All you need to know about piping design practices for Reactors
Reactors are used in processing units to carry catalysts that assist the chemical transformation of feeds. They also act as agents to remove unwanted materials from the feed. It contains special fluids with high temperatures and pressure.
Reactors are vertical steel hollow vessels that are usually cylindrical. One of the primary features of reactors is to support the requirement for catalyst loading and unloading. The use of catalyst-charged containers is essential to modern processes. It has widespread application in the production of chemical and refinery products.
Multiphase Process of Reactors
- The feed is heated to react with the catalyst adequately.
- Feed enters from the top head of reactors.
- Catalysts are filled following the length of the reactor.
- As the feed transfers down the reactor, it gets converted into the desired product.
- Catalysts promote the chemical reaction and then the intended products get extracted from the bottom of the reactor.
What are Catalytic Reactors?
Catalysts are chemical species that come in various sizes depending on the process requirements. They start becoming saturated after some time, and cause a decrease in the effectiveness. It is necessary to regenerate them. Poisoned catalysts cannot be renewed and so replacement is the only option that remains.
Specific Considerations for Piping Design of Reactors
Locate the Reactor
The piping designer should simplify the interconnection between the reactor and its nearby equipment such as pumps, feed exchangers, heaters and more. Following documents enable the designer to locate the reactor on the plot plan.
- Piping and Instrumentation Diagrams (P&IDs)
- Plot Plans
- Process Vessel Sketch
- Piping & Plant Layout Specification
Reactors are sited on the plot plan as per the process sequence defined in the schematic layout.
Either side of the pipe rack is the best location for reactors. It can be as close as possible to the heater as per defined safety and layout guidelines. This helps reduce the costs of high-temperature piping.
Provide enough space for operator movement, operations & maintenance access and catalyst loading/unloading.
Analyze reactor transportation, erection & other constructability issues while finalizing the location on the plot plan. Locating reactors close to accessibility reduces maintenance efforts.
After specifying the reactor location on the plot plan, consider the below recommendation.
- Elevation review and support selection
- Location and orientation of nozzle on the vessel
- Platform and access necessity
- Support cleat location detailing
- Lifting lugs and earthing lugs location planning
- Finalizing vessel nameplates location
Provide a separate support structure to the platforms around reactors and for access to piping and valves. Moreover, the platform can be connected to the vessel shell if welding is allowed and cleats are provided.
Conclusion
Ready to develop a cost-effective and intuitive reactor equipment and piping layout for your processing facilities? Consider hiring an engineering company that provides industrial piping design services using the latest software and ASME codes & standards.
