The dry (pore filling) impregnation is primary method for preparing hydrotreating and other catalysts. Generally, the procedures used are poorly studied in terms of improving metal distribution from particle to particle. Methods of improving mixing are difficult and time consuming and are mostly skipped. In this work, Discrete Element Method (DEM) simulations coupled with a novel algorithm allowing the fluid transfer to and between particles were used in combination with geometrically equivalent experiments to study the effect of baffles in a double cone impregnator during dry catalyst impregnation. DEM simulations were performed with both two and four baffles. It was found that baffles significantly reduced the mixing time, thus increasing overall content uniformity while maintaining other process parameters. Additionally, one-to-one baffled experiments were conducted at 3 distinct fill levels to validate the findings from simulations. More simulation results provided by particle tracking techniques have further quantified the poor axial mixing, and better elucidated the improved mixing by adding baffles. This work will aid in the development of simulations capable of analyzing dry catalyst impregnation in limitless parameters, geometries, and conditions for improving overall mixing, content uniformity, and product quality.

Improved mixing in catalyst impregnation using a double cone incorporated with baffles

244th National Meeting (2012)

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