Compacting elements for reducing fluidisation in catalyst carrier for tubular reactors and associated methods
A catalyst carrier for insertion into a reactor tube of a tubular reactor that comprises a container containing particles of catalyst. The container further contains a compacting element for reducing fluidisation of the particles of catalyst.
1 . A catalyst carrier, the catalyst carrier comprising a container containing (i) a radial flow catalyst bed comprising particles of catalyst and (ii) a compacting element that reduces fluidisation of the particles of catalyst, wherein the compacting element comprises a compressible element comprising one or more pads of a compressible material and configured to apply a compressive force to the particles of catalyst, wherein the compressible element is positioned at a top end of the catalyst bed and interposed between the particles of catalyst and a lid or closing end of the container, wherein the compacting element compacts the particles of catalyst when the container is closed; and
wherein the catalyst carrier is inserted into a reactor tube of a tubular reactor.
2 . The catalyst carrier of claim 1 , wherein the compressible element comprises a ceramic material.
3 . The catalyst carrier of claim 1 , wherein the ceramic material comprises refractory ceramic fibres.
4 . The catalyst carrier of claim 1 , wherein the ceramic material comprises alumina fibres, silica fibres, alumino-silicate fibres, titania fibres, zirconia fibres or a mixture of two or more of these.
5 . The catalyst carrier of claim 1 , wherein the ceramic material comprises a non-woven material.
6 . The catalyst carrier of claim 1 , wherein the compressible material has a bulk density of less than about 400 kg/m 3 .
7 . The catalyst carrier of claim 1 , wherein the container comprises an annular chamber containing the particles of catalyst, the annular chamber having a perforated inner chamber wall defining an inner channel, a perforated outer chamber wall, a top surface closing the annular chamber and a bottom surface closing the annular chamber;
and optionally wherein the compacting element is within the annular chamber on top of the particles of catalyst.
8 . The catalyst carrier of claim 7 , wherein the compacting element comprises an annular element.
9 . The catalyst carrier of claim 7 , wherein the compacting element is configured as an interference fit within the annular chamber.
10 . The catalyst carrier of claim 1 , wherein the compacting element comprises a tamping element configured to tamp the particles of catalyst.
11 . The catalyst carrier of claim 10 , wherein:
the tamping element comprises a portion of a lid or closing end of the container; or
wherein the tamping element is interposed between a lid or closing end of the container and the particles of catalyst.
12 . The catalyst carrier of claim 10 , wherein the tamping element comprises a rigid, resilient and/or compressive portion.
13 . The catalyst carrier of claim 1 , wherein the compacting element comprises an intumescent material.
14 . The catalyst carrier of claim 1 , wherein the compressible material has a bulk density of less than about 200 kg/m 3 .
15 . The catalyst carrier of claim 1 , wherein the compressible material has a bulk density of 100 to 200 kg/m 3 .
16 . The catalyst carrier of claim 1 , wherein the compressible material has a bulk density of 150 to 200 kg/m 3 .