Gerard B.

Hawkins
Managing Director

Quench Converter
ARC Converter
Tube Cooled
Toyo MRF-Z
Adiabatic Beds

Inlet
Manway

Manway
Inert Balls

Catalyst
Discharge Chute

Exit

Catalyst
Discharge Chute

Vessel Wall

Shot Pipe

Sparge Pipe
Mesh

Sparge
Holes

10
Max Rate
Curve

Methanol Concentration (mol%)

Methanol
6

Equilibrium

0
180

200

220

240

260

Temperature (C)

280

300

320

MUG

Separator
Flash Drum

Benefits are

Simple
Reliable
Well proven
Capacity up to 3000 mtpd

Recover heat into saturator circuit

The catalyst doesnt see all the gas.
Poor catalyst loading can lead to cold core
developing

Significant flow mal-distribution

Some zones are cold
Can lose reaction

Some zones are hot

High byproducts levels
High rate of catalyst deactivation

Catalyst density

Low
flow

Normal

Cool

Normal

It is not caused by the quench lozenges being

poor distributors of the cool incoming gas.
The reverse is true - the lozenges are very good
distributors.
The problem is that voidage variations across the
bed can cause varying flows down different parts
of the reactor.
ARC retrofit developed to overcome problem.

Catalyst Support
Plates

Individual / Separate
Catalyst Beds

Gas Mixing
System

Ca t a
ly s t

x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

e d
b

* Figures in red are from current

operating records (Sept. '96)

Inlet Temperature

* Figures in black are from ARC

design case

Exit Temperature

Bed 1 223 C
Bed 1 251 C

Bed 1 270 C

Bed 2 223 C

Bed 1 291 C

Bed 2 262 C

Bed 3 237 C

Bed 2 270 C
Bed 2 301 C

Bed 3 261 C

Bed 3 270 C
Bed 4 230 C
Bed 4 269 C

Bed 3 289 C

Bed 4 260 C

Temperature

Quench Converter

Equilibrium
Line

ARC Converter

% Methanol

Increase in
Methanol %

% increase in by-products

200
150
100
50
0

10

20
30
40
temperature stand. dev. C

50

QCC + Comp
ICI 51-7
ICI 51-7
A ARC + Comp
A
Ethanol

200

69

ppm

Propanol

71

28

ppm

Butanol

71

33

ppm

MEK

13

<5

ppm

Decane C10

2.6

0.9

ppm

Undecane C11

1.8

0.6

ppm

Dodecane C12

1.2

0.4

ppm

Tridecane C13

0.7

0.3

ppm

Production (te/day)

1,650
1,600
1,550
1,500
1,450
1,400

200

400

600

800

Days on line

1,000

1,200

1,400

Key features
improved gas mixing
no penalty on pressure drop
better utilisation of the converter volume
minimise the by-product levels

Arc Revamp
Catalyst Loading
Lozenge removal

activity

Converter inspection
Fit ARC internals
Catalyst loading
Bed 5
Bed 4
Bed 3
Bed 2
Bed 1
0

14

days

21

ARC converters have exhibited an instability

This is highlighted by inlet and outlet temperatures
varying as per a sine wave
Feedback occurs over warm loop interchanger
Normally stable but can become unstable
Leads to loss of strike in converter

Action is to reduce circulation rate

Manway

Manway

Catalyst
Discharge Port

Outlet
Inlet

Syn Gas

Purge
Crude
Cooler
Heat Recovery
Unit

Crude

Loop
Interchanger

Methanol Concentration (mol%)

10
Max Rate
Curve

Methanol
Equilibrium

6
4
2
0
180

200

220

240

260

Temperature (C)

280

300

320

Cheaper loop with heat transfer and reaction

Smooth catalyst temperature profile
Good catalyst utilisation
Mechanically simple
All converter effluent available at high temperature
Can be used to heat saturator water

Mixing shall be effective

Mixer should
either not impede loading
or be easy to install and remove.

Mixer should enhance safe operation and be

mechanically robust.
Leakage of gas bypassing mixer should be
minimized.

Gas Inlet

Cooling
Tube

Catalyst Loading

Catalyst
Central Pipe

Inert Balls
Steam Outlet
BFW Inlet
Gas Outlet &
Catalyst Unloading

Cooling Tube

Outlet Collector

Cooled Bed
Scallops

Adiabatic Beds

Methanol Concentration (mol%)

10
Max Rate
Curve

9
8

Methanol
Equilibrium

7
6
5
4
3
180

200

220

240
260
Temperature (C)

280

300

320

28-32 Bara steam raised

Good approach to equilibrium
Low pressure drop, 0.5 to 0.75 bar
Catalyst discharge complex
Small number of tubes (c.f. Lurgi converter)

Syn Gas

Steam
Crude
Cooler

Purge

Loop
Interchanger
Crude

Methanol Concentration (mol%)

10
Max Rate
Curve

Methanol
Equilibrium

6
4
2
0
180

200

220

240
260
Temperature (C)

280

300

320

Cross flow means high heat transfer coefficient

Smaller surface area

Good utilisation of shell volume

Raised steam at between 30-40 bara
But
Costly (not as expensive as Uhde/Lurgi)
Large interchanger required
Pressure is slightly lower than Uhde/Lurgi

Casale
Horizontal Adiabatic Converter

Methanol Concentration (mol%)

10
Max Rate
Curve

Methanol
Equilibrium

6
4
2
0
180

200

220

240
260
Temperature (C)

280

300

320

All the gas sees all of the catalyst

Cheap vessels - can be spherical
Vessels can be designed the same
Reduces CAPEX

But
Large loop interchanger
Multiple vessels (excluding Casales Horizontal
Converter)
Beds are shallow and so mal distribution can be a
problem

Relative Catalyst Volumes

Base Case 2800 te/day plant (Chile 3)
Fixed circulation rate (recycle ratio = 4.2)
Reactor

Catalyst Volume (m3)

ARC

242

TCC

175

SRC

150

Loop pressurised to 7 bar with nitrogen

Heated to 180C
Add small amount of H2 for calibration
Heat to give peak temperature of 220C
Add hydrogen to 2%
Monitor temperatures
When exotherm profile moves through bed start
soak
Increase H2 and temperature

Similar to Reduction
Use air instead
Again exothermic
Also requires soak
Can not fully guarantee full oxidation
Procedure is available

Process Information Disclaimer

Information contained in this publication or as otherwise
supplied to Users is believed to be accurate and correct
at time of going to press, and is given in good faith, but it
is for the User to satisfy itself of the suitability of the
Product for its own particular purpose. GBHE gives no
warranty as to the fitness of the Product for any
particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent
that exclusion is prevented by law. GBHE accepts no
liability for loss or damage resulting from reliance on this
information. Freedom under Patent, Copyright and
Designs cannot be assumed.