Catalyst Handling Technology – Offshore Changeout and Vaccuum


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PELLET ATTRITION

The inset above shows a sample of extruded pellets that have suffered attrition damage during vacuum transfer from ground level into the bed. Whilst the fines produced as a result of attrition retain the same catalytic properties as the undamaged pellets, the fines are virtually useless within the bed because they put up a block against product flow. It is for this reason up until the development of Dialog Technivac’s ‘Clamflo’ system vacuum loading and unloading of beds regardless of the inherent advantages has not been the preferred handling method.

Originally invented by Dialog Technivac in 1987 the ‘Clamflo’ ultra low attrition hopper became the first vacuuming separator to reduce attrition to virtually zero. Whilst there have been a number of attempts to copy its capabilities it still remains the most efficient in the service industry.

The non prevention of catalyst pellet attrition during the loading and unloading of beds is a significant cost factor which often is overlooked and once discovered it can already be too late. Pellet attrition causes two problems :-

Any attrition during loading will increase the pressure drop across the bed, decrease the bed’s efficiency, shorten the life of the bed and increase plant operating costs.
Any attrition during the unloading of re-usable catalyst will directly reduce the amount of recoverable material, increase recovery costs and necessitate the purchase of top up material.

ESTIMATING THE COSTS OF ATTRITION

In the first instance although pellet attrition during bed loading will have a direct effect on plant operating costs estimating what that increased cost is might not be that easy. However the cost of attrition as far as the catalyst itself is concerned is a relatively simple matter.

In basic terms if attrition is zero the full value of the catalyst is retained and if for example attrition reaches 50% then half of what was actually paid for the catalyst is completely lost. In the example shown on the opposite page 10% attrition would equate to Ł5 thousand and 50% would equate to Ł25 thousand pounds. In financial terms therefore the real cost of carrying out any changeout is :-

If this simple formula is applied to any changeout it is easy to see that if attrition is not controlled the actual value of destroyed catalyst could easily be in excess of the changeout service charges.

ELIMINATING ATTRITION

Completely eliminating attrition regardless of whatever handling method is used in reality is an impossibility. Nevertheless Dialog Technivac’s ‘Clamflo’ system with a proven performance of < 0.1% is very close to the mark and in perspective as the example shows out of a total of 50 x 200 hundred litre drums Dialog Technivac attrition is a mere bucket full.

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