Comprehensive Catalyst Handling & Reactor Maintenance

PLANT-TECH undertakes comprehensive maintenance of catalytic reactors of any type and design in nitrogen or toxic atmosphere which allows for environment friendly, fast and safe handling of non re-generated catalyst and avoids pyrophoric reactions. Plant-Tech offers this specialized service to Refineries, Petrochemicals, Fertilizer, Chemical, Gas, Power, Iron and steel plants and other allied industries. Comprehensive Catalyst Handling is an Environment friendly method which completely eliminates the risk of self igniting reactions, covers the entire process of unloading (vacuuming), screening of catalyst and loading of reactors.

Plant-Tech provides the following steps involved in the Catalyst Handling:

Unloading/Vacuuming of Catalyst:

The used catalyst requires to be removed from the vessel/reactor. Catalyst unloading may be accomplished through specifically designed dump nozzles or through other openings/discharge spouts, or it is extracted through the top man way using specifically designed powerful vacuum units with built-in nitrogen cooling and re-circulation. The catalyst is immediately unloaded in approved drums or bins.

Screening of Catalyst:

PLANT-TECH sets new standards with ultra modern and highly mobile automatic screening device that separates the various catalyst materials on site. Specifically designed screening machines allows for the separation of catalyst and inert in, up to six fractions.

Loading of Catalyst:

It is the final process executed in the Catalyst Handling and Reactor Maintenance service. It includes two different processing ways:

  • Sock Loading
  • Dense Loading

In “Sock Loading” process, the catalyst and inerts are loaded using a specific “Lay flat” design hose that slows down and controls the loading speed.

Dense Loading:

Plant-Tech has been licensed for “Dense Loading” of reactors by Premier Organization like UOP, the process licensor of various Refining and Petrochemical process technologies. Besides to that, Plant-Tech is also having a technical collaboration with Petroval, France to provide other dense loading technologies such as DENSICAT & CATAPAC for reactor vessels and UNIDENSE loading technology for reformer tubes.

Plant-Tech can also arrange other renowned dense loading technologies as per the client’s requirements through its various technical partners from around the world.

The various Dense Loading Technologies use a rotating movement in the “Dense Loading” process in order to distribute the material evenly over the bed surface. The main objective of this technique is to increase the loading density of the catalyst wherein the amount of catalyst packed per cubic volume is higher as well as more uniform in nature.

Life Support Breathing Apparatus

Plant-Tech offers safe and reliable services in inert and toxic atmosphere with the aid of specialized life support breathing systems, which are flame-proof units comprising a respiration, communication, monitor and alarm system. Plant-Tech Life Support System allows Breathing Apparatus (BA) Technicians to enter the most hazardous environments with complete safety. Furthermore, each technician has a third air supply in the form of an escape/egress air bottle.

To back up the whole system, a standby personnel is deputed for safety reasons. The Stand-by personnel keeps a continuous monitor over the personnel inside the reactor and communicates constantly with him. During emergency he shall act as the situation demands and to the best of his discretion. Moreover, all team members will be in constant communication with each other.

Reactor Internal Maintenance Services

As part of its total Reactor Service and Catalyst Handling, Plant-Tech also performs Assembling and De-Assembling activities on the reactor internals.

  • Additionally Plant-Tech offers the following services in inert and toxic atmospheres:
  • Inspection of tanks, vessels, columns and towers including video inspection accompanied by a detailed report.
  • Welding and Mechanical repair works.
  • Cleaning of Volatile material within the confined spaces.
  • Cleaning of tanks and vessels.

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