Method of filling catalyst in the hydrogen reactor

Answer 1

The filling method of the catalyst in the hydrogen reactor is as follows:

** I. Pre-loading preparation **
1. ** Organization and personnel **
- Set up a temporary command center to lead and coordinate the loading work.
- The equipment and technical personnel shall give technical clarification to the construction personnel so that they are familiar with the filling plan such as the type, sequence, and quantity of the agent. At the same time, they shall carry out the safety education and professional technical training so that the construction personnel can master the safety protection knowledge, the usage method of protective equipment, and the filling procedure.
2. ** Personnel Health and Protection **
- Prepare the clothes and gas protection equipment for the work inside the machine.
- The workers in the reactor had to undergo the necessary physical examination and do a good job of monitoring.
3. ** Tools and materials **
- Prepare the necessary tools for loading, such as the loading hoppers, loading bags, rakes, measuring tape, and notebooks.
- Arrange and mark the disassembled thermocouples, sleeves, channel plates, distribution plates, etc. in an orderly manner, and assign a special person to prevent them from being mixed up.
- Confirm that the reactor is clean, dry, and free of debris.
- From taking the agent from the ground to loading it into the reactor, each step was confirmed by a special person, who recorded the name, quantity, time, and so on.
- Protect the reactor well during construction intervals and do a good job of preventing rain. Also, bring out as many loading tools as you put into the reactor to prevent items from being left behind in the reactor.
- Prepare the catalyst filling map, which indicates the type, quantity and elevation of each layer of materials. Mark the lines in the reactor and connect the external air supply breather.

** II. Requirements for filling techniques **
1. ** Requirements **
- The catalyst is highly water-absorbing, so it must be covered with waterproof canvas when transported to the site. It must not be piled up in the open air. The loading should be carried out in dry weather without wind, rain, or fog. It is strictly prohibited to load in rainy days or when the humidity is high. Unless the weather is bad and the loading is interrupted, the loading should be carried out day and night. When the reactor is forced to be interrupted, the reactor entrance should be covered.
2. ** Operation Requirements **
- The catalyst should be handled lightly to prevent it from being crushed. The crushed catalyst should be sieved. The filling process should be guided by a canvas duct to make the catalyst evenly scattered. The free falling height should be less than 1 meter. Each layer of ceramic balls or catalyst should be raked flat once before being loaded to prevent the center from being cone-shaped.
- Keep the filling process clean and prevent foreign objects from falling into the catalyst. The items brought in and out by the operator must be registered and must not be lost or lost. It is forbidden to bring in items that may pollute the catalyst into the loading site.
- The catalyst installation personnel had to stand on a wooden board prepared in advance to prevent the catalyst from being crushed. They had to wear clean shoes to prevent dirt from entering.
- There will be a special person responsible for recording, measuring, and collecting samples. Each barrel of catalyst must be opened for inspection. If it is found to be discolored or crushed, it must not be used.
- The reactor's valve should be wrapped to prevent the sealing surface of the valve from being damaged during filling.

** 3. The specific loading steps **
1. ** Operating procedures on the ground **
- Place the barreled catalyst on the ground near the reactor, put the barreled catalyst on the scale with manpower and a shovel, weigh it and record it, then put it into the ground feeding bunker, and lift the bunker to the top of the reactor with a crane or an electric gourd.
- The top feeding funnel of the reactor and its internal canvas feeding pipe shall be installed in advance. The catalyst shall be sent into the reactor through the top feeding funnel and the canvas feeding pipe. The feeding funnel shall be sent to the ground by a crane and then repeated. The loading shall be lifted by an electric gourd.
2. ** Operating procedure of the reactor top **
- Before filling the reactor, check the size of the ceramic ball and the catalyst again.
- The suction device was installed at the entrance of the reactor to suck out the dust during the loading process and form a counter-current to ensure a good loading environment.
- Put down the ladder and lighting facilities to ensure that the brightness in the reactor is suitable for operation. As the loading process is carried out, keep the ladder at an appropriate height from the material level of the reactor so that the operating personnel can replace and check the work.
- Two operators, wearing air masks and safety ropes tied around their waists, went down to the reactor. They checked the height of the pipe fitted with the valve and the pipe connected below the valve from the loading surface, as well as the tightness of the pipe. They also checked the clarity and accuracy of the internal layering. When the catalyst needed to stop falling, they could use a steel card to clamp the pipe opening of the canvas pipe.
- First, the discharge tube was filled with porcelain balls with a diameter of 3 mm.
- Use a shovel to transport the barreled catalyst to a scale for weighing and recording, then load it into the ground feeding funnel. After loading, use a crane to lift it to the top of the reactor and unload the catalyst into the fixed feeding funnel at the top of the reactor.
- Add the ceramic balls at the bottom of the reactor layer by layer according to the specifications and the marked size. After adding a ceramic ball of each specifications, rake and detect and record the amount added; add protective agent or catalyst according to the requirements of the filling diagram, rake and detect every 500mm until the catalyst is added to the height left when the upper ceramic balls and the cold hydrogen box are installed. When the loading level of each layer of catalyst is about to approach the position of the thermowell, the thermowell should be inserted in time and then continue to be loaded after it is fixed.

In addition, there was another special filling method, which was to first prepare the mixed catalyst (mix the stiffening catalyst and the inertia ceramic ball evenly), and then fill the mixed catalyst into the shell-tube reactor to form a mixed catalyst layer. A layer of stiffening catalyst was filled under the mixed catalyst layer to form a stiffening catalyst layer, and a layer of inertia ceramic ball and a layer of support spring were filled under the stiffening catalyst layer to form the inertia ceramic ball layer and the support spring layer respectively. The mixed catalyst contains a certain proportion (for example, 65 - 90wt% of the hydrogen catalyst and 10 - 35wt% of the inertia ceramic ball, and the preferred proportion is 80wt% of the hydrogen catalyst and 20wt% of the inertia ceramic ball), the height ratio of the mixed catalyst layer and the hydrogen catalyst layer is a certain (for example, 1:(4 - 7), and the preferred proportion is 1:5.5), the height of the inertia ceramic ball layer is 100 - 300mm, and the diameter of the inertia ceramic ball is 6 - 10mm.
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