Abstract:
An overhead catalyst loading device eliminates the need for lower flanges of the overhead catalyst structural support frame or dedicated overhead trolley beams to prevent ash build up collecting on a selective catalytic reactor (SCR) reactor box and provides an advantageous electric hydraulic lifting mechanism suitable for integration into a SCR device. The overall width of the SCR device is reduced since the structural support frame in the SCR device fits in the gaps between catalyst blocks. The overhead electric hydraulic catalyst loading device also minimizes the chance of injury during catalyst block installation by using an electric hydraulic actuated lifting mechanism consisting of spacers and structural telescopic members which may comprise holes and pins for height adjustment to allow for loading and unloading catalyst blocks into and out of a SCR device. Methods of lifting and loading and unloading a catalyst block are also presented therein.

Description:
[0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 61/887,645 filed Oct. 7, 2013 and titled “Electric Hydraulic Catalyst Loading and Unloading Device and Methods Therefor.” The compete text and disclosure of this patent application is hereby incorporated by reference as through fully set forth herein in its entirety. 
     
    
     BACKGROUND 
       [0002]    The present invention generally relates to a selective catalytic reduction (SCR) device for converting NO x  in the gas stream into H 2 O and N 2 . More particularly, the present invention is directed to a catalyst loading device for loading and unloading catalyst blocks in an SCR device, and methods therefor. 
         [0003]    SCR devices using catalyst blocks are often used in applications where NO x  removal from flue gases is needed. In such cases, the SCR catalyst blocks are placed within the SCR reactor through which the combustion flue gases are conveyed.  FIG. 1  shows a perspective view of an SCR reactor box (or SCR device) with fully and partially loaded catalyst block sections. There is an entrance for the catalyst loading device to enter for loading and unloading the catalyst blocks. The entrance and height between layers of catalyst is such that it allows enough space for the catalyst loading device (with or without a catalyst block) and the operator to enter the SCR device for loading and unloading the catalyst blocks. As shown in  FIG. 1 , the height between layers of catalyst layers is very limited, ranging anywhere from 10 to 12 feet high. As the available space between the top of the catalyst block and overhead obstructions (e.g., piping, sonic horns, sootblowers, etc.) is minimal, there is only room for the catalyst loading device structure, and no room for lifting machinery. 
         [0004]    In order to remain effective, the catalyst should be protected from accumulation of particulate contaminants, which may deposit on the catalyst or otherwise restrict gas flow to and/or through the catalyst. Also catalyst is deactivated over time by the NOx removal process. In either case, removal and replacement or reloading of a catalyst block may be periodically required. 
         [0005]    Existing industry solutions include a commercial walk behind fork lift on heavy duty pertinent grating, expanding hydraulic carts running on a secondary grid below the catalyst blocks, or multiple overhead trolley beam and hoists. 
         [0006]    Typically, catalyst loading devices used in the industry run on the lower flanges of the overhead catalyst structural support frame or dedicated overhead trolley beams. This means that the shapes of the catalyst supporting beams are typically constructed of overhead trolley beams with flanges. These flanges continue to be a problem since they can collect ash which can fall off and are a starting place for catalyst pluggage. 
         [0007]    Catalyst loading device structural support frames that require lifting from underneath the catalyst blocks continue to be a problem since they must be wider than the catalyst blocks, requiring extra space on one side of the block for the structural support frame and lifting mechanism, which also increases the overall width of the catalyst reactor box. 
         [0008]    One method of loading and unloading catalyst blocks in a SCR device typically uses walk behind forklifts to move the catalyst blocks into the approximate location and then moves them into final placement with pry bars, which may increase the chance of personal injury. 
         [0009]    United States Patent Application Publication Number US 2014/0227073 to Nelson et al. is drawn to an overhead catalyst loading device that eliminates the need for lower flanges of the overhead catalyst structural support frame or dedicated overhead trolley beams to prevent ash build up collecting on a SCR reactor box and provides an advantageous lifting mechanism suitable for integration into a SCR device. Nelson et al. uses a hydraulic pump to provide pressure to a lifting mechanism to engage a lifting frame of a lifting structure, and the force exerted by the lifting mechanism is transmitted into the lifting structure, causing it to be displaced vertically, thereby lifting the catalyst block coupled thereto. See  FIGS. 2 and 3  for drawings of the prior art catalyst loading device. 
         [0010]    It would be desirable to provide a catalyst loading device that eliminates the need for overhead trolley beams with ledges in the form of the support beam flanges to prevent ash build up collecting on the SCR reactor box and provides an advantageous electric hydraulic lifting mechanism suitable for integration into the SCR unit that minimizes the chance of injury, lessens the exertion of operator energy, and increases the speed and rate of loading and unloading catalyst blocks in the SCR device, which remains of significant commercial interest in the industry. 
       BRIEF DESCRIPTION OF INVENTION 
       [0011]    The present invention is directed to an electric hydraulic catalyst loading device and a method for loading and unloading catalyst blocks in a selective catalytic reduction (SCR) device. 
         [0012]    In accordance with one embodiment of the present invention, an overhead catalyst loading device eliminates the need for lower flanges of the overhead catalyst structural support frame or dedicated overhead trolley beams to prevent ash build up from collecting on the SCR reactor box and provides an electric hydraulic advantageous lifting mechanism suitable for integration into the SCR device. The catalyst loading device and lifting mechanism can be designed to straddle the catalyst blocks in either their width (short) or length (long) dimension based on the requirements of the SCR device and equipment or component arrangement. Furthermore, it also minimizes the chance of injury during catalyst block installation by using an electric hydraulic actuated lifting mechanism for loading and unloading the catalyst blocks into the SCR device. 
         [0013]    The problem of ash collection on the flanges of overhead trolley beams which can fall off and be a starting place for catalyst pluggage is solved by an overhead catalyst loading device that eliminates the need for overhead trolley beams with ledges in the form of the support beam flanges to prevent ash build up from collecting on the SCR reactor box. 
         [0014]    The problem of requiring extra space on one side of the catalyst blocks within the SCR reactor box for the structural support frame and lifting mechanism is solved by the fact that the structural support frame in the SCR device for the catalyst loading device is required to be no wider than the catalyst blocks. Therefore, no extra space is required on either side of the catalyst blocks for the cart support frame and the overall width of the SCR device is reduced. When temporary grating is supplied for personnel safety only one piece grating the size of the catalyst block needs to be removed during installation of the catalyst block. 
         [0015]    The problem of using pry bars for final placement of catalyst blocks during loading and unloading that increases the chance of personal injury is solved by using an electric hydraulic actuated lifting mechanism for loading and unloading the catalyst blocks into the SCR device. 
         [0016]    The problem of using a hand/foot hydraulic pump requiring operators to exert a great amount of energy to operate the lifting mechanism and decreasing the rate of loading and unloading of the catalyst blocks is solved by the use of an electric hydraulic operated lifting mechanism. 
         [0017]    The catalyst loading device is advantageously constructed of conventional steel or other suitable material structural members (e.g., angles, C-sections, I-beams, T-beams, box sections, tubular members, bar or flat stock, hexagonal sections, octagonal sections, etc., but not limited thereto) to reduce costs. 
         [0018]    The catalyst loading device comprises a lower support frame, wherein vertically oriented structural members are attached to a horizontal oriented lower support member. The structural members function as lower legs preferably constructed of tubular members or bar stock movably inserted into upper legs preferably constructed of tubular members of the upper lifting frame to adjust the height of the upper lifting frame for moving the catalyst loading device to a different grade or catalyst block layer in the SCR device or to transport the catalyst loading device to storage via inserting pins through holes in the structural members or legs at a desired height. A horizontally oriented lower support member is located between the lower legs and connected thereto on each end thereof. The lower support member provides extra support during loading and unloading of the catalyst blocks. Furthermore, the lower support member also provides mounting support for the hydraulic cylinder and rotatable wheels. Rotatable wheels are attached to the lower support member to enhance maneuverability within the SCR device and may include a lock therewith to prevent movement of the catalyst loading device during loading and unloading of the catalyst block. The rotatable wheels allow for the elimination of all overhead trolley beams inside the reactor box. The catalyst loading device moves into place via rotatable wheels in guide tracks on the top flange surface of the structural support frame (not shown) straddling catalyst blocks. The catalyst loading device can be rolled 90 degrees to the loading path into the SCR device and also moved 90 degrees sideways over to the next loading path. 
         [0019]    An upper lifting frame is movably engaged with respect to the lower support frame. The upper lifting frame comprises horizontal oriented structural members preferably attached to vertically oriented tubular structural members together to form a rectangular or square shaped lifting frame with the tubular structural members extending from the horizontal oriented structural members. Furthermore, lifting lugs are attached to the front-side or back-side of the upper lifting frame for coupling the catalyst blocks thereto for loading and unloading the blocks in the SCR device. In another embodiment, lifting lugs may also be assembled at other locations of the upper lifting frame (e.g., towards a first-end and/or a second-end of the lifting structure, but not limited thereto). A horizontally oriented upper support member is located between the structural members or upper legs and connected thereto on each end thereof. The upper support member provides extra support during loading and unloading of the catalyst blocks. Furthermore, the upper support member also provides a mounting support for the spacer. The upper lifting frame further comprises other structural members, including, but not limited to, angles and flat stock (or plate), for support bracing for lifting catalyst blocks and mounting other structural members, a battery, a hydraulic pump, and motor, but not limited thereto. 
         [0020]    Accordingly, one aspect of the present invention is drawn to a catalyst loading device, comprising: at least one lower support frame; an upper lifting frame movably engaged with respect to the lower support frame; and means for coupling catalyst blocks to the upper lifting frame. The means for coupling the catalyst to the lifting structure includes lifting lugs, pins, fasteners, bolts, or any suitable device known to one skilled in the art, but not limited thereto. 
         [0021]    The upper lifting frame or lower lifting frame may comprise a lifting mechanism for loading and unloading the catalyst blocks into a SCR device. Accordingly, another aspect of the present invention is drawn to a lifting mechanism, comprising: at least one hydraulic pump; at least one vertically oriented hydraulic cylinder fluidically connected to the at least one hydraulic pump; at least one vertically oriented spacer attached to the at least one hydraulic cylinder; a power supply; and a motor attached to the hydraulic pump and wired to the power supply to operate the hydraulic pump. The spacer is interchangeable with various spacer designs or telescopic for height adjustment of the upper lifting frame based on the requirements of the SCR device and equipment or component arrangement. Alternatively, the hydraulic cylinder may be attached to the upper support member at the upper end of the spacer instead of the lower support member at the bottom of the spacer. The power supply may be a battery or electrical connection to a power source (e.g., 110 volt electrical outlet) and the motor may be electrically driven. 
         [0022]    To allow for height adjustment of the upper lifting frame of the catalyst loading device for different sizes and heights of catalyst blocks, the spacer may be assembled in one of the following ways, but not limited thereto. In one embodiment, as at least one spacer that is rigidly connected to the at least one hydraulic cylinder and is interchangeable for different sizes and heights of catalyst blocks. As used herein, rigidly connected elements move together as a unit. In another embodiment, as at least one spacer comprising telescoping structural members with holes and pins for height adjustment of the upper lifting frame of the catalyst loading device for different sizes and heights of catalyst blocks. Telescopic or telescoping as used herein refers to having or consisting of structural member sections designed to slide into one another and/or describes the movement of one structural member section sliding out from or into another structural member section from its initial state of position. These structural members may be tubular members, but not limited thereto. 
         [0023]    The second adjustable spacer comprises at least one vertically oriented upper structural member rigidly connected to the upper support member and at least one other vertically oriented structural member attached to the at least one hydraulic cylinder connected to the lower support member. The lower structural member telescopically moves out from or into the upper structural member. Both structural members have at least one hole so that at least one pin can be inserted therethrough for adjusting the height of the upper lifting frame. During adjustment of the upper lifting frame, the upper structural member slides along the lower structural member vertically up or down until the upper lifting frame is at the desired height. Once the upper lifting frame is at the desired height, a pin is inserted through the hole to fix the adjustable spacer and upper lifting frame to the desired height. A hole is included in the upper support member to allow the lower structural member to slide therethrough during adjustment of the upper lifting frame to the desired height as shown in  FIG. 16 . Alternatively, the hydraulic cylinder may be attached to the upper support member at the upper end of the spacer instead of the lower support member at the bottom of the spacer. The vertically oriented tubular structural members or legs of the upper lifting frame and vertically oriented structural members or legs of the lower support frame are also telescopic so the lower support frame structural members can move out from or into the upper lifting frame structural members during height adjustment of the upper lifting frame. The lower support frame and upper lifting frame structural members may still comprise holes and pins for locking the upper lifting frame to a desired height for adjusting the height of the upper lifting frame for moving that catalyst loading device to a different grade or catalyst block layer in the SCR device or to transport the catalyst loading device to storage. 
         [0024]    A switch may be assembled to the upper lifting frame or lower support frame and wired to the power supply and to the motor. The switch may be a manual push button switch with an up and down button that acts to transmit power from the power supply to drive the motor to operate the hydraulic pump. The switch will control the operation of the lifting mechanism to raise and lower the upper lifting frame. 
         [0025]    There may be two hydraulic cylinders with spacers assembled thereto; one hydraulic cylinder and spacer located towards the first end of the catalyst loading device and the other hydraulic cylinder and spacer located towards the second end of the catalyst loading device; both hydraulic cylinders and spacers are assembled to the upper and lower support members and centered approximately between the two structural members or legs of the respective first and second end of the catalyst loading device. 
         [0026]    The present invention facilitates movement of catalyst blocks in an SCR device. The catalyst loading device is maneuvered into place over the catalyst blocks and removably coupled to the catalyst blocks for loading and unloading of the blocks in an SCR device. The catalyst loading device moves into place via rotatable wheels in guide tracks on the top flange surface of the structural support frame (not shown) straddling catalyst blocks between the structural members or legs. The upper lifting frame is positioned to a desired height via one of the various spacer designs. Catalyst blocks are then coupled via lifting lugs on the catalyst loading device to the upper lifting frame. 
         [0027]    Another aspect of the present invention is drawn to a method of lifting a catalyst block, wherein a hydraulic pump provides pressure to a hydraulic cylinder, wherein the application of force by the hydraulic cylinder displaces a spacer vertically, causing it to vertically raise the upper lifting frame attached thereto, thereby lifting the catalyst block coupled to the upper lifting frame. The hydraulic pump may be an electric or hand/foot hydraulic pump, but not limited thereto. 
         [0028]    Once the catalyst blocks are moved into position in the SCR device, the pressure exerted by hydraulic pump may be released, permitting the hydraulic cylinders to retract. This lowers the spacer and the upper lifting frame attached thereto. Catalyst blocks are de-coupled from upper lifting frame once they are in a desired position. The catalyst loading device allows the catalyst blocks to be set directly in place without the use of a pry bar, thereby minimizing the chance of personal injury. 
         [0029]    Accordingly, another aspect of the present invention is drawn to a method of loading and unloading a catalyst block into an SCR device, comprising the steps of: moving a catalyst loading device via wheels attached thereto in guide tracks over top of the catalyst block; positioning a upper lifting frame of the catalyst loading device to a desired height; coupling the catalyst block to the upper lifting frame of the catalyst loading device; operating a lifting mechanism causing force to be applied to displace a spacer vertically, causing it to vertically raise the upper lifting frame attached thereto, thereby lifting the catalyst block coupled to the upper lifting frame; moving the catalyst loading device into a desired position for loading or unloading the catalyst block; releasing pressure exerted by the lifting mechanism to lower the spacer and upper lifting frame attached thereto; decoupling the catalyst blocks from the catalyst loading device to allow the catalyst block to be placed at the desired position. 
         [0030]    In another embodiment of the present invention, fasteners such as screws, bolts, keyed, pinned or splined connections, or other structures known to one of ordinary skill in the art may be used to construct the catalyst loading device. 
         [0031]    In another embodiment of the present invention, welded connections or other structures and/or methods known to one of ordinary skill in the art may be used to construct the catalyst loading device 
         [0032]    In another embodiment of the present invention, the structural members and/or legs may be comprised of tubular or solid circular, square, or other shapes known to one of ordinary skill in the art. 
         [0033]    In yet another embodiment of the present invention, the spacer(s) comprises telescoping structural members with holes and pins to allow for height adjustment of the upper lifting frame of the catalyst loading device for different sizes and heights of catalyst blocks. 
         [0034]    In yet another embodiment of the present invention, the hydraulic cylinder may be attached to the upper support member instead of the lower support member. 
         [0035]    In another embodiment, the hydraulic cylinders and spacers may be offset with respect to one another instead of directly opposite and in line with one another. For example, one hydraulic cylinder may be mounted towards the front side of the catalyst loading device, while the other is mounted towards the back side of the catalyst loading device. 
         [0036]    In another embodiment, multiple lifting mechanisms may be employed; each comprising single or multiple sets of hydraulic cylinders and spacers. 
         [0037]    In another embodiment, multiple power supplies may be employed to provide power and to drive multiple motors to operate single or multiple sets of hydraulic pumps. 
         [0038]    The relevant portion(s) of any specifically referenced patent and/or published patent application is/are incorporated herein by reference in its entirety. 
         [0039]    The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific benefits attained by its uses, reference is made to the accompanying drawings and descriptive matter in which exemplary embodiments of the invention are illustrated. These and other non-limiting aspects and/or objects of the disclosure are more particularly described below. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0040]    The following is a brief description of the drawings, which are presented for the purposes of illustrating the exemplary embodiments disclosed herein and not for the purposes of limiting the same. 
           [0041]      FIG. 1  illustrates a perspective view of an SCR reactor box or device showing the environment is limited by space constraints between catalyst sections for loading and unloading of catalyst blocks. 
           [0042]      FIG. 2  illustrates a perspective view of one embodiment of a prior art version of a catalyst loading device. 
           [0043]      FIG. 3  illustrates a front section view of the one embodiment of a prior art version of the catalyst loading device of  FIG. 2 . 
           [0044]      FIG. 4  illustrates a perspective view of one embodiment of the catalyst loading device of the present disclosure. 
           [0045]      FIG. 5  illustrates a front view of one embodiment of the catalyst loading device of the present disclosure. 
           [0046]      FIG. 6  illustrates a side view of one embodiment of the catalyst loading device of the present disclosure. 
           [0047]      FIG. 7  illustrates a top plan view of one embodiment of the catalyst loading device of the present disclosure. 
           [0048]      FIG. 8  illustrates a perspective view of one embodiment of the catalyst loading device of the present disclosure showing the spacer comprised of telescoping structural members with holes and pins. 
           [0049]      FIG. 9  illustrates a side view of one embodiment of the catalyst loading device of the present disclosure showing the spacer comprised of telescoping structural members with holes and pins. 
           [0050]      FIG. 10  illustrates a perspective view of one embodiment of the catalyst loading device of the present disclosure showing the spacer comprised of telescoping structural members with holes and pins while in the lowered position. 
           [0051]      FIG. 11  illustrates a perspective view of one embodiment of the catalyst loading device of the present disclosure straddling catalyst blocks for loading and unloading. 
           [0052]      FIG. 12  illustrates a perspective view of another embodiment of the catalyst loading device of the present disclosure showing the spacer comprised of telescoping structural members with holes and pins straddling catalyst blocks for loading and unloading. 
       
    
    
     DETAILED DESCRIPTION OF INVENTION 
       [0053]    A more complete understanding of the processes and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the existing art and/or the present development, and are, therefore, not intended to indicate relative size and dimensions of the assemblies or components thereof. 
         [0054]    Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function. 
         [0055]    The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. 
         [0056]    It should be noted that some terms used herein are relative terms. For example, the terms “front”, “back”, “first”, “second” are relative to the view shown in the figure, and should not be construed as requiring a particular orientation or location of the structure. For example, although the lifting mechanism is depicted as being located towards the backside of the catalyst loading device, it may alternatively be located at the front side. Similarly, the terms “upper” and “lower” are relative to each other in location, i.e. an upper component is located at a higher elevation than a lower component. Furthermore, the terms “width”, “length”, “short”, and “long” are relative to each other in size or measurement, i.e. width or short side is smaller in distance than a length or long side of a component. 
         [0057]    The terms “vertical” or “vertically” and “horizontal” or “horizontally” are used to indicate direction relative to an absolute reference, i.e. ground level. However, these terms should not be construed to require structures to be absolutely parallel or absolutely perpendicular to each other. For example, a first vertical structure and a second vertical structure may not be necessarily parallel to each other. 
         [0058]    To the extent that explanations of certain terminology or principles of the heat exchanger, boiler, and/or steam generator arts may be necessary to understand the present disclosure, and for a more complete discussion of catalyst-containing devices, SCRs, or of the design of modern utility and industrial boilers, the reader is referred to Steam/its generation and use, 41 st  Edition, Kitto and Stultz, Eds., Copyright© 2005, The Babcock &amp; Wilcox Company, Barberton, Ohio, U.S.A., the text of which is hereby incorporated by reference as though fully set forth herein. 
         [0059]    The present invention is directed to a catalyst loading device and methods for lifting and loading and unloading catalyst blocks in a SCR device. The present invention moves via rotatable wheels in guide tracks on the top flange surface of the structural support frame (not shown) that the catalyst blocks rest on inside the SCR device. Therefore, the shape of the structural support frame has no effect on the function of the catalyst loading device and fits in the gaps between catalyst blocks. The present invention eliminates the need for overhead trolley beams with ledges in the form of the support beam flanges that ash would otherwise collect on in the SCR reactor box. The ash collection in the SCR reactor is dramatically reduced, thus minimizing ash clumps from falling on the catalyst blocks and creating a starting spot for pluggage. 
         [0060]    Since the structural support frame in the SCR device for the catalyst loading device fits in the gaps between the catalyst blocks, no extra space is required on either side of the catalyst blocks for the cart support frame and the overall width of the SCR device is reduced. Only one piece grating the size of the catalyst block needs to be removed during installation of the catalyst block. Permanent grating can be left in place for personal protection at all times without interfering with installation of the catalyst blocks or operation of the SCR device. Moreover, the catalyst loading device works equally well when only temporary grating is permitted to minimize ash buildup with fuels that readily adhere to one another. In this case, there is only one small opening in the grating at any time corresponding to the size of a catalyst block. Furthermore, the overall width of the SCR device is reduced. 
         [0061]    Referring to the drawings generally, wherein like reference numerals designate the same or functionally similar elements throughout the several drawings, and to  FIG. 4  in particular, there is shown a perspective view of a first embodiment of a catalyst loading device, generally designated  400 . The catalyst loading device has a front side  402  and a back side  404 , and a first end  406  and a second end  408 . 
         [0062]    Referring to  FIG. 5 , there is illustrated a front view of the catalyst loading device generally designated  500  having a upper lifting frame  510  movably engaged with respect to a lower support frame  512 . 
         [0063]    Referring to  FIGS. 4 and 5 , upper lifting frame  510  comprises horizontally oriented structural members  414 ,  514  preferably attached to vertically oriented tubular structural members or legs  416 ,  516  together to form a rectangular or square shaped lifting frame  418  with the tubular structural members extending from the horizontal oriented structural members. Lifting lugs  420 ,  520  are assembled to structural members  414 ,  514  at the front side and back side for coupling to the catalyst blocks  1199  (see also  FIG. 11 ) for loading and unloading the catalyst blocks  1199  into and out of the SCR device. In another embodiment as shown in  FIGS. 6 and 7 , lifting lugs  622 ,  722  may also be assembled to structural members  724  towards the first end  706  and towards the second end  708  of the catalyst loading device  600 ,  700 . Accordingly, in other embodiments, only lifting lugs  420 ,  520  may be assembled or only lifting lugs  622 ,  722  may be assembled to the catalyst loading device. Accordingly, in other embodiments, both lifting lugs  420 ,  520  and lifting lugs  622 ,  722  may be assembled to the catalyst loading device. In other embodiments of the invention, lifting lugs may be assembled at other various locations on the upper lifting frame and/or other structural members. Referring to  FIG. 3 , a horizontally oriented upper support member  626  is located between structural members  616  and connected thereto on each end thereof. The upper support member  626  provides extra support during loading and unloading of the catalyst blocks. Furthermore, the upper support member  626  also provides a mounting support for the spacer  628 . 
         [0064]    Referring to  FIG. 6 , a lower support frame  612  comprises vertically oriented structural members or legs  630  attached to a horizontal oriented lower support member  632 . Structural members  630  are movably inserted into structural members  616  of the upper lifting frame  610 . To adjust the height of the upper lifting frame  610  for moving the catalyst loading device to a different grade or catalyst block layer in the SCR device or to transport the catalyst loading device to storage, structural members  630  and  616  have holes  634 , which together with pins  636 , allow for positioning the height of the upper lifting frame  610  to a desired height. The pins  636  are inserted through holes  634  in structural members  630  and  616  once the structural members  616  are adjusted to the desired height for upper lifting frame  610 . Referring back to  FIG. 6 , a horizontally oriented lower support member  632  is located between the structural members  630  and connected thereto on each end thereof. The lower support member  632  provides extra support during loading and unloading of the catalyst blocks. Furthermore, the lower support member  632  also provides a mounting support for the hydraulic cylinder  638  and rotatable wheels  640 . The catalyst loading device moves into place via rotatable wheels  638  in guide tracks on the top flange surface of the structural support frame (not shown) straddling catalyst blocks between the structural members or legs. Rotatable wheels  640  are attached to the lower support member  632  to enhance maneuverability within the SCR device and may include a lock therewith to prevent movement of the catalyst loading device during loading and unloading of the catalyst block. The rotatable wheels  640  allow for the elimination of all overhead trolley beams inside the reactor box. The catalyst loading device  600  can be rolled 90 degrees to the loading path into the SCR device and also moved 90 degrees sideways over to the next loading path. 
         [0065]    Referring to  FIGS. 4 and 6 , the catalyst loading device  400 ,  600  may comprise a lifting mechanism for loading and unloading the catalyst blocks into a SCR device. The lifting mechanism comprises at least one: hydraulic pump  442 ; at least one vertically oriented hydraulic cylinder  438 ,  638  fluidically connected to the hydraulic pump  442 ; vertically oriented spacer  428 ,  628  attached to the at least one hydraulic cylinder  438 ,  638 ; a power supply  444 ; and a motor  446  attached to the hydraulic pump  442  and wired to the power supply  444  to operate the hydraulic pump  442 . Referring to  FIG. 4 , the hydraulic cylinders  438  are mounted to lower support member  432 . Spacers  428  are mounted to the hydraulic cylinder at one end and mounted at the other end to upper support member  426 . Alternatively, the hydraulic cylinder  438 ,  638  may be attached to the upper support member  426 ,  626  at the upper end of spacer  428 ,  628  instead of the lower support member  1432 ,  632  at the lower end of spacer  428 ,  628 . The spacer  428 ,  628  is interchangeable with various spacer designs for height adjustment of the upper lifting frame  610  based on the requirements of the SCR device and equipment or component arrangement. The electric hydraulic lifting mechanism increases the rate that catalyst blocks can be loaded and unloaded into the SCR device, as well as, decreases the amount of energy exerted by the operators during operation of the lifting mechanism. 
         [0066]    To allow for height adjustment of the upper lifting frame  610  of the catalyst loading device  400 ,  600  for different sizes and heights of catalyst blocks, spacer  428 ,  628  can be assembled one of the following ways, but not limited thereto. In one embodiment, as a spacer that is rigidly connected to the hydraulic cylinder and is interchangeable for different sizes and heights of catalyst blocks. As used herein, rigidly connected elements move together as a unit. In another embodiment, as telescoping structural members with holes and pins, similar to structural members  630  and  616  with holes  634  and pins  636 , which are adjustable for different sizes and heights of catalyst blocks. These structural members may be tubular members, but not limited thereto. 
         [0067]    In yet another embodiment of the catalyst loading device  800 ,  900 ,  1000  includes a spacer  848 ,  948  comprising telescoping structural members  850 ,  852 ,  950 ,  952  with holes  854 ,  954  and pins  856 ,  956  as shown in  FIGS. 8 through 10 . The spacer  848 ,  948  comprises at least one vertically oriented upper structural member  850 ,  950  rigidly connected to the upper support member  826 ,  926  and at least one other vertically oriented lower structural member  852 ,  952  attached to the at least one hydraulic cylinder  838 ,  938  connected to the lower support member  832 ,  932 . Alternatively, the hydraulic cylinder  838 ,  938  may be attached to the upper support member  826 ,  926  at the upper end of spacer  848 ,  948  instead of the lower support member  832 ,  932  at the lower end of spacer  848 ,  948 . The lower structural member  852 ,  952  telescopically moves out from or into the upper structural member  850 ,  950 . Both structural members have at least one hole  854 ,  954  so that at least one pin  856 ,  956  can be inserted therethrough for adjusting the height of the upper lifting frame  810 ,  910 . During adjustment of the upper lifting frame  810 ,  910 , the upper structural member  850 ,  950  slides along the lower structural member  850 ,  950  vertically up or down until the upper lifting frame  810 ,  910  is at the desired height. Once the upper lifting frame  810 ,  910  is at the desired height, a pin  856 ,  956  is inserted through the hole  854 ,  954  to fix the adjustable spacer  848 ,  948  and upper lifting frame  810 ,  910  to the desired height. A hole  1058  is included in the upper support member  1026  to allow the lower structural member  41052  to slide therethrough during adjustment of the upper lifting frame to the desired height as shown in  FIG. 10 . The vertically oriented tubular structural members or legs  816 ,  916  of the upper lifting frame  810 ,  910  and vertically oriented structural members or legs  930 ,  930  of the lower support frame  812 ,  912  are also telescopic so the lower support frame structural members can move out from or into the upper lifting frame structural members during height adjustment of the upper lifting frame. The lower support frame and upper lifting frame structural members may still comprise holes and pins for locking the upper lifting frame to a desired height for adjusting the height of the upper lifting frame for moving that catalyst loading device to a different grade or catalyst block layer in the SCR device or to transport the catalyst loading device to storage. 
         [0068]    Referring to  FIG. 7 , hydraulic pump  742  is mounted to structural member  760  and/or structural member  762 . Motor  746  is mounted to the hydraulic pump  742 . Alternatively, motor  746  could be mounted also to a structural member such as  762  in addition to or independently of hydraulic pump  742 . The power supply  744  is mounted on structural member  764  and/or structural members  766 . The power supply  744  may be a battery or electrical connection to a power source (e.g., 110 volt electrical outlet) and the motor  746  may be electrically driven. Structural members  760 ,  762 ,  764 , and  766  also provide stiffening and support for loading and unloading the catalyst blocks. 
         [0069]    Referring also to  FIG. 4 , a switch  468 ,  768  may be assembled to the upper lifting frame and wired to the power supply  474 ,  744  and to the motor  446 ,  746 . The switch may be a manual push button switch with an up and down button that acts to transmit power from the power supply to drive the motor to operate the hydraulic pump. 
         [0070]    Referring to  FIGS. 4 and 6 , there may be two hydraulic cylinders  438 ,  638  with spacers  428 ,  628  assembled thereto; one hydraulic cylinder and spacer located towards the first end  406  and the other hydraulic cylinder and spacer located towards the second end  408  of the catalyst loading device  400 ,  600 ; both hydraulic cylinders and spacers assembled to the upper and lower support members  426 ,  626 ,  432 ,  632 , respectively, and approximately centered between the two structural members  612 ,  630  of the respective first and second end  406 ,  408  of the catalyst loading device  400 ,  600 . The word “center” or “centered” in this context refers to the relationship of the hydraulic cylinders  438 ,  638  and spacers  428 ,  628  relative to the symmetrical axis between the structural members  612 ,  630  in  FIGS. 4 and 6 , and not to a specific center point or location in space. 
         [0071]    Referring to  FIG. 7 , in another embodiment of the present invention lifting lugs  722  may be attached to horizontally oriented structural member  724 . Horizontally oriented structural members or cross members  770  are attached to structural members  714  to provide stiffening and support for loading and unloading catalyst blocks, as well as, mounting support for structural members  760 ,  762 ,  764 , and  766  and hydraulic pump  742 , motor  746 , and power supply  744 . Horizontally oriented structural members  772  are attached to structural member  411  at one end and attached to structural member  774  at the other end. Structural members  772  provide additional stiffening and support for loading and unloading catalyst blocks. 
         [0072]    Referring to  FIG. 11 , the catalyst loading device  1100  straddles over the top of the catalyst blocks  1199 , which would be located between structural members  1116  and  1130 . The catalyst blocks  1199  are coupled to the catalyst loading device via the multiple lifting lugs  1195  on the catalyst blocks  1199  and the corresponding lifting lugs  1122  on the catalyst loading device  1100 . In another embodiment of the present invention, the other lifting lugs  1120  may be used to couple the catalyst blocks  1199  to the catalyst loading device  1100  via corresponding lugs on the catalyst blocks  1199 . The catalyst loading device and lifting mechanism can be designed to straddle the catalyst blocks in either their width (short) or length (long) dimension based on the requirements of the SCR device and equipment or component arrangement. 
         [0073]    The present invention facilitates movement of catalyst blocks in an SCR. The catalyst loading device is maneuvered into place over the catalyst blocks and removably coupled to the catalyst blocks for loading and unloading of the blocks in an SCR device. 
         [0074]    Referring to  FIG. 11 , catalyst loading device  1100  moves into place via wheels  1140  in guide tracks on the top flange surface of the structural support frame (not shown) straddling catalyst blocks  1199  between structural members  1116  and  1130 . The upper lifting frame  1110  is positioned to a desired height via the spacer  1128  (or spacer  848  per  FIG. 8 ) design. Catalyst blocks  1199  are then coupled to the catalyst loading device  1100  via the four lifting lugs  1195  on the catalyst blocks and the four lifting lugs  1122  on the catalyst loading device  1100 . 
         [0075]    Now referring to  FIGS. 4 and 11 , in order to lift the catalyst blocks  1199 , switch  468  is operated to provide power from the power supply  444  to drive the motor  446  to operate the hydraulic pump  442 . The hydraulic pump  442  provides pressure to a hydraulic cylinder  438 , wherein the application of force by the hydraulic cylinder  438  displaces a spacer  428  vertically, causing it to vertically raise the upper lifting frame  1110  attached thereto, thereby lifting the catalyst block  1199  coupled to the upper lifting frame  1110 . 
         [0076]    Once the catalyst blocks  1199  are moved into position in the SCR device, the pressure exerted by hydraulic pump  442  may be released, permitting the hydraulic cylinders  438  to retract. This lowers the spacer  428  and the upper lifting frame  1110  attached thereto. Catalyst blocks  1199  are de-coupled from upper lifting frame  1110  once they are in a desired position. The catalyst loading device  400 ,  1100  allows the catalyst blocks  1199  to be set directly in place without the use of a pry bar, thereby minimizing the chance of personal injury. 
         [0077]    The embodiments depicted in  FIGS. 1-11  are intended to illustrate in a non-limiting way to the ordinarily skilled artisan the breadth and scope of potential various embodiments of the present invention that may be adapted to various SCR devices and catalyst block designs. Accordingly, other various embodiments are envisioned, such as, the alternative method of attaching lifting lugs  420  to the front side  402  and back side  404  of the catalyst loading device  400  on the upper lifting frame  1110  in lieu of lifting lugs  1122 . In another embodiment envisioned, the hydraulic cylinders may be offset with respect to one another instead of directly opposite and in line with one another. For example, one hydraulic cylinder may be mounted towards the front side of the catalyst loading device, while the other is mounted towards the back side of the catalyst loading device. In yet another embodiment envisioned, multiple lifting mechanisms may be employed, each comprising single or multiple sets of hydraulic cylinders, hydraulic pumps, motors and batteries, etc. 
         [0078]    Referring to  FIGS. 6 and 8 , in yet another embodiment of the present invention, spacer(s)  848  comprises telescoping structural members with holes and pins to allow for height adjustment of the upper lifting frame  810  of catalyst loading device  800  for different sizes and heights of catalyst blocks, similar to structural members  630  and  616  with holes  634  and pins  636 . These structural members may be tubular members, but not limited thereto. In yet another embodiment, structural members  630  and  616  may be rigidly assembled structural members (i.e., not adjustable for height adjustment), and spacer(s)  848  may be telescoping structural members or tubes with holes and pins to allow for height adjustment of the upper lifting frame  810  of catalyst loading device  800  for different sizes and heights of catalyst blocks.  FIG. 12  shows an alternative embodiment where catalyst loading device  1200  is straddling catalyst block  1299  with the telescoping structural members  1252  and  1250  including holes  1254  and pin  1256  comprising spacer  1248  to allow for height adjustment of the upper lifting frame. Structural members  1216  and  1230  may also be telescoping to allow the upper lifting frame to move up and down for height adjustment. Further, upper support member  1226  may comprise hole  1258  to allow structural member  1252  to slide therethrough during height adjustment of the upper lifting frame (see also structural member  1052  in  FIG. 10 ). In an alternative embodiment of the present invention, as shown in  FIG. 11 , the holes  1134  in structural members  1116  may be slotted, which allow pings  1136  to move up and down within the slotted holes as necessary for operation and manipulation of the catalyst loading device  1100 . 
         [0079]    In yet another embodiment of the present invention, catalyst loading device  800 ,  900  includes a spacer  848 ,  948  comprising telescoping structural members  850 ,  852 ,  950 ,  952  with holes  854 ,  954  and pins  856 ,  956 . 
         [0080]    In yet another embodiment of the present invention, the hydraulic cylinder  438  may be attached to the upper support member  426  instead of the lower support member  432 . 
         [0081]    The present invention is not intended to be limited to only the foregoing examples. 
         [0082]    The present disclosure has been described with reference to exemplary embodiments, it will be understood that it is not intended that the present invention be limited thereto Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. In some embodiments of the invention, certain features of the invention may sometimes be used to advantage without a corresponding use of the other features. It is intended that the present disclosure be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.