Catalyst Screening and Cleaning
As a result of temperature changes, erosion, and operating pressures, catalyst will accumulate particle chips and fine contaminants that will ultimately compromise its efficiency. These smaller particles gather during the unit’s operation and increase the operating pressure required from the inlet feed compressor. The particles can also divert or channel the reactor feed through the catalyst bed. In order to maximize conversion and operating efficiency, it is recommended that all particle chips and fines are removed where possible.
Catalyst Changers utilizes an environmentally friendly filtration system that filtrates/separates air borne particulates so that no hazardous material is emitted during the removal process. Our innovative dusting system will separate 3 different sizes of material plus dust. By variable speed control the intensity can be adjusted to reduce catalyst breakage and effectively remove any dust generated from the unloading process. Contaminants will be transferred into containers and shipped out for disposal and any of the remaining catalyst that can be re-purposed will be. Our vacuum units have also been utilized to remove dust generated while sand blasting or for high volume air movement to circulate/cool ambient air in confined spaces. New technology ensures better results and cleaner air.
Catalyst Loading Services
At Catalyst Changers we will proudly tell anyone “we can load any reactor or vessel on any site”. By utilizing equipment that is modular we can transport, setup, load and complete a project faster, regardless of the location, resulting in less downtime for our clients. And, because our systems require less space to setup in we are able to mitigate the inconvenience factor to our customer’s workforce.
Depending on the sector, specific Catalysts and specific application requirements must be taken into consideration. We work hand in hand with Catalyst manufacturers to ensure that their product is being loaded to the very critical disbursement, level and density specifications they require to deliver maximum performance.
The two methods we use for loading are:
Sock Loading – This involves placing the catalyst into a hopper on the top of the reactor man-way and discharging it through a canvas or rubber tube called a “sock”. One end of the sock is attached to the Loading Hopper discharging pipe and the other end travels to within 3 feet of the catalyst support grate or grid. The loading technician will crimp the Sock to restrict free fall of material as they spread the catalyst evenly in a random pattern. As the bed level rises the Sock is cut to keep the free fall of catalyst to the required distance, and discarded sections are removed from the reactor.
Dense Loading – is done with a mechanical device that ensures a uniform distribution of catalyst throughout the entire diameter of the reactor, and better total bed density as the catalyst is being loaded. A Dense Loading system can increase the loading density by as much as 10 – 20 percent; depending on the type and shape of catalyst that is being loaded. Dense Loading almost always improves the liquid or gas flow, eliminates catalytic bed settling, and allows for a longer run cycle between catalyst replacements.