By utilizing a specially trained workforce and purpose-built equipment, Catalyst Handling can execute catalyst projects efficiently and safely, with minimal delays from fusing, minimal catalyst attrition, and excellent dust control systems.
At Catalyst Handling we pride ourselves on being able to load any reactor, vessel, or column, on any site. Our equipment is also built to be modular; allowing for ease of transport and set up, yet still creating a smaller onsite presence or "footprint" than traditional catalyst equipment.
Sock Loading involves placing the catalyst into a hopper on the top of the reactor manway and discharging it through a canvas or rubber "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 achieved by 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.
Catalyst Handling Resources use Unidense™ technology for the loading of primary reformers. This technology allows consistent loading of catalyst into each tube, ensuring that all pressure drops (dP) are within the pre-determined range. Both Unidense™ and Uniloading™ services are available.
The loading of Tubular Reformers and all associated mechanical works is provided by our expert teams. Upon completion of a project, all removed catalyst is packaged in UN approved containers ready for shipment or disposal as required.
Catalyst Handling has been using Dense Phase Loading equipment for over 20 years, and have loaded many reactors without requiring an onsite crane. This process is particularly effective for loading horizontal vessels, Sulphuric Acid Converters, or in situations where high winds and inclement weather are likely to occur. This equipment can be set up with limited access, has an exceptionally small onsite footprint, and can be a very beneficial alternative to traditional loading. Loading rates can be up to 525 - 700 cubic foot per hour (15-20 m3/hr) depending on distance and the material to be transported.