Dense loading is a technology that maximises catalyst performance and therefore the performance of the reactor itself. Commonly used in the petroleum refining and petrochemical industries. It offers the following advantages:
However, conventional Dense Loading methods have, at times, caused flow mal-distribution, differential pressure build-up, and other such problems stemming from catalyst damage resulting from uneven loading density or loading surface and poor loading machine performance. The operation of the equipment is also key, as you are only as good as the Technician operating it and having been in business for over 40 x years we have been witness to many of our customers receiving sub-standard dense loads from well-established operators and traditional equipment.
In order to solve these problems, a high-performance loading technology called the JE loader has been developed.
The JE loader has been in existence for over 20 years (having been established in Japan in the late 1990’s) and has been used and trusted by many of the largest petroleum and petrochemical operators globally.
This industry leading technology which has been subject to several significant upgrades; is the most modern and technologically advanced system available in the market. Rather than being air driven and using whips and brushes to strike the catalyst at constant rates, the JE loader is electrically operated and offers an unparalleled amount of bed profile management with adaptive control (DVC) allowing responsive and instant adjustments. In addition, the current generation of JE Loader is small enough to be carried by the operator as luggage for international travel, as such we can respond quickly, efficiently and without delay if required.
Alongside class leading training and ongoing customer support, with operators based in the US, Europe and Asia, we can cover all continents and geographical locations quickly. With over 100 million+ Kg’s loaded to date and trusted by many of the largest catalyst manufacturers and process operators we welcome the opportunity to show you what we can do.
Cat Tech also offer the TURBOcat Dense Loader. This unique air driven technology can load rates of up to 25m3 per hour and provides an alternative to the class leading JE loader.
The synergies between our vast experience as Catalyst Handlers and our specialist Dense Loading division allows us to provide a best in class catalyst loading service.
CATcap tubular loading technology is a system which pioneers the way in which tubular reactors are loaded. Due to the success of our systems many have tried to imitate it and failed. We have found that no other technique produces the same high level of uniformity and consistent loading.
Cat Tech has always been a technology pioneer in the tubular market
Our trained professionals have decades of experience managing tubular change outs including
With some reactors containing over 10,000+ tubes, our knowledge and technology in this field allows us to offer a fast, reliable and trusted method which has been used in a number of the world largest and valuable tubular vessels in the world.
A major breakthrough in catalyst unloading technology is now available and Cat Tech are proud to be setting new standards for safety in the Industry.
CATNap® patented technology eliminates the need for working in dangerous nitrogen filled environment typically created in Hydrotreaters and Hydrocrackers whilst routine maintenance is carried out. Whilst standard industry practice has historically dictated that the removal of self-heating and pyrophoric catalyst means an inert atmosphere is a must, this is no longer the case. Instead a proprietary CATnap® chemical applied as part of a modified reactor shutdown procedure coats the catalyst surfaces suppressing self-heating and toxic/pyrophoric dust allowing your catalyst to be safely unloaded in air.
Cat Tech’s proprietary Catalyst Passivation Process gives you safer, faster and cleaner change outs on your treating, cracking and reside units.
Catalyst passivation eliminated hazards, improves productivity and delivers financial benefit to your site.
To date CATnap® has been applied to over 350 units worldwide and through re-engineering and process development we can ensure that your catalyst unload is first and foremost the safest possible option, and the most cost effective. Whether carrying out a skim or full catalyst removal, CATnap® allows you to exploit a combination of significant risk and cost reduction measures whilst ensuring the catalyst remains fully regenerable.
We offer a full pre-engineering evaluation at zero cost.
Cat Tech has a deep-seated history in regards to the installation process involved with CD Tech towers. Cat Tech & CD Tech were at the time Shell owned companies, and due to the shared ownership Cat Tech were approached to assist with the onsite installations alongside CD Tech.
During the project development phase, Cat Tech’s senior management team held meetings with CD Tech representatives at an early stage in order to develop and trial the most practicable solutions for the catalyst bale removal and replacement. As a direct result of this, the CD Tech guidance notes for installation and catalyst bale handling were developed.
The solution and service were a success, which then enabled CD Tech to globally market the technology and licenses were sold around the world.
CD Tech then went on to be purchased by CB&I, and more recently CB&I became part of McDermott.
Cat Tech has more experience with all licensors, units and processes in the ammonia industry than any other contractor and can deliver success on any unit or process, including refits, revamps, partial unloads, cartridge replacements and inspection or repairs under inert conditions.
Cat Tech’s patent CATcade reformer tube loading system is simple, effective and delivers high quality results in all conditions. CATcade’s patented designs reduces human error and material fatigue making it the best choice for better, faster loading and DP results.
Our Industry Leading CE approved Sentry 4 Life Support System by Breathesafe International Ltd, provides the safety platform for all Confined Spare Entry and our trained technicians follow tried and tester Standard Operating Procedures.
Let us put our experience to work for you.
The world is evolving, and our client’s processes are evolving too. With a greater focus on alternate technologies, renewable and biodegradable fuels which are needed to meet the pressures of environmental preservation, our clients are introducing ever more renewable & biodegradable feedstocks into their plants.
We recognise that there is a future beyond fossils and Cat Tech are adapting our services to help clients to deal with this change which will help reduce the impact on the environment and help lower polluting emissions. Due to the various types of biomass feedstock being introduced there can be a need for higher levels of pre-treatment via guard beds and a potentially greater frequency of catalyst change out due to some of the characteristics certain feedstocks can contain and the way these impact the catalyst and potential agglomeration.
At Cat Tech we have developed efficient ways for dealing with ‘gummy’ or agglomerated catalyst, and due to our global network of resources should the need to carry out a change out at short notice we are there if you need us.
We also note that many of our customers are considering altering some of their in-situ production units to service this market, and we can help you with evaluation and execution of the conversions along with installation of new units. Our experts are on hand to work with clients from the design concept to through installation.
We have already carried multiple renewable catalyst change out projects and we are setting the benchmark in this field. The world is evolving and Cat Tech is.