ILS - 6-Parallel Multi Reactor Catalyst Testing Unit
This is an example for a Multi Reactor Catalyst Testing unit, which we have designed for Repsol as multipurpose tool for catalyst and feedstock evaluation for hydroprocessing reactions (e.g. hydrodesulfurization and hydrocracking). The greatest challenge in this project was to design a unit that fulfils all budget, space and safety requirements while providing a large flexibility in operating conditions (T, P, F,X) as well as the capability to handle a large variety of feedstocks and products. Also unit robustness was key element as catalytic studies up to multiple months need to be executed.
Reactors can be individually operated as well as sets of two (3×2). Therefore ILS chose to design the unit in a modular fashion to reduce engineering and cabling work as well as minimizing footprint while providing good user access. The hard- and software was designed according to the standards of Repsol, which allows future expansions and also makes operation and service much easier.
High-temperature, high pressure diaphragm pumps in combination with high-temperature coriolis flow meters have been selected to dose different feedstocks independently of their properties. Optimized Reactors in multi-zone split shell ovens give enough space for larger catalyst amounts while ensuring plug-flow conditions, avoiding wall effects and axial dispersion. The pressure control and gas/liquid separation and striping section was designed to handle huge variations in pressures and flows by using novel 2-phase membrane pressure controllers. An integrated online GC, as well as exit gas flow meters and automatic liquid product recovery and sampling has been used to provide a tight mass balance.
Altogether this gives Repsol a powerful tool with high flexibility to support the refineries and productions sites much quicker. Also catalyst evaluation capacity and data quality could be improved without the need to hire more operators.