We frequently encounter coked, fused or agglomerated catalysts, especially with residue desulfurization (RDS) units. Conventional unloading methods rely on jackhammers or tank cleaning heads to remove the fused catalyst, which increases the risks to personnel and reactor internals. Inefficient hydro-blasting solutions also generate large amounts of wastewater, which is problematic and costly.
CR3’s Advanced Wet Dumping combines drilling with high-pressure water jetting technology to unload heavily fused catalysts faster and safer than manual methods by eliminating the need for nitrogen, reducing cool-down times, and shortening overall unloading schedules by at least 50% on average. It significantly decreases the amount of wastewater generated and maintains the integrity of the internal components as no mechanical equipment is used during the process.
The spent catalyst feeds into a spiral classifier, which drains the water from the spent catalyst before it drops into UN approved containers. The water is separated, cleaned and treated in a closed-loop system prior to being re-used.
Commercially proven, our Advanced Wet Dumping technology is safer, faster and more reliable than conventional unloading methods. Virtually all the fused catalyst can be unloaded without having to enter the vessel, thereby reducing risks to personnel.
The unloading can be carried out under normal atmospheric conditions, as the water helps to passivate the spent catalyst. Catalyst replacement schedules are reduced significantly due to faster reactor cooldown times combined with higher and more consistent unloading rates meaning the entire change-out duration can be guaranteed. This all adds up to a substantially more effective and efficient solution that delivers increased value and lower overall costs to our clients.