Process for loading a reactor

Abstract

There is provided a method for loading solid particles into a multi-tube reactor having an upper tube-sheet holding together the upper ends of the multitude of reactor tubes, the method comprising positioning a loading device having a plurality of holes on top of the upper tube-sheet such that the loading device rests on and substantially covers the upper tube-sheet and the holes correspond to the reactor tubes, the loading device comprising a plurality of adjacent polygonal plates, each polygonal plate having from 1 to 30 holes, each hole corresponding to one reactor tube; pouring the particles over the combined polygonal plates covering the tube-sheet; sweeping the particles through the holes in the plates into the respective reactor tubes; removing residual particles and any dust remaining on and between the plates; and removing the loading device.

1 . A loading device for loading particles in a multi-tube reactor, comprising: 
 a discrete plate having a shape that provides a spacing between adjacent plates positioned on the multi-tube reactor to collect dust and partial particles, wherein a single aperture through the plate corresponds to and aligns with a single respective reactor tube within the multi-tube reactor.    
     
     
         2 . The loading device of  claim 1 , wherein the shape enables placement of the plate on the multi-tube reactor proximate the single respective reactor tube without interfering with neighboring reactor tube openings.  
     
     
         3 . The loading device of  claim 1 , further comprising an insert extending from the discrete plate, the insert configured to at least partially extend into the respective reactor tube.  
     
     
         4 . The loading device of  claim 1 , further comprising a tubular insert extending from the discrete plate, the tubular insert configured to at least partially extend into the respective reactor tube.  
     
     
         5 . The loading device of  claim 1 , wherein the discrete plate is made of a polymer.  
     
     
         6 . The loading device of  claim 1 , wherein the discrete plate is made of a polypropylene.  
     
     
         7 . The loading device of  claim 1 , wherein the discrete plate is made of a polyvinyl chloride.  
     
     
         8 . The loading device of  claim 1 , wherein the spacing has a width less than the smallest dimension of a single whole particle.  
     
     
         9 . The loading device of  claim 1 , further comprising a tubular insert extending from the discrete plate around the single aperture, the tubular insert configured to extend into the respective reactor tube a depth of from 1.1 to 1.5 times a predetermined depth of the respective reactor tube that is to be kept free from particles when loaded.  
     
     
         10 . A loading device for loading particles in a multi-tube reactor, comprising: 
 a discrete plate having a shape that provides a spacing between adjacent plates positioned on the multi-tube reactor to collect dust and partial particles, the spacing having a width less than the smallest dimension of a single whole particle, wherein the plate has at least one aperture that corresponds to and aligns with at least one respective reactor tube within the multi-tube reactor.    
     
     
         11 . The loading device of  claim 10 , further comprising at least one insert extending from the at least one aperture, the at least one insert configured to at least partially extend into the at least one respective reactor tube.  
     
     
         12 . The loading device of  claim 10 , wherein the discrete plate is made of a polymer.  
     
     
         13 . A method for loading solid particles into a multi-tube reactor, comprising: 
 positioning a plurality of discrete plates on top of an upper tube-sheet of the multi-tube reactor, whereby the plates substantially cover at least a portion of the upper tube-sheet and each plate has a shape that provides a spacing between adjacent plates having a width for collecting dust and partial particles;    pouring the particles over at least a portion of the plates covering the tube-sheet and into apertures through the plates; and    removing any dust remaining in the spacing between adjacent plates.    
     
     
         14 . The method of  claim 13 , wherein the shape of each plate enables the positioning of the plurality of discrete plates on the multi-tube reactor such that each of the plurality of discrete plates are proximate a single respective reactor tube without interfering with neighboring reactor tube openings.  
     
     
         15 . The method of  claim 13 , wherein the positioning the plurality of discrete plates comprises inserting fixing means of the plates into a top of reactor tubes of the multi-tube reactor to provide for alignment of the apertures in the plates with corresponding reactor tubes.  
     
     
         16 . The method of  claim 13 , wherein the positioning the plurality of discrete plates comprises disposing inserts coupled to the plates into a top of reactor tubes of the multi-tube reactor to provide for alignment of the apertures in the plates with corresponding reactor tubes.  
     
     
         17 . The method of  claim 13 , wherein the spacing has a width less than the smallest dimension of a single whole particle.  
     
     
         18 . The method of  claim 13 , wherein each of the plurality of discrete plates have a single aperture corresponding to and aligning with a single respective reactor tube within the multi-tube reactor.  
     
     
         19 . The method of  claim 13 , wherein the plurality of discrete plates are made of a polymer.  
     
     
         20 . The method of  claim 13 , further comprising removing the plurality of discrete plates.