Catalyst Loading Technology for Fixed-Bed Reactors: From Empirical Heuristics to Data-Driven Intelligent Regulation

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Abstract
Fixed-bed reactors are pivotal in chemical industries, where catalyst loading critically determines reactor performance and economy. This critical review delineates and analyzes a three-stage evolution of loading technology: from empirical manual methods, through scenario-adaptive innovations, to closed-loop intelligent systems. It aims to decode the underlying scientific principles, assess the performance enhancements and inherent limitations of each stage, and critically examine the architectural framework and constraints of intelligent loading systems. Industrial validation data, such as from a 2.4 Mt/a hydrocracker, demonstrate potential improvements (e.g., 20–22% catalyst life extension, 1.8% bed pressure-drop fluctuation). However, the progression presents complex trade-offs in terms of scalability, cost, and standardization. The future direction is discussed, pointing toward addressing challenges in multi-physics modeling, digital twin integration, and fundamental research gaps. This work provides a balanced framework for evaluating loading technology evolution, acknowledging its context-dependent applicability.
Funding Information
  • National Natural Science Foundation of China (52075050)
  • General Project of Philosophy and Social Sciences Research in Colleges and Universities of Jiangsu Province (2025SJYB1436)
  • 2025 Jiangsu Provincial Education Science Planning Project (C/2025/02/80)
  • Youth Fund Project of Jiangsu Vocational College of Electronics and Information (JSEIZYB202403)
  • 2025 School-Level Teaching Construction and Reform Project of Jiangsu Vocational College of Electronics and Information (JX-JG-202514)
  • Program for Excellent Scientific and Technological Innovation Teams in Colleges and Universities of Jiangsu Province
  • Program for Excellent Teaching Teams of the “Qing Lan Project” in Colleges and Universities of Jiangsu Province
  • Project of Huaian Key Laboratory of Reverse Engineering and Digital Design under the Huaian Innovation Service Capacity Program (HAP202303)

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