Fixed Bed Reactor Scale-up Checklist The purpose of this checklist is to identify the stages and potential problems associated with the scale up of fixed bed reactors from the drawing board to the full scale plant, and to determine how they should be checked. The checking can be done using various methods. These are: • Literature data. • Lab testing. • Calculation. • Modeling. • Semi-tech testing. • Piloting or Sidestream testing. Identifying the stages that need to be addressed for a particular catalyst/reactor development will help in estimating the time needed for the development of the reactor

1. GBH Enterprises, Ltd.
Process Engineering Guide:
GBHE-PEG-RXT-806
Fixed Bed Reactor Scale-up Checklist
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the information
for its own particular purpose. GBHE gives no warranty as to the fitness of this
information for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability resulting from reliance on this
information. Freedom under Patent, Copyright and Designs cannot be assumed.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

2. Process Engineering Guide:
Fixed Bed Reactor Scaleup Checklist
CONTENTS
SECTION
0
INTRODUCTION/PURPOSE
3
1
SCOPE
3
2
FIELD OF APPLICATION
3
3
DEFINITIONS
3
4
CHECKLIST
4
DOCUMENTS REFERRED TO IN THIS PROCESS
ENGINEERING GUIDE
24
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

3. 0
INTRODUCTION / PURPOSE
The purpose of this checklist is to identify the stages and potential problems
associated with the scale up of fixed bed reactors from the drawing board to the
full scale plant, and to determine how they should be checked.
The checking can be done using various methods. These are:
·
Literature data.
·
Lab testing.
·
Calculation.
·
Modeling.
·
Semi-tech testing.
·
Piloting or Sidestream testing.
Identifying the stages that need to be addressed for a particular catalyst/reactor
development will help in estimating the time needed for the development of the
reactor.
It is important to know as early as possible in the design process, whether there
will be a need for a pilot or Sidestream unit. If a Sidestream unit or pilot plant
needs to be built, it must be designed to address any specific residual problems.
There have been examples where multi-million pound fixed bed reactor
Sidestream rigs have not identified any of the problems that occurred on the final
plant. This checklist can be used to determine what potential problems there
might be that would need to be resolved by a pilot or Sidestream unit.
It is assumed that at the start of the exercise, laboratory tests have been
undertaken with pure reactants and powdered catalysts in order to determine the
conversion and selectivity at certain pressure (probably atmospheric) and a
range of temperatures.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

4. 1
SCOPE
This Process Engineering Guide covers the factors to be taken into consideration
for the design and operation of a full scale fixed bed reactor and the most
appropriate option for determining each factor.
2
FIELD OF APPLICATION
This Guide applies to process engineers and related process development staff
in GBH Enterprises world-wide.
3
DEFINITIONS
For the purposes of this Guide, no specific definitions apply.
4
CHECKLIST
It is important to consider each factor and to answer the question: How and when
will each of the factors be determined or checked? This will enable the scale up
strategy to be determined and the need for piloting or Sidestream testing
assessed All the factors on the list should be addressed but the need for action
can be taken on a judgmental basis depending on how critical the new process
will be.
It is recommended that experts from outside the business are brought into the
discussions in order to provide an independent view on the issues and that the
results of the discussion on each factor are recorded in writing, so that they can
be reviewed, if the reactor design changes.
The factors that need to be considered in a fixed bed reactor scale-up are listed
below and the most likely option for dealing with each factor is given. This list
only includes factors that are important for the reactor development and does not
deal with factors specific to catalyst development and manufacture.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

5. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

6. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

7. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com