Unidense™

The main fractions of the worldwide Syngas market are covered by ammonia (50%), refinery hydrogen (22%) and methanol (12%). Unidense™ can be used to load primary reformer tubes in ammonia, methanol or hydrogen plants. This are reformers with up to 1000 tubes with an internal tube diameter from 70 mm (2,8") to 150mm (6"). There are two general methods for loading steam-methane reforming catalyst:

1) Sock Loading

The older sock loading method requires a separate step to fill the socks, and the actual loading requires a longer shutdown and produces a less uniform fill than brush loading. The sock method is somewhat antiquated and provides lower quality results. However it does not require a license fee and may be economic depending on local conditions. The sock method may be a good choice for reloading a few tubes, but for a total furnace load, the other methods are preferred.

2) Trickle loading

Experience from a large number of trickle loadings has confirmed that the technique is significantly quicker than traditional sock loading methods. It also produces less pressure drop variation and less need for tube vibration or re-loading of catalyst tubes. The improved flow distribution resulting from the more homogeneous pressure drop across the reformer ensures optimized operating efficiency in the Primary Reformer by achieving uniform process gas exit temperature and methane slip. The improved operating efficiency also minimizes potential for tube failure by lowering and achieving a more uniform tube wall temperature. In the world trickle loading is being utilized more frequently than sock loading.

Most used trickle technique is the Unidense™ technique: the technique uses carefully designed springs on a cable, which are used to give a controlled and uniform free-fall of catalyst, minimizing damage, as it is poured into the tubes.

Advantage:

For more information see: www.unidense.com