Abstract: A dense loading system with wave loader is a device intended to maximize and evenly distribute catalyst within a catalyst reactor. More specifically, the device provides a dense loading machine that uses air/nitrogen to propel catalysts within the space of a catalyst reactor. To accomplish this, the system includes a unique arrangement of components that utilizes a hybrid distribution of catalyst through a specifically shaped catalyst distribution disc. Further, the catalyst distribution disc is subjected to both pneumatic and rotational forces with the help of a sparger system and a motor system. In addition, the system provides a dense loading machine that may be operated manually or autonomously. Further, the device may load catalyst in radial waves, may achieve targeted area loading, and includes a gyroscopic auto alignment system for the catalyst distribution disc. Thus, the dense loading system that can efficiently and evenly distribute catalyst within a catalyst reactor.

Abstract: An equal flow scale catcher device, or EFSC, is designed based on a unique scale catching technology for a reactor. With multiple scale catching modules, the EFSC offers equal flows to a catalyst bed or distribution tray of the reactor, independent of each module's degree of saturation with particles of an incoming fluid during operation. Thus, the innovative EFSC system achieves substantial uniformity of fluid delivery across the distribution tray of the reactor and the static pressure field above the liquid level on the distribution tray. Further, the EFSC effectively captures solid particles in the incoming fluid to the reactor and solid particles that form at the top head of the reactor. The EFSC employs a modular structure that allows optimal configuration of the scale catching modules and scale catching units inside each scale catching module, thus efficiently facilitating simple and efficient installation, maintenance, and/or replacement of the EFSC.

Abstract: A catalyst loading and unloading system for chemical reactors has an extendable catalyst transfer tube that is fed by a catalyst hopper and controlled by a tube displacement mechanism; more particularly, by a winch mechanism. As the reactor chamber fills with catalyst, a lower end of the extendable catalyst transfer tube is displaced upward by the tube displacement mechanism to correspond with the rising height of the catalyst bed within the chamber. The extendable catalyst transfer tube may further be used to vacuum old catalyst out of the reactor chamber.