Denstone® Catalyst

Bed Support Media

Norton Chemical Process
Products Corporation
 Denstone® Catalyst Bed Support Media: The Optimum
Catalyst Support for a Wide Range of Applications
Norton: A world
leader in catalyst
bed support technology
For decades, Norton has been
committed to advancing its catalyst
bed support technology. We have
linked our support development to
that of our catalyst carriers and pro-
prietary catalysts, which enables us
to offer a profound understanding of
catalyst bed support media. As a
result, Denstone® supports optimize
performance and economy. Their
long service life translates into
lower operating costs, no matter
what the application.
Norton now offers the industry’s
broadest selection of standard and
specially formulated support
spheres, pellets, rings and other
shapes. Each formulation is devel-
oped to meet specific process
requirements and reflects our
unique knowledge of both the
process and catalyst technology.
Top-notch service
worldwide, with
inventory for fast
delivery
Table of Contents Norton maintains inventory near
Company background ..............................................................2 end-user sites all over the world.
With two North American produc-
Applications and product benefits............................................3
tion facilities and multiple regional
Denstone 2000 support media ................................................4 warehouses, as well as manufactur-
Denstone 99 support media ....................................................4 ing and warehouse locations in
Denstone 80 support media ....................................................4 England, Germany, Australia,
Denstone 57 support media ....................................................4 Singapore and India, we can deliver
Independent tests ....................................................................5 our product wherever and whenever
Crush strength pressure drop ..................................................6 it is needed.
Product specification matrix ....................................................7 With our 24-hour customer order
Typical applications ..................................................................8 line, your shipment is just a phone
Process controls ......................................................................9 call away. You can reach us by
Quality manufacturing ............................................................10 calling (330) 673-5860. In Europe,
call 44 (0) 1782 744566.
Custom-engineered products ................................................11
Locations................................................................................12

2
A profile of
proven benefits
The long service life and optimum
performance of Denstone spheres,
pellets and rings have set the
industry standard for 50 years.
Norton continues to establish new
standards with product innovations.
Benefits
Will not plug bed or
catalyst
The monolithic, rather than layered,
structure of Denstone supports
eliminates in-service spalling and
delamination, which prevents the
incidence of fine chips or splinters
that can plug the bed or catalyst.
Will not contaminate
catalyst
Maximum resistance to erosion and
attrition minimizes the possibility of
catalyst contamination. Denstone
supports are not hydroscopic.
High thermal shock
resistance
Denstone supports have an
extraordinary ability to withstand
extreme thermal shock without
breaking. The IR fusion point of
Denstone media is in excess of
1100° C (2000° F).
Will not poison catalyst
Denstone support media are free of
sulfur, boron and other common
catalytic poisons. Analysis of
crushed spheres have determined
the leachable iron content to be less
than 0.1%. Tests on spheres,
immersed in 10% hydrochloric acid
and boiled for 64 hours, have indi-
cated a leachable iron content of
less than 0.005% by weight. In each
case, the iron content is expressed
as Fe2O3. Tests establish that leach-
able chlorides and sulfur (as S04)
are each less than 1 ppm by weight
for both crushed and uncrushed
spheres.

Applications for • Air drying • Hydrodealkylation

Denstone catalyst bed • Alkylation • Hydrogenation
support media • Catalytic conversion • Hydrotreating
Denstone spheres, pellets, rings • Catalytic cracking • Isomerization
and other shapes are universally • Catalytic oxidation • LPG treatment
accepted for a wide range of • Catalytic reforming • Methanation
refining, chemical and
• Condensation • Molecular sieve separation
petrochemical applications.
• Dehydrogenation • Polymerization
• Desiccant dryers • Shift conversion
• Desulfurization • Sulfur recovery
• Hydrocracking • Thermal cracking

3
Denstone 2000 Support Media:
The ultimate catalyst bed support
Denstone 2000 supports survive
depressurization and maintain their
integrity better than any support
media available. Rigorous side-by-
side testing of 13mm (¹⁄₂ in.) spheres
has proven Denstone 2000 supports
to be superior to competitive
products in four major areas:
Excellent
Compressive Strength
Denstone 2000 spheres
demonstrated 53% greater
crush strength than the nearest
competitor. (ASTM C-515)
Stand Up Better to
Thermal Shock
Denstone 2000 spheres retained
their compressive strength edge over
competitive balls even after being
heated to 427° C (800° F), then
dropped into water at room tempera-
ture. The test was repeated using
spheres heated to 815° C (1500° F),
with Denstone 2000 supports
demonstrating a 61% compressive
strength advantage over the nearest
competitor.
Superior Impact
Resistance in Two Tests
In both free-fall drop and ASTM
D-3029 impact tests, Denstone 2000
supports proved to be superior to its
competitors.
100% Survival in Rapid
Depressurization Tests
After being heated in hydrogen to
454° C (850° F) at 1500 psi, then
depressurized instantly to ambient
pressure, all Denstone 2000 spheres
remained intact.
4
Denstone 99 Support
Media and Microspheres
Norton developed the 99+% alumina
formulation of Denstone 99 support
media for high-temperature and
steam applications where leached
silica can coat downstream equip-
ment. Denstone 99 support media
are available in standard spheres as
well as microspheres, which are
used for the support and retention of
small-sized catalysts and
absorbents. Norton can also supply
Denstone 99 media in rings, pellets
and other specially-tailored shapes.
Denstone 99 support media retain
their integrity even at temperatures
as high as 1250° C (2280° F) and
pressures of 35.2 kg/cm (500 psig),
making it ideal for applications
including:
• Ammonia production
• Methanol and hydrogen production
• Alkylations using hydrogen fluoride
at high temperatures
• Naphtha reforming
• Isomerization
Denstone 80 Support
Media for Special
Applications
Norton engineered Denstone 80
supports to provide maximum
chemical resistance in ethylene
dryers and special catalytic
applications. The special porcelain
formulation enables Denstone 80
supports to withstand the demands
of ethylene applications, where other
clay-based supports commonly fail.
Denstone 57
Support Media:
The Industry Standard
Since the 1950s
Many refineries and chemical plants
continue to rely on Denstone 57
supports, Norton’s original catalyst
bed support media.
Customer Tests Prove
Reliability of Denstone Supports
Denstone support media
survive load and thermal
cycling better.
A major refiner independently
conducted a series of rigorous
tests to compare the robustness of
Denstone 2000 catalyst bed support
media against competitive supports.
The refiner tested 13mm (¹⁄₂ in.)
spheres for structural integrity
in a battery of tests at their own
laboratory.
Following a simple impact test,
which involved dropping 100
samples of each sphere 22 feet
onto a ¹⁄₂ in. steel plate, 100% of the
Denstone 2000 spheres remained
intact, compared to only 60% of the
competitive supports.
The test was repeated after
heating the spheres to 427° C
(800° F) and dropping them into
water at room temperature. Again,
all the Denstone 2000 supports
survived, while only 20% of the
other supports remained intact.
The refiner — now a satisfied
customer — determined Denstone
2000 supports to be the optimal
support for structural integrity in
their reactors.
Cross section of Denstone® 2000 supports vs. Competitors

5
Denstone Media Crush Strength
and Pressure Drop Specifics
Will not crush. Crush Strength
The high crush strength of spheres
25mm 19mm 13mm 6mm
and pellets permits using deep Sphere Size
1 in. ³⁄₄ in. ¹⁄₂ in. ¹⁄₄ in.
beds. The following data were
obtained in standard tests by Denstone 57 Supports 635kg 430kg 170kg 55kg
1400 lb 950 lb 370 lb 120 lb
crushing individual spheres
between two flat steel plates. Denstone 99 Supports 635kg 430kg 170kg 55kg
1400 lb 950 lb 370 lb 120 lb
Low pressure drop. Denstone 2000 Supports 794kg 544kg 225kg 73kg
1750 lb 1200 lb 500 lb 160 lb
The low pressure drop of Denstone
spheres and pellets cannot be Note: Weights are minimum values.
matched by screened materials of
random sized and shaped particles.
Denstone supports are also avail-
able in ring form, a lower pressure
drop alternative intended for use as
a hold-down media.

PRESSURE DROP VS. GAS RATE

4000
3500 ABC D E FG H I J K L
4
3.5 3000
3 2500
2.5 2000

2
1500
Sphere Size
1.5 1200 Line mm in.
1.2 1000 A 1.5 ¹⁄₁₆
∆P – IN. H2O/FT.

900
1 B 2.5 ¹⁄₁₀
∆P – Pa/m

800
.9
.8
700 C 3 ¹⁄₈
600
.7 D 6 ¹⁄₄
.6 500
E 10 ³⁄₈
.5 400
350 F 13 ¹⁄₂
.4
.35 300 G 16 ⁵⁄₈
.3 250 H 19 ³⁄₄
.25 200 I 25 1
.2 J 32 1¹⁄₄
150
K 38 1¹⁄₂
.15 120
L 50 2
.12 100
.2 .25 .3 .35 .4 .5 .6 .7 .8 .9 1 1.2 1.5 2 2.5 3 3.5 4
Fs – m/s 
kg/m3

.2 .25 .3 .35 .4 .5 .6 .7 .8 .9 1 1.2 1.5 2 2.5 3

Fs – FT./S 
LBS/FT.3

6
How to Specify
Denstone Catalyst Bed Support Media

Typical Chemical Denstone 57 Denstone 57 Denstone 80 Denstone 2000 Denstone 99

Composition Support Spheres Pellets Support Spheres Support Spheres Support Spheres
SiO2 67.40% 67.40% 66.10% 74.2% <0.20% max
Al2O3 24.10% 24.10% 26.20% 19.2% >99.00% min
TiO2 1.18% 1.18% 1.25% 0.90% <0.5% max
CaO 0.39% 0.39% 0.61% 0.13% —
MgO 0.51% 0.51% 0.25% 0.34% —
K2O 3.28% 3.28% 2.43% 2.36% 0.35% max
Na2O 1.18% 1.18% 2.51% 1.73% —
Leachable Iron <0.1% <0.1% <0.005% <0.1% —
Typical Denstone 57 Denstone 57 Denstone 80 Denstone 2000 Denstone 99
Physical Properties Support Spheres Pellets Support Spheres Support Spheres Support Spheres
Free space (%) 40% — 40% 40% 40%
Particle density (gm/cc) 2.3 2.3 2.4 2.2 3.0
Specific heat
@ 100° C (cal/gm °C) 0.25 0.25 0.25 0.25% —
Apparent porosity by weight <0.4% <0.4% <0.4% 2 – 6% <7%
Apparent porosity by volume <1% <1% <1% 4 – 13% <20%
Crush strength - ¹⁄₄ in. 55kg (120lb) — 91kg (200lb) 73kg (160lb) >75kg (165lb) min
Crush strength - ¹⁄₂ in. 170kg (370lb) — 182kg (400lb) 225kg (500lb) >200kg (400lb) min
Crush strength - ³⁄₄ in. 430kg (950lb) — — 544kg (1200lb) >550lb (250kg) min
Crush strength - 1in. 635kg (1400lb) — — 794kg (1750lb) >500kg (1100lb) min
Max. Operating Temp. 982° C (1800°F) 982° C (1800°F) 982° C (1800°F) F982° C (1800°) 1500° C (2732° F)
Typical 1362kg/m3 1362kg/m3 1440kg/m3 1330kg/m3 1842kg/m3
Packing Density 85 lb/ft3 85 lb/ft3 90 lb/ft3 83 lb/ft3 115 lb/ft3

SIZES AVAILABLE
Denstone 57 Denstone 57 Denstone 80 Denstone 2000 Denstone 99
Support Spheres Pellets Support Spheres Support Spheres Support Spheres
(mm) (in.) (mm) (in.) (mm) (in.) (mm) (in.) (mm) (in.)
03 ¹⁄₈ 03 x 03 ¹⁄₈ x ¹⁄₈ 03 ¹⁄₈ 03 ¹⁄₈ 1.5 ¹⁄₁₆
06 ¹⁄₄ 04 x 06 ³⁄₁₆ x ¹⁄₄ 06 ¹⁄₄ 06 ¹⁄₄ 2.5 ¹⁄₁₀
10 ³⁄₈ 06 x 10 ¹⁄₄ x ³⁄₈ 10 ³⁄₈ 10 ³⁄₈ 03 ¹⁄₈
13 ¹⁄₂ 10 x 13 ³⁄₈ x ¹⁄₂ 13 ¹⁄₂ 13 ¹⁄₂ 06 ¹⁄₄
16 ⁵⁄₈ 13 x 16 ¹⁄₂ x ⁵⁄₈ 19 ³⁄₄ 16 ⁵⁄₈ 10 ³⁄₈
19 ³⁄₄ 16 x 19 ⁵⁄₈ x ³⁄₄ 25 1 19 ³⁄₄ 13 ¹⁄₂
25 1 19 x 22 ³⁄₄ x ⁷⁄₈ — — 25 1 19 ³⁄₄
32 1¹⁄₄ 22 x 32 ⁷⁄₈ x 1¹⁄₄ — — 32 1¹⁄₄ 25 1
38 1¹⁄₂ — — — — 38 1¹⁄₂ 38 1¹⁄₂
50 2 — — — — 50 2 50 2

A complete set of certified specifications is available upon request.

7
Typical Applications of
Denstone Spheres, Pellets and Rings
Desiccant Dryer
A typical desiccant dryer uses a 1¹⁄₂mm (¹⁄₁₆ in.)
extrudate molecular sieve. A 5cm (2 in.) depth of
3mm x 3mm (¹⁄₈ in. x ¹⁄₈ in.) ceramic pellets are Catalyst
5cm (2 in.) layer - 3mm x 3mm (¹⁄₈ in. x ¹⁄₈ in.) pellets
placed directly under the molecular sieves. 8cm (3 in.) layer - 6mm (¹⁄₄ in.) spheres
10cm (4 in.) layer - 13mm (¹⁄₂ in.) spheres
13cm (5 in.) layer - 19mm (³⁄₄ in.) spheres

Hydrocracker
In typical petroleum processes using a 3mm (¹⁄₈ in.)
diameter pellet catalyst, the bed is identical to the
one described above, except that the catalyst can
be placed directly on top of 6mm (¹⁄₄ in.) support Catalyst
8cm (3 in.) layer - 6mm (¹⁄₄ in.) spheres
spheres, thus eliminating the layer of pelletized 10cm (4 in.) layer - 13mm (¹⁄₂ in.) spheres
support media. 13cm (5 in.) layer - 19mm (³⁄₄ in.) spheres

Petrochemical Reaction
In petrochemical applications such as oxidation
reactions, larger catalysts and supports–typically
6mm (¹⁄₄ in.) diameter– are used.
Catalyst
10cm (4in.) layer - 10mm (³⁄₈ in.) spheres
13cm (5 in.) layer - 19mm (³⁄₄ in.) spheres

Downflow Reactors
Where the gas phase is fed through a centrally
located inlet, the spheres in the top layer are at 15cm (6 in.) layer - 25mm (1 in.) spheres

least 25mm (1 in.) diameter. Frequently downflow

reactors use larger spheres because they have the
mass necessary to prevent the top of the bed from
being dished out by the inlet velocity of the gas
impinging on the bed’s surface.
Catalyst
10cm (4 in.) layer - 10mm (³⁄₈ in.) spheres
15cm (6 in.) layer - 19mm (³⁄₄ in.) spheres

Upflow Reactors
Where it is necessary to prevent catalyst bed
fluidization, spheres are graded in reverse order
on top of the bed. The sphere size depends upon
the size of the catalyst. To provide sufficient mass
to prevent fluidization, at least 229mm (9 in.) of
spheres are installed atop the bed.
13cm (5 in.) layer - 19mm (³⁄₄ in.) spheres
10cm (4 in.) layer - 13mm (¹⁄₂ in.) spheres
5cm (2 in.) layer - 6mm (¹⁄₄ in.) spheres
Catalyst
5cm (2 in.) layer - 6mm (¹⁄₄ in.) spheres
10cm (4 in.) layer - 13mm (¹⁄₂ in.) spheres
13cm (5 in.) layer - 19mm (³⁄₄ in.) spheres

8
 Process Control:
Norton’s Assurance of Quality
Pre-Qualification
Norton qualifies the optimum
raw materials well in advance of
manufacturing. Extensive testing of
core samples from the mine site
identifies specific areas of prime
reserves to ensure a consistent
supply far into the future. Standard
raw material tests are conducted
in our laboratories as well as the
supplier’s to confirm data accuracy.
Finished Product Tests
The following tests are performed
on all products.
• Strength
• Size
• Shape
• Chemical composition
• Porosity
• Appearance
• Autoclave depressurization test
(Denstone 2000 support media
only)
Special tests are performed on
products designed for highly
demanding applications.
• Thermal shock
• Thermal cycling
Blend Qualification • Thermal compression
When our testing does reveal subtle • Free-fall drop
changes in raw material composi-
tion, our experimentally-derived • Impact resistance
knowledge of the relationships Additional tests are available on
between material characteristics customer request
and final product allows us to apply
Predictive Process Control to fine- • Attrition
tune the blend at the front end to • Elemental analysis
guarantee a consistent, high-quality
support media. • X-ray analysis

Lot Qualification Process Checks • Corrosion

Our prequalification procedures
ensure that only the prime mining
sites are tapped; but we don’t
stop there. Each shipment of raw
materials must pass additional
testing before we accept it at
the plant.
Norton follows documented
procedures at every stage of the
manufacturing cycle to ensure
consistent final product quality.
• Mixing
• Forming
A copy of Norton’s documented
test methods can be provided on
request.
Certification to European
Standard EN10204:1991 is
available on request with
any shipment.

• Drying
• Firing
• Screening
• Packaging
• Shipping

9
Optimum Performance and
Economy Through Quality Manufacturing
Experienced people and automated
equipment worldwide ensure that
Denstone products exceed your
performance expectations…and that
we will deliver the products to you
when you need them.
People — Our technical and
production personnel offer a high
level of experience in formulating
and firing Denstone supports to
meet various requirements — and
the most critical deadlines.
Employees are trained in Statistical
Process Control (SPC) as part of
Norton’s total quality management
philosophy.
Equipment — Our manufacturing
facilities employ computer-controlled
equipment to ensure close toler-
ances and exceptional product con-
sistency.
10
International Capabilities —
Norton has product design,
manufacturing and warehousing
capabilities in the U.S., Canada,
Australia, England, Singapore
and Germany.
ISO Certification — Norton
Chemical Process Products
Corporation’s worldwide
headquarters, U.S. sales offices and
manufacturing facilities are
certified by BVQI to ISO 9001:1994.
Norton’s Stoke-on-Trent, UK
operation is approved and certified
though BSI to ISO 9001:1994.
ACCREDITED
ANSI RAB
QMS
ISO 9001
Quality Mission
Norton Chemical Process
Products Corporation’s Quality
Mission is to exceed customer
expectations by:
• Delivering excellence in both
perceived and realized value
• Providing products and
services that are of a higher
quality than our competitors
• Providing complete customer
satisfaction and conform to
their changing needs
• Maintaining open
communication with
our customers
• Focusing on continuous
improvement
• Maintaining our quality
system through employee
involvement, teamwork,
collaboration, breakthrough
thinking, judicious resource
allocation, creative problem
solving, constancy of purpose
and determination to succeed
In our culture “Quality In
Everything We Do” is the
only acceptable behavior.
When No Standard Product Will Do
Norton’s decades of experience
developing and manufacturing the
optimal catalyst bed support media
make us uniquely qualified to pro-
vide custom products for particularly
difficult or unusual applications. Ask
us about product development part-
nerships and custom-engineered
solutions. No matter what your
application, no matter where you
are, you will find us an exceptionally
responsive resource.
Other Exceptional
Products for Catalytic
Applications
MacroTrap™ guard bed media keep
pressure drop down, profits up.
Norton manufactures a unique
macroporous ceramic medium that
effectively filters particulate matter
from the feed stock, thus protecting
the catalyst bed from fouling and
subsequent pressure drop buildup
across the catalyst bed. In fact,
actual field applications prove that
MacroTrap guard bed media keep
catalyst reactors running longer
without the need for costly
skimming operations.
For more information on
Catalyst Carriers Products for
MacroTrap media, request Tailored to Meet Mass Transfer
brochure GB-1. Your Needs Norton manufactures a wide range
Norton engineers and manufactures of standard and high-performance
packings, trays and internals in
catalyst carriers to meet your specif-
ceramic, metal and plastic materials
ic process needs for size, shape, for mass transfer applications.
porosity and surface area. To learn more about Norton’s
For more information on offerings, contact the sales
Norton’s capabilities, request representative nearest you.
brochure CAT-3.

11
Worldwide Office Locations
Worldwide Headquarters Sales Offices
Norton Chemical Process Products Australia
Corporation Carborundum Australia Pty. Ltd.
P.O. Box 350 Unit 8, No. 7, Packard Avenue
Akron, OH 44309-0350 Castle Hill NSW, Australia 2154
Telephone: (330) 673-5860 Telephone: (61) 2 9894 6599
U.S. Toll Free: 1-888-NORTON-1 Fax: (61) 2 9894 6622
Fax: (330) 677-7245
www.nortoncppc.com France
Norton Chemical Process Products
Main Office Europe BP No. 148
Norton Chemical Process Products Rue de L’Ambassadeur
European Operations 78702 Conflans St. Honorine
King Street France
Fenton, Stoke-on-Trent Telephone: (33) 1 3490 4000
ST4 2LT England Fax: (33) 1 3490 0788
Telephone: (44) 1782 744561
Fax: (44) 1782 744330 Holland
Norton Chemical Process Products
Main Office Japan Helium weg 24
Norton KK 3812 BM Amersfoort
Norton Chemical Process Products Netherlands
Division Telephone: (31) 33 46 500 50
Ichiban-cho NN Building Fax: (31) 33 46 500 54
15-5 Ichiban-cho
Chiyoda-Ku, Tokyo, Japan Russia
102-0096 Norton Russia
Telephone: (81) 3 3263 0096 Office 440
Fax: (81) 3 3263 0097 1 Gagarina Avenue
Saint Petersburg 196105 Russia
Telephone: (7) 812 294 8530
Fax: (7) 812 294 8572

The information presented herein is believed

Norton Chemical Process to be accurate and reliable, but is presented
Products Corporation without guarantee or warranty on the part
of Norton Chemical Process Products
P.O. Box 350
Corporation. Further, nothing contained
Akron, Ohio 44309-0350 herein shall be taken as an inducement or
Telephone: (330) 673-5860 recommendation to manufacture or use any
Fax: (330) 677-7245 of the herein described materials or processes
www.nortoncppc.com in violation of existing or future patents.

A Saint-Gobain Company

© 1993 Norton Chemical Process Products Corporation 3/99 DEN-2R

 Denstone Catalyst ®

Norton Chemical Process Products Corporation Bed Support Media

There’s a Reason Why We Are No. 1…
Actually, Six Reasons
Norton has led the industry with its catalyst bed support
media technology for more than 50 years. As processes
become more demanding and the cost of failed media
increases, Norton has worked to develop a product that
can withstand even the most demanding process condi-
tions. The product, Denstone® 2000 support media, can
withstand the combined effects of load, temperature and
depressurization without chipping, spalling or breaking —
better than any support currently available.
Recently, Norton set out to prove the superiority of
Denstone supports over other support media. Spurred
by another manufacturer’s benchmarking effort, Norton
conducted a battery of six tests to compare media strength
and resiliency of 13-mm (¹⁄₂-inch) samples of Denstone
2000 media and the competitor’s leading product. The tests
were designed to mirror process conditions that tend to
challenge the integrity of the support spheres. In many
cases, the tests were identical or similar to ASTM
certified testing methods.
The result: Denstone 2000 supports demonstrated
significantly superior mechanical and thermal strength.
These properties ensure that Denstone 2000 supports
will withstand the conditions in your reactor without
breaking, chipping or spalling.
Your catalyst bed is worth protecting: Don’t risk it
with inferior bed support media.

Reason No. 1: Reasons No. 2 & 3:

Excellent Compressive Strength
Compressive strength is a key indicator of proper media
processing: The lack of crush strength indicates uneven
pore distribution, internal cracks or fines that can cause the
media to break or chip when subjected to thermal cycling
common in hydrocracking and reforming units. Conversely,
a high degree of compressive strength means that the
media’s internal pore structure and uniform material
composition will provide the strength necessary to
remain intact even under demanding conditions.
Crush strength test method. Fifteen sample spheres
were loaded one at a time between two steel plates on a
compressive strength test unit with a capacity of 2250kg
(5,000 pounds). The average load applied at which each of
the 15 spheres failed is depicted for all three products.
(ASTM C-515).
Flat Plate Crush Strength of Denstone 2000
Supports Exceeds Competition
800
700 725
600
FPCS (lbs.)
Better Impact Resistance in Two Tests
Installing the support media rarely involves kid gloves:
Containers of supports are knocked around, picked up
and dropped uncountable times before they reach the
reactor. Then, the media is dropped as much as 7.6m
(25 feet) into the reactor. Loading with the use of a sock
lessens the impact somewhat; but the potential for further
chipping or breakage still exists. The fractured media, in
turn, can increase pressure drop due to channeling and
catalyst bed plugging. In addition, chips or fines can foul
the catalyst, decreasing operating efficiency and ultimately
increasing the cost of catalyst regeneration.
Two types of impact energy can cause media failure:
Breakage can occur due to the impact of the support
media being dropped onto a stationary surface, which gen-
erally occurs during loading. Breakage also occurs when
weight falls upon the media. This type of impact occurs
when the spheres are crushed together during shipping
and handling or when other media fall on top of the
spheres.
Drop test method.
Fifty samples of Denstone 2000 Supports
each media were Prove Superiority in Drop Test

500 100
dropped 7.6m (25 90
100

400 feet) through a pipe 80

300 343
onto a steel plate, 70

285 with a 450mm (18 60

% Survival

200 59
inch) free fall from 50

100 the bottom of the 40

30
pipe to the plate. 30
0 20
The table compares
Denstone Major North Major 10
2000 American European the percentage of
0
Support Competition Competition spheres to survive
Media Denstone Major North Major
without breaking, 2000
Support
American
Competition
European
Competition
chipping or spalling. Media
 Impact test method. Using 20 samples of each media, Reason No. 6:
a 90-gram (3.15-oz.) tup was dropped from 300mm to Passes the Ultimate Test: Rapid Depressurization
600mm (12 inches to 24 inches) onto individual spheres. A hydrocracking tower experienced an extreme rapid drop
Impact resistance was determined using the mean failure in pressure. Already weakened by repeated thermal
load (ASTM D-3029). cycling, the catalyst bed support media shattered. The cat-
Denstone 2000 Supports alyst migrated downward through the broken support
Have Significant Edge in ASTM Test media. Within a short time, the refiner was forced to shut
0.3 down the unit for an emergency changeout. The time and
0.277 money involved was tremendous and could have been
avoided had the refiner been using a support media that
could withstand rapid depressurization. That is why Norton
0.2
developed this test.
Impact ft- lbs.

Autoclave Procedure. Approximately 200 samples of

each media are heated to 427° C (850° F) at 10.3 MPa
0.1 0.116 (1500 psia) in an autoclave chamber containing hydrogen.
The chamber was then depressurized instantaneously to
0.067 ambient pressure. The chart below lists the percentage of
spheres surviving without breakage.
0
Denstone 2000 Supports
Denstone Major North Major Pass the Ultimate Autoclave Test
2000 American European 100
Support Competition Competition 100
Media 90
88
80
Reasons No. 4 & 5:
Stands Up to Thermal Shock 70

% Survival
Even gradual changes in temperature, whether moderate 60

or extreme, can weaken support spheres. Process 50

conditions common in fixed-bed catalytic applications 40

weaken the supports over time and make them 30

increasingly susceptible to breakage or chipping. To see 20 25

how the supports stand up against thermal shock, we 10
heated 15 sample spheres of each media to 427° C 0
(850° F), then dropped them into water at room Denstone Major North Major
2000 American European
temperature. The surviving spheres were then tested Support Competition Competition
Media
for compressive strength as outlined above. The test
was repeated using spheres heated to 815° C (1500° F).

Denstone 2000 Supports

Maintain Strength After Thermal Shock
®
800

700 725 Norton Chemical Process

600 Products Corporation
P.O. Box 350
FPCS (lbs.)

500
Akron, OH 44309-0350
400 456 Phone (330) 673-5860
Fax (330) 677-7245
300 343
www.nortoncppc.com
285
200 222 Main Office Europe
207
100 142
Phone: (44) 1782 744561
74 86 Fax: (44) 1782 744330
0
Initial FPCS FPCS after 850° F FPCS after 1500° F Main Office Japan
(427° C) (815° C) Phone: (81) 3 3263 0096
Denstone 2000 Major North Major Fax: (81) 3 3263 0097
Support Media American European
Competition Competition
A Saint-Gobain Company

The information presented herein is believed to be accurate and reliable, but is

presented without guarantee or warranty on the part of Norton Chemical Process
Products Corporation. Further, nothing contained herein shall be taken as an
inducement or recommendation to manufacture or use any of the herein described
materials or processes in violation of existing or future patents.

© Copyright 1998 Norton Chemical Process Products Corporation 3/99 Bulletin DenSix
 ® Denstone® 99
Norton Chemical Process Products Corporation Support Media
Microspheres

Low-silica Denstone 99 catalyst Denstone® 99 Support Media

bed supports are also available in Nominal Size Range
sizes ranging from ¹⁄₄ in. to 2 in. (6mm
Size Range
to 50mm) in diameter. Upon request,
in. in. [mm]
Norton can provide even smaller high
alumina microspheres. ¹⁄₁₆ 0.05 – 0.10 [1.3 – 2.5]
¹⁄₁₀ 0.09 – 0.13 [2.3 – 3.3]
A Profile of Proven Performance
¹⁄₈ 0.11 – 0.21 [2.8 – 5.3]
• Monolithic structure eliminates in-
¹⁄₄ 0.21 – 0.32 [5.3 – 8.1]
service spalling and delamination,
which prevents the incidence of ³⁄₈ 0.32 – 0.44 [8.1 – 11.2]
fine chips and splinters plugging ¹⁄₂ 0.44 – 0.59 [11.2 – 15.0]
beds of catalysts. ³⁄₄ 0.69 – 0.88 [17.5 – 22.4]
• Maximum resistance to 1 0.88 – 1.15 [22.4 – 29.2]
erosion and low attrition 2 1.90 – 2.20 [48.3 – 55.9]
minimizes the possibility of
Denstone Products: The Industry Typical Chemical Analysis
catalyst contamination.
Standard for Over 30 Years Al2O3 >99%
• High thermal shock resistance.
Denstone catalyst bed supports SiO2 <0.20%
are universally known for their reliable Denstone 99 Support Media TiO2 0.57%
performance in a wide range of Typical Applications Fe2O3 0.034%
chemical and petrochemical applica- • Ammonia production, where MgO 0.0004%
tions. Norton continues to set new temperatures can reach 2280° F Na2O 0.23%
standards with product innovations. (1250° C) with pressures as high
K2O 0.0002%
Extending the Sphere… as 500 psig (35.2 kg/cm2)
Norton has extended its sphere of • Methanol and hydrogen Crush Strength Data
catalyst bed support media with production, primarily reforming Nominal Size Crush Strength
the introduction of Denstone® 99 • Alkylation processes using hydro- in. lb. [kg]
microspheres, a 99%+ alumina gen fluoride at high temperatures ¹⁄₁₆ 20 [9]
support media for long life and • Naphtha reforming ¹⁄₁₀ 30 [14]
optimum performance in chemical, • Isomerization ¹⁄₈ 50 [23]
petrochemical and refining applica-
¹⁄₄ 120 [55]
tions. The microspheres are available Additional Denstone Support
in ¹⁄₁₆ in., ¹⁄₁₀ in. and ¹⁄₈ in. (1.6mm, Media Products ³⁄₈ 200 [90]
2.5mm and 3.2mm) sizes for the In addition to Denstone 99 ¹⁄₂ 370 [170]
support and retention of small-sized microspheres, Norton helps you ³⁄₄ 950 [430]
catalysts and absorbants. optimize your performance and 1 1400 [635]
Like all Denstone 99 support economy with other Denstone 2 >2000 [>900]
media, Denstone 99 microspheres support media products.
are characterized by their low silica Norton Chemical Process
• Denstone® 57 supports, Products Corporation
content (<0.2%). The high degree of
the industry standard for P.O. Box 350
purity and strength make the product
support systems Akron OH 44309-0350
ideal for high-temperature and steam
applications where leached silica can • Denstone® 80 supports for Phone (330) 673-5860
proprietary applications Fax (330) 677-7245
coat downstream equipment or foul or
poison the catalyst bed. • Denstone® 2000 supports, a A Saint-Gobain Company
superior product designed to The information presented herein is believed to
survive rapid depressurization be accurate and reliable, but is presented without
guarantee or warranty on the part of Norton Chemical
Process Products Corporation. Further, nothing
contained herein shall be taken as an inducement
or recommendation to manufacture or use any of the
herein described materials or processes in violation
of existing or future patents.

© Copyright 1997 Norton Chemical Process Products Corporation 7/97 Bulletin D99-1