Catalyst inspection, loading and start-up
To avoid surprises while loading the reactor, it is important for the prospective catalyst to be inspected in terms of both quality and quantity. The catalyst must meet the acceptance criteria for use and the quantity and loading density must be such that there is enough material to load as intended or pre-scribed. Inferior catalyst quality or short-loading can cause serious performance problems, such as increased pressure drop, lower conversion and shorter cycle length. Once the catalyst has been inspected and found acceptable for use, it needs to be loaded by specialised companies, in accordance with industry best practices.
It is recommended that the loading process be supervised by an independent loading supervisor unrelated to the handling company itself. The loading supervisor should inspect the reactor and internals prior to loading, check the loading density and the correct installation of the internals and issue a written loading report for future reference. The start-up should be conducted in accordance with the manufacturer’s guidelines or industry best practices as applicable. The start-up process should also be documented in a start-up report.
Catalyst Intelligence can assist with inspection, loading and start-up, to save time and ensure that industry best practices are being used. If the right catalyst is loaded in accordance with industry standards, then the catalyst can be expected to perform as predicted.
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