Commissioning and Qualification of Equipment and Systems · loading and unloading. The use of catalyst-charged vessels are essential to modern processes. There are many catalyst-charged

Verification / Qualification Protocol

1-3 Equipment configuration for a reactor Page 1

Commissioning and Qualification of Equipment and Systems

Section 1-3

Equipment configuration for a reactor



Table of Contents 1 Reactor Equipment Configuration & Operation ......................................... 3

1.1 Example of Catalyst Filter Preparation ............................................. 19

1.2 Continuous-Stirred-Tank-Reactor (CSTR) ........................................ 20

1.3 Reactor Design ................................................................................. 22

1.4 Process Vessel Data Sheet .............................................................. 26



1 Reactor Equipment Configuration & Operation Hydrogen Reactor (Hydrogenator) System

Pressure test reactor with nitrogen, including hydrogen feed line



Inert Reactor and perform oxygen test



Charge catalyst - via slurry make-up vessel and re-inert reactor









Charge other reactants



Charge hydrogen via sparge line at required pressure

Heat reactants to required temperature



Hydrogenate until uptake of hydrogen reduces to zero – this signifies reaction end-point



Sample the reaction contents to confirm reaction complete



Purge head space with nitrogen and re-inert reactor





Cool the contents of the reactor to ambient temperature



Prepare catalyst filter

Transfer reactor contents to next vessel via catalyst filter







1.1 Example of Catalyst Filter Preparation



1.2 Continuous-Stirred-Tank-Reactor (CSTR)

In chemical engineering, reactors are vessels designed to contain chemical reactions. The design of a chemical reactor deals with multiple aspects of chemical engineering.

Diagram of a chemical reactor

Chemical engineers design reactors to ensure that the reaction proceeds with the highest efficiency towards the desired output product, producing the highest yield of product while requiring the least amount of money to purchase and operate. Normal operating expenses include energy input, energy removal, raw material costs, labor, etc. Energy changes can come in the form of heating or cooling, pumping to increase pressure, frictional pressure loss (such as pressure drop across a 90o elbow or an orifice plate), agitation, etc.

Chemical process reactor

Reactor vessel



In a continuous-stirred-tank-reactor (CSTR), one or more fluid reagents are introduced into a tank reactor equipped with an impeller. The impeller stirs the reagents to ensure proper mixing.

Impeller (agitator) in a CSTR

Reactor vessel in-situ



Process schematic for a typical CSTR

1.3 Reactor Design

Reactors are used in processing facilities to contain catalysts that promote chemical transformation of feeds. Reactors are generally vertical steel hollow vessels and often operate under very high temperatures and pressures. One of the principal layout features of the reactor is the requirement for catalyst loading and unloading. The use of catalyst-charged vessels are essential to modern processes. There are many catalyst-charged vessels within the category of reactors. Catalysts promote a reaction but do not react in any way themselves. The catalyst used inside reactors is generally ball or pellet shaped and, depending on the type of service, can be made from a variety of materials, including alumina, zinc oxide, and expensive metals such as platinum and palladium. Most reactors are vertically mounted vessels with elliptical heads. Generally, connections are limited to inlet and outlet, maintenance access, unloading, sample, and temperature. Internally, reactors are furnished with bed supports, screens, inlet baffles, outlet collectors, catalysts, and inert materials. Reactors are located within a process unit adjacent to related equipment and in a suitable position for operation and catalyst loading and unloading. A reactor operates in sequence and close to a steam-generator/furnace because expensive high-temperature piping runs must be minimized.



Typical Chemical Reactor

The general requirements for reactor plant layout design provides instructions on how to locate nozzles, instruments, piping, and controls to provide convenient and safe platforms for operator and maintenance access. Nozzle requirements and overall dimensions of the reactor are highlighted on the process vessel sketch furnished by process engineering and are included in the process release package.

There are four principal methods of support for reactors: a skirt from a concrete foundation, lugs from concrete piers, a ring girder from a concrete table top, and a skirt from a concrete table top.

Methods for Reactor Support



Reactor elevation is dictated by the catalyst’s unloading nozzle or clearance for the outlet piping. To set the elevation of reactors, the plant layout designer requires the following information:

• Reactor dimensions

• Type of heads

• Support details

• Bottom outlet size

• Unloading nozzle size

• Client preference for catalyst handling Nozzles are located to suit process operation and maintenance requirements, and to facilitate an economic and orderly interconnection of piping between the reactor and related equipment. The following information is required to locate and elevate reactor nozzles:

• Process vessel sketch

• Instrument vessel sketch

• Piping and instrumentation diagram

• Piping line list

• Nozzle summary

• plant layout specification

• Insulation requirements

The process inlet is located at the top head of the reactor along with maintenance access, which is used for catalyst loading. The process outlet and the catalyst unloading nozzle are located on the bottom head of the reactor.

Temperature instruments are usually required at reactors; they are used to measure the temperature at different levels of the catalyst bed. These instruments can be individual nozzles located at various levels on the shell of the reactor or, to minimize multiple connections, immersed in a well from the top of the reactor, either on an individual nozzle or through the maintenance access. Instrument requirements for reactors are usually highlighted on a vessel instrument sketch that is furnished by the instrument engineer.



Platforms are required at reactors for access to valves, instruments, blinds, maintenance accesses, and catalyst loading. Platform elevations are determined by the items that require operation and maintenance.

Piping arrangement

Reactor piping must be arranged for ease of support and positioned to suit interconnection with related equipment. Because reactors often operate at very high temperatures, piping must be arranged with sufficient flexibility to absorb excessive stress under usual operating conditions. Relief valves are usually furnished as part of the reactor piping system.

Handling such removable items as relief valves and valve drives for off-site repair and catalyst loading can be achieved by fixed handling devices or by mobile equipment. Fixed handling devices can be davits or, for structure-mounted reactors, trolley beams.

Davit arms



1.4 Process Vessel Data Sheet

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Commissioning and Qualification of Equipment and Systems · loading and unloading. The use of catalyst-charged vessels are essential to modern processes. There are many catalyst-charged