The main reasons for dense loading

• Load additional catalyst in the available space compared to sock loading  (up to 25%) – improving reactor productivity
• Ensure uniform distribution of the catalyst – to prevent channeling, mal-distribution and hot spots. 

Common Dense Loading issues

There are various dense loading machines operating in today’s market and there are reported issues related to Quality, Reliability and Costs, mainly:

• Catalyst attrition through mechanical movements
• Creation of hills and troughs as the loaders cannot distribute the catalyst consistently even over the reactor
• Time consuming process for set-up of machines, personnel reactor entry/exit/re entry and bed  measurement stoppages
• Break downs cause delays
• Machines are complicated and quality of load is highly dependent on Operator
• Significant amount of dust is loaded with the catalyst, prolonging Start Up time and risk of increased SOR pressure drop.
• High costs related to mobilization and travel