Catalyst Handling
Gravity Unloading (bottom dumping)
This method is the preferred and most applied due to its speed and cost effectiveness. The catalyst is dumped into bins, drums, bags or luger boxes by simply removing a blind flange from the reactors dump nozzle.
Vacuum Unloading
Where gravity unloading is not, or no longer feasible, a vessel entry technician inside the reactor will vacuum out the catalyst through a four or six inch diameter suction hose, if necessary using a jackhammer to break up the fused portions or layers. The vacuumed out catalyst can than be separated through a knife-gate, or be accumulated in the box of the vacuum truck and be dumped, on an appropriate site provided by the customer. This method is more costly, however it provides a solution where different parts or layers of catalyst or support balls need to be separated (skimmed).
Soft Vacuum
When it is important to reduce the breakage of the catalyst to an absolute minimum, "capacity-sensor” equipment will be used in conduction with the regular vacuum equipment. This equipment will allow vacuuming out catalyst while maintaining the downstream vacuum pipe full at all times.
Side Unloading (auguring)
This option is often used in situations where a small side flange is the only means of vessel access and vacuuming is not the preferred method.
Water Blasting
This method is rarely used, and only performed when absolutely no other means are suitable. Remote operated ultra high-pressure water lances are introduced to break up the catalyst, and vacuum equipment is used to remove the sludge and effluents.
Catalyst Loading
Catalyst can be loaded using licensed technology such as UNIDENSE* and DENSICAT** or by conventional means using different types of loading sock, hoses and hoppers, depending our customers needs.
Catalyst handling can be performed in all three categories (Class 1, 2and 3) of confined space activity as defined by OHS/OSHA. During all the above mentioned features, our quality control standards can all be monitored on closed circuit video from the life support system van where all other vital safety parameters are monitored such as: vessel temperature, air quality, LEL, etc.
Lock on Life Support
Catalyst Services is proud to be the first company of its kind that successfully developed, manufactured and implemented a NIOSH approved lock on life support system. This high tech, supplied air breathing systems allows our vessel entry technicians to safely operate in oxygen deficient, toxic or otherwise IDHL environments.
