Catalytic Reactor
Reaction Equipment
Catalytic Reactor
1. Product Overview
The catalytic reactor is key equipment for carrying out catalytic reaction processes in chemical production. It consists of a reactor shell, catalyst support structures, gas/liquid distribution devices, heat exchange elements, and a control system, converting raw materials into target products through the catalyst bed.
Typical applications: hydrotreating, catalytic cracking, catalytic reforming, desulfurization and denitrification, ammonia synthesis, methanol synthesis, CO shift conversion, etc.
Key features: high catalyst loading capacity, uniform gas–liquid distribution, efficient heat and mass transfer, resistance to high temperature and pressure, and suitability for long-term continuous operation.
2. Working Principle
Feed gas/liquid enters the catalyst bed uniformly through the inlet distributor. Under the action of the catalyst, the feed undergoes the target chemical reaction and is converted into products. As the reaction releases or absorbs heat, the reaction temperature is controlled by internal heat-exchange elements or inter-stage heat exchangers. Products leave the reactor through the outlet collector and pass to the downstream separation system.
3. System Classification
By Catalyst State
| Type | Features | Application Scenarios |
|---|---|---|
| Fixed-bed | Catalyst stationary, simple structure | Hydrotreating, CO shift, ammonia synthesis |
| Fluidized-bed | Catalyst fluidized/suspended, good heat transfer | Catalytic cracking, Propylene ammoxidation |
| Moving-bed | Catalyst moves slowly, continuous regeneration | Catalytic reforming |
| Slurry-bed | Catalyst suspended in liquid phase | Fischer-Tropsch synthesis, Direct coal liquefaction |
By Heat Exchange Method
| Type | Features | Application Scenarios |
|---|---|---|
| Adiabatic | No internal heat exchange, inter-stage cooling | Reactions with less heat release |
| Tubular | Catalyst in tubes, shell-side heat exchange | Strong exothermic reactions (e.g., ethylene oxidation) |
| Cold-shot | Cold raw gas injected between stages | Ammonia synthesis, Methanol synthesis |
4. Detailed Technical Parameters
4.1 Common Materials
| Material | Applicable Temp | Applicable Media | Remarks |
|---|---|---|---|
| 16MnR/Q345R | ≤450℃ | General chemical media | Carbon steel, lower cost |
| 15CrMoR | ≤550℃ | High-temp hydrogen-containing | Hydrogen corrosion resistant |
| 0Cr18Ni10Ti (321) | ≤600℃ | Corrosive media | Stainless steel |
| 316L | ≤400℃ | Chloride, sulfuric acid media | Pitting resistant |
| Inconel 625 | ≤800℃ | High-temp strong corrosion | Special alloy, high cost |
4.2 Fixed-Bed Typical Specification Table
| Catalyst Volume (m³) | Design Pressure | Design Temp (℃) | Shell Diameter | H/D Ratio | Heat Exchange |
|---|---|---|---|---|---|
| 0.1～0.5 | 1.0～4.0MPa | ≤450 | DN300～DN600 | 3～5 | Adiabatic/Tubular |
| 1～5 | 1.0～8.0MPa | ≤500 | DN600～DN1200 | 3～8 | Adiabatic cold-shot/Tubular |
| 5～20 | 2.0～15MPa | ≤500 | DN1200～DN2400 | 5～10 | Adiabatic/Tubular |
| 20～100 | 2.0～20MPa | ≤550 | DN2400～DN4000 | 5～12 | Multi-stage adiabatic/Tubular |
Note: Tubular reactors usually have a single tube diameter of DN25～DN50; the number of tubes depends on capacity.
4.3 Design Conditions & Performance Indicators
| Parameter | Specification |
|---|---|
| Bed pressure drop | 0.01～0.05MPa/m bed (depends on catalyst size) |
| Gas distribution uniformity | Deviation ≤±5% |
| Bed temp uniformity | Radial temp diff ≤±5℃ |
| Heat exchange elements | Tubular/Coil/Serpentine |
| Catalyst support | SS grid + ceramic ball support layer |
| Internal components | Inlet distributor, outlet collector, thermocouple sleeve |
4.4 Electrical Parameters
| Applicable Region | Voltage | Frequency |
|---|---|---|
| China/Russia/Central Asia | 380V | 50Hz |
| Middle East/Southeast Asia/Africa | 400V / 415V | 50Hz |
| South Korea | 380V | 60Hz |
| Americas (if needed) | 440V / 480V | 60Hz |
The reactor body is static equipment; electrical parameters mainly involve heat tracing, instrumentation, and control systems.
5. Core Component Selection
| Component | Common Brands | Features & Applications |
|---|---|---|
| Inlet distributor | Custom design | Umbrella, pipe-hole, swirl type, selected by media |
| Catalyst support grid | Custom | 316L/Alloy, open area ≥80% |
| Thermocouple | Yokogawa, Endress+Hauser | Multi-point, monitors bed temp distribution |
| Control valve | Yamatake, ABB, Sufa | Auto flow/temp regulation |
| Control system | DCS/PLC | Integrated T, P, flow monitoring & alarm |
Customers can specify brand preferences. Refurbished equipment depends on inventory.
6. Typical Application Fields
Petroleum Refining: Hydrotreating, catalytic reforming, hydrocracking Coal Chemical: CO shift, methanol synthesis, Fischer-Tropsch Fertilizer: Ammonia synthesis, urea synthesis Environmental: SCR denitrification, VOCs catalytic combustion Fine Chemicals: Hydrogenation reduction, selective oxidation
7. Design Standards & Certifications
| Standard | Description |
|---|---|
| GB/T 150-2011 | Pressure Vessels |
| HG/T 20586-2011 | Design code for industrial furnaces in chemical plants |
| GB 50160 | Fire prevention code for petrochemical enterprises |
| ISO 9001:2015 | Quality Management System |
| CE | Available upon request |
| EAC | Available for Russia & Central Asia |
| GOST-R | Available for Russian market |
| ASME VIII | Available for Americas market |
8. Customizable Options
| Option | Details |
|---|---|
| Shell material | CS/15CrMoR/321/316L/Inconel |
| Reactor type | Fixed-bed/Fluidized-bed/Moving-bed/Slurry-bed |
| Heat exchange | Adiabatic/Tubular/Cold-shot/Internal coil |
| Internal components | Distributor type, catalyst loading/unloading structure |
| Insulation | Internal (castable) / External (aluminum silicate) |
| Catalyst | Can assist in recommending suppliers (not included in equip. quote) |
9. Warranty Terms
| Equipment Status | Warranty Period | Warranty Scope |
|---|---|---|
| New Equipment | 12 Months | Shell, internal components, heat exchange, instrument ports |
| Refurbished Equipment | 6 Months | Shell, internal components, heat exchange, instrument ports |
| Idle Equipment (As-is) | 3 Months | Main functional parts |
Final warranty terms are subject to the contract. All orders include installation guidance and remote debugging support.
10. Packaging & Delivery
| Item | Packaging Method |
|---|---|
| Reactor Shell | Bare with steel straps, flange protected |
| Internal Components | Wooden box |
| Heat Exchange Elements | Wooden box |
| Instruments/Accessories | Waterproof sealed in wooden box |
Container Capacity Estimation (for reference only):
Small catalytic reactor (≤DN600): approx. 1x 20'GP or 40'HQ Medium-Large (≥DN1200): Break-bulk shipment
Installation: On-site guidance available. Large reactors recommend our technicians for internal component installation (travel & accommodation borne by buyer).
11. Information Required for Quotation
To get an accurate quote, please provide:
Reaction type and chemical equation Catalyst type, loading volume, particle size Working pressure, working temp (Inlet/Outlet) Feed composition, flow rate, space velocity Reaction heat effect (Exo/Endo, heat value) Target product and conversion rate requirements Reactor type preference (Fixed-bed/Tubular, etc.) Shell material requirement Local voltage and frequency Equipment status preference: New/Refurbished/Idle Budget range & brand preference (if any) Delivery terms: FOB/CIF/DDP Destination port or delivery address (for freight calculation)