Introduction:
This practical and highly-interactive course includes various practical sessions and exercises. Theory learnt will be applied using one of our state- of-the-art simulators.
This course is designed to provide participants with a detailed and up-to-date overview on catalyst material handling, loading, unloading, oxidation, reduction and technique. It covers the preparation of catalyst change plan; executing the catalyst project efficiently and safely; the catalyst change operation main requirement; the work in inert and toxic atmospheres plus hot and hostile environments; the reactor cooling utilizing a proprietary liquid nitrogen system; the unloading and loading of catalyst under inert or normal atmospheres; the dense phase loading systems; and the innovative, purpose built-equipment ensuring low catalyst attrition rate.
Further, the course also covers the catalyst sampling and particle measurement; the vacuum unloading with closed loop nitrogen re-circulation; the catalyst transportation, storage & containment (un approved); the tubular reformer loadings using unidense® loading and conventional techniques; the pre-sulphiding (DMDS injection); the metals reclamation and disposal of materials; the shutdown planning, coordination and execution; the edge equipment; the modifications for catalytic reactors, vessels on a blinds to blinds’ basis; and the confined space and inert/toxic entry operations.
During this interactive course, participants will learn the unloading of catalyst under inert/toxic atmosphere; the screening of catalyst under continuous nitrogen purging; the loading by conventional and licensed loading technologies; the HSE requirement; the environment requirement; the catalyst change/replacement report; and the catalyst change learned lessons and case studies.
Course Objectives
Upon the successful completion of this course, each participant will be able to:-
- Apply systematic techniques in handling, loading, unloading, oxidation and reduction of catalyst material handling
- Prepare catalyst change plan and execute catalyst projects efficiently and safety with minimal delays from fusing, minimal catalyst attrition and dust control systems
- Identify catalyst change operation main requirement including pre-commissioning of reactors and vessels
- Determine work in inert and toxic atmospheres in hot and hostile environments as well as reactor cooling utilizing a proprietary liquid nitrogen system
- Unload and load catalyst under inert or normal atmospheres and dense phase loading systems
- Use dense phase loading system in transferring catalyst directly from grade to reactor man way without using cranes and hoppers
- Describe innovative and purpose build-equipment ensuring low catalyst attrition rate and perform catalyst sampling and particle measurement
- Employ vacuum unloading with closed loop nitrogen re-circulation and catalyst transportation, storage and containment
- Use tubular reformer loadings using unidense loading and conventional techniques
- Perform pre-sulphiding, metals reclamation, disposal of materials, shutdown planning, coordination and execution
- Describe edge equipment, modification for catalyst reactors, vessels on a blinds to blinds basis, confined space and inert toxic entry operations
- Unload catalyst under inert/toxic atmosphere, screen catalyst under continuous nitrogen purging and apply loading by convention and licensed loading technologies
- Enumerate HSE requirement, environment requirement, catalyst change/replacement report and lesson learned
Who Should Attend
This course covers systematic techniques of catalyst material handling for those who are involved in loading, unloading, oxidation and reduction. This includes refinery, chemicals and petrochemical engineers, supervisors and operations staff.
Training Methodology
All our Courses are including Hands-on Practical Sessions using equipment, State-of-the-Art Simulators, Drawings, Case Studies, Videos and Exercises. The courses include the following training methodologies as a percentage of the total tuition hours:-
30% Lectures
20% Practical Workshops & Work Presentations 30% Hands-on Practical Exercises & Case Studies 20% Simulators (Hardware & Software) & Videos
In an unlikely event, the course instructor may modify the above training methodology before or during the course for technical reasons.
Course Outlines:
The following program is planned for this course. However, the course instructor(s) may modify this program before or during the course for technical reasons with no prior notice to participants. Nevertheless, the course objectives will always be met:
Day 1
| Welcome & Introduction |
| PRE-TEST |
| Preparing Catalyst Change Plan |
| Execute Catalyst Project Efficiently & Safely
Minimal Delays from Fusing ● Minimal Catalyst Attrition ● Dust Control Systems |
| Catalyst Change Operation Main Requirement
Pre-Commissioning of Reactors & Vessels |
| Work in Inert & Toxic Atmospheres Plus Hot & Hostile Environments |
| Case Study & Related Video |
| Recap |
Day 2
| Reactor Cooling Utilizing a Proprietary Liquid Nitrogen System |
| Unloading & Loading of Catalyst Under Inert or Normal Atmospheres |
| Dense Phase Loading Systems
Transfer of Catalyst Directly from Grade to Reactor Man Way, Without the Use of Cranes & Hoppers |
| Innovative, Purpose Built-Equipment Ensuring Low Catalyst Attrition
Rate |
| Case Studies & Related Video |
| Recap |
Day 3
| Catalyst Sampling & Particle Measurement |
| Vacuum Unloading with Closed Loop Nitrogen Re-Circulation |
| Catalyst Transportation, Storage & Containment (UN approved)
Catalyst Loading of Reactors Using UOP® Dense Loading & Conventional Techniques |
| Tubular Reformer Loadings using Unidense® Loading & Conventional Techniques |
| Pre-Sulphiding (DMDS Injection) |
| Case Studies & Related Video |
| Recap |
Day 4
| Metals Reclamation & Disposal of Materials |
| Break |
| Shutdown Planning, Coordination & Execution |
| Edge Equipment
Life Support Systems ● Vacuum Unloading ● Screening Equipment ● Modular Equipment |
| Modifications for Catalytic Reactors, Vessels Etc. on a Blinds to Blinds’
Basis |
| Break |
| Confined Space & Inert/Toxic Entry Operations |
| Case Studies & Related Video |
| Recap |
| Lunch & End of Day Four |
Day 5
| Unloading of Catalyst Under Inert/Toxic Atmosphere |
| Screening of Catalyst Under Continuous Nitrogen Purging
Loading by Conventional & Licensed Loading Technologies |
| HSE Requirement |
| Environment Requirement
Catalyst Change/Replacement Report |
| Catalyst Change Learned Lessons |
| Course Conclusion |
| POST-TEST |
| Presentation of Course Certificates |