BUCHEN-ICS has further developed an innovative filling system to enable reactors and vessels to be filled with catalyst or other bulk materials without the need for a crane – no matter how strong the wind or how bad the weather. A unique solution that will make it much easier for businesses to plan ahead.
In most cases, a crane has to be brought in to help out when reactors and vessels need to be filled with bulk material as it can lift up the material (packed, for example, in big bags) and place it next to the opening. However, regulations stipulate that a large area must be cordoned off around the lifting area (suspended loads) to keep everyone safe – and work must be stopped if it rains too heavily or if there are strong winds. This is where BUCHEN’s dense phase conveying system (DPC) comes into play. This upgraded material-friendly system enables reactors and vessels to be filled without interruption in places where a crane may not be used for safety or weather reasons.
The material is safely conveyed upwards through the pipe instead of having to be lifted up by crane
And this is how it works: the dense phase conveyor consists of two storage tanks that are firmly fixed in a frame on the ground and completely weatherproof. The material is conveyed pneumatically from the first tank into a stainless steel pipe. The material can be conveyed vertically up to 90 metres above ground – no matter what the size, shape or weight of the granules may be. At the same time, the second tank is filled with material. This enables the filling process to be completed uninterrupted and ensures that the whole of the pipeline is filled throughout. Once the material reaches the top of the vessel/reactor, it is automatically transferred into a filling container – also protected against the weather – before the actual filling of the reactor begins. This makes it possible for a variety of filling techniques to be deployed such as sock loading or dense loading. An additional hose line links the filling container with a vacuum unit below so that any dust particles generated by the filling process can be vacuumed off.
The dense phase conveying system is suitable for all types of reactors and vessels
The dense phase conveying system is suitable for all types of reactors and vessels. As it can be stored in a 20' container, it can be transported to and installed wherever it is needed in no time at all. Whether it is raining, stormy or there is simply a lack of space: BUCHEN’s new filling system can be used to fill reactors in CCR, HC, Claus and styrene plants as well as molecular sieve vessels, HDS reactors, vessels in ethylene/propylene hydrogenation plants as well as narrow PSA plants.
Everything under control: the system first underwent extensive tests; a 30-metre-high scaffold was built to simulate the exact conditions
This innovative system first underwent an extensive test phase that lasted several months to check it worked smoothly. This was carried out on BUCHEN’s own premises in Cologne where it had had a 30-metre-high scaffolding tower built specifically for this purpose. The developers tested the system under a variety of different conditions. After all the tests had been passed with flying colours, the company then put on a special event in the autumn of 2016 to present the technology to its customers. Since then, it has been deployed in various projects and proven to be an absolute success each and every time.
By using hose lines and a filling container next to the opening of the reactor/vessel, the BUCHEN-ICS specialists ensure that the material is conveyed safely and remains dry throughout