributor comprises

a conduit section having a first end and a second end, wherein the first end is in particle flow communication with a supply of particles for the outer layer of particles, and wherein the conduit section has a plurality of orifices disposed between the first end and the second end; and

a plurality of particle dispersal assemblies, each particle dispersal assembly being disposed adjacent to a respective orifice in the conduit section, wherein each particle dispersal assembly comprises a deflecting surface disposed relative to its respective orifice such that particles can flow vertically from the respective orifice and be dispersed by the deflecting surface.

14. A method for loading particles into a vessel to form a particle bed comprising an inner layer of particles and an outer layer of particles, the inner layer of particles arranged radially and concentric with the outer layer of particles, the inner layer containing at least a first type of particle of different granulometry or composition or both granulometry and composition from a second type of particle contained in the outer layer, the method comprising:

discharging particles for the inner layer from an inner particle distributor onto an upper surface of the inner layer to form the inner layer of particles of increasing height as the particles are discharged, the inner particle distributor having a lowermost particle discharge position;

discharging particles for the outer layer from an outer particle distributor onto an upper surface of the outer layer to form the outer layer of particles of increasing height as the particles are discharged, the outer particle distributor having a lowermost particle discharge position;

segregating the particles for the inner layer from the particles for the outer layer with a sliding barrier while the particles for the inner layer and the particles for the outer layer are discharged, the sliding barrier having a top end and a bottom end; and

lifting the sliding barrier from a lower section of the vessel to an upper section of the vessel thereby placing the inner layer of particles located below a horizontal plane passing through the bottom end of the sliding barrier in direct contact along an interfacial zone with the outer layer of particles located below the horizontal plane passing through the bottom end of the sliding barrier;

wherein the lowermost particle discharge position of the inner particle distributor is maintained from 70 mm to 2000 mm above the upper surface of the inner layer during the step of discharging particles for the inner layer;

wherein the lowermost particle discharge position of the outer particle distributor is maintained from 70 mm to 2000 mm above the upper surface of the outer layer during the step of discharging particles for the outer layer; and

wherein the bottom end of the sliding barrier is maintained at a position ranging from below the upper surface of the inner layer to no more than 20 mm above the upper surface of the inner layer and ranging from below the upper surface of the outer layer to no more than 20 mm above the upper surface of the outer layer during the step of lifting the sliding barrier.

15. The method according to claim 14 wherein the top end of the sliding barrier is maintained above the upper surface of the inner layer during discharging particles for the inner layer and the sliding barrier is maintained above the upper surface of the outer layer during discharging particles for the outer layer.

16. The method according to claim 14 wherein the top end of the sliding barrier is maintained above the lowermost particle discharge position of the inner particle distributor during discharging particles for the inner layer and the top end of the sliding barrier is maintained above the lowermost particle discharge position of the outer particle distributor during discharging particles for the outer layer.

17. The method according to claim 14 wherein the inner particle distributor has an uppermost particle discharge position at an elevation higher than the lowermost particle discharge position for the inner particle distributor, wherein the outer particle distributor has an uppermost particle discharge position at an elevation higher than the lowermost particle discharge position for the outer particle distributor, wherein the top end of the sliding barrier is maintained above the uppermost particle discharge position of the inner particle distributor and above the uppermost particle discharge position of the outer particle distributor.

18. The method according to claim 14 wherein the sliding barrier is lifted to a final elevation in the vessel and the inner particle distributor, the outer particle distributor, and the sliding barrier are left in the vessel after completion of loading the particles into the vessel.

19. The method according to claim 14 wherein the lowermost particle discharge position of the inner particle distributor is maintained from 70 mm to 2000 mm above the upper surface of the inner layer during the step of discharging particles for the inner layer, the lowermost particle discharge position of the outer particle distributor is maintained from 70 mm to 2000 mm above the upper surface of the outer layer during the step of discharging particles for the outer layer, and the bottom end of the sliding barrier is maintained below the upper surface of the inner layer and below the upper surface of the outer layer during the step of lifting the sliding barrier by

sensing whether particles of the inner layer are below a lower limit level for the inner layer using a first probe and generating signals in response thereto;

sensing whether particles of the inner layer are above an upper limit level for the inner layer using a second probe and generating signals in response thereto;

sensing whether particles of the outer layer are below a lower limit level for the outer layer using a third probe and generating signals in response thereto;

sensing whether particles of the outer layer are above an upper limit level for the outer layer using a fourth probe and generating signals in response thereto; and

providing particles to the inner particle distributor, providing particles to the outer particle distributor, and lifting the sliding barrier responsive to the signals from the first probe, the second probe, the third probe, and the fourth probe.

20. The method according to claim 19 further comprising at least one of the following steps (a) to (d):

(a) particles are provided to the inner layer at a volumetric rate greater than a volumetric rate of providing particles to the outer layer responsive to the first probe for the inner layer generating signals indicating that the particles of the inner layer are below the lower limit level for the inner layer at the same time the third probe is generating signals indicating that the particles of the outer layer are above the lower limit level for the outer layer,

(b) particles are provided to the outer layer at a volumetric rate greater than a volumetric rate of providing particles to the inner layer responsive to the first probe generating signals indicating that the particles of the inner layer are above the lower limit level for the inner layer at the same time the third probe is generating signals indicating that the particles of the outer layer are below the lower limit level for the outer layer,

(c) the sliding barrier is lifted responsive to the second probe generating signals indicating that the particles of the inner layer are above the upper limit level for the inner layer at the same time the fourth probe is generating signals indicating that the particles of the outer layer are above the upper limit level for the outer layer, the sliding barrier lifted until at least one of (i) the second probe generates signals indicating that the particles of the inner layer are below the upper limit level for the inner layer or (ii) the fourth probe generates signals indicating that the particles of the outer layer are below the upper limit level for the outer layer, or

(d) lifting of the sliding barrier is slowed or halted responsive to the first probe generating signals indicating that the particles of the inner layer are below the lower limit level for the inner layer at the same time the third probe is generating signals indicating that the particles of the outer layer are below the lower limit level for the outer layer.