Catalyst unloading frequently exposes personnel to hazardous environments that involve confined space entry, toxic atmospheres, chemicals and or inert entry. Many of these situations require staff to perform tasks for long durations, which is physically demanding and extremely dangerous.

Minimising the exposure to hazardous environments is what led to the development of Rover – A remotely operated vehicle designed to significantly reduce and even eliminate personnel entering confined spaces to unload catalysts.


CR3 developed Rover, a multi-purpose tracked and remotely operated vehicle for unloading spent catalysts that improves safety by eliminating inert entry. It minimises schedules through the machine’s ability to start jobs earlier and operate continuously, saving at least 1 shift on average over conventional methods. For large reactors, multiple units can be used simultaneously to minimise schedules further.

Rover operates in all types of conditions, including underwater and in temperatures up to 100 degrees Celsius. It is also certified to operate in zone 0 classified areas. Rover is equipped with lights, a camera and a vacuum hose. An additional mechanical arm can be customised with tools for specific applications, such as removing fused or coked catalysts.


Proven to minimise confined space entry significantly, Rover also reduces replacement schedules on challenging jobs by up to 30%. Jobs can start earlier due to Rover’s ability to tolerate higher temperatures and inert entry is significantly reduced.

Rover unloads essentially, the entire contents, at rates comparable to or better than conventional unloading, yet it is more productive as Rover does not require frequent rest breaks and can remain in the reactors longer than personnel that regularly need to rotate due to the conditions and heavy nature of the work.

Since 2017, clients have recognised the outstanding value of Rover. They now specify it in their contracts as a requirement for unloading reactors.


  • Minimise inert entry (N2) for catalyst unloading as well as other applications
  • Faster and more productive catalyst unloading
  • Shorter catalyst replacement schedules
  • Operates in all conditions
  • Start unloading sooner
  • Does not need to stop for breaks
  • Enhanced safety