Basic Procedures For Unloading Catalysts
While each instance of catalyst unloading will vary depending on the situation, the following is a general guideline on what needs to occur when using a catalyst unloading system. As stated, certain procedures will need to be adapted to the current situation.
1. Before the blowers of the acid plant and the circulating systems for the acid are shut down, the converter must be purged and the catalyst beds should be cooled to approximately 90 degrees.
2. All manhole covers and all pertinent insulation must be removed. Instrumentation such as thermocouplets and thermowells should also be removed so as to avoid damaging any of the components.
3. After ensuring that all safety equipment has been checked and is in use, double-check that it is safe to enter the converter. All procedures for vessel entry should be adhered to.
4. Quartz rock and catalyst that is in the vicinity of the manhole entry should be the first removed. It is crucial that these substances are removed completely. Continue removing the substances working towards the opposite side of the container.
5. As the containers being used to temporarily store the quartz rock and the catalyst fill are completely filled, move the containers to a separate dry area where they are protected from the elements.
6. Once all of the substances are removed completely, both the support grids and plates should be cleaned thoroughly. Below the catalyst bed there is a bed separation plate which should also be carefully cleaned.
7. Carefully inspect the converter and check if there are any repairs which are needed to be performed. Repair these as necessary. It is crucial to check for any gas bypasses due to mechanical damage. These, too, will need to be repaired.
By following these instructions, the process of removing and unloading the catalyst material can be done simply and safely. Remember to follow all safety precautions that the company already follows and do not expose the catalyst to any form of precipitation as this greatly heightens the danger that those present will face in the catalyst working area.