Catalyst Changeout - The Challenge

23 reactors, 2,160 m³ of catalyst to replace and nearly five million kilograms of catalyst handled. Mourik’s CCO project in Porvoo, Finland, brought together 112 colleagues from 11 nationalities to deliver a major catalyst change-out.

Delivering a project of this scale meant coordinating people, equipment and activities within a demanding schedule, while maintaining safety and quality throughout. From late August to the first week of October, teams from the Netherlands, Latin America, Mourik UK, Mourik GmbH and Unidense combined their expertise on site.

The solution

Thorough preparation laid the groundwork. Every team member completed a week of training, all supervisors came from within Mourik, and two additional crews provided relief to support continuity and keep teams focused.

Specialist equipment included six new catalyst vacuum units, each with a capacity of 8,000 m³/h. Detailed inspection protocols kept every step closely monitored and fully traceable, allowing the team to identify deviations early and take action to protect the schedule. Clear communication with the client kept everyone aligned.

On site, colleagues shared knowledge, anticipated challenges and looked out for one another. Safety was part of daily practice, with team members actively identifying risks and suggesting improvements.

The result

All 23 reactors were emptied on schedule, and the project was completed according to plan. The client praised both the equipment and the team’s performance.

“In my 23 years in catalyst handling, this was the largest project I have ever carried out,” says Operational Manager Jeroen Elbers. “Seeing everything go according to plan was fantastic. The calm and focus during execution made all the difference. I’m incredibly proud of our team performance.”

A major project delivered through careful preparation, specialist expertise and strong teamwork. Thank you to everyone who contributed.