The challenge

Many production processes use catalysts—auxiliary substances that accelerate the process. Periodically, these catalysts need to be replaced: the old catalyst is removed, and the reactor is refilled with a new one.  

Replacing catalysts requires specialized knowledge to ensure the process runs safely and efficiently. The faster the replacement, the sooner the production process can restart. The loading process is carried out carefully and according to a specific method: high density and even distribution improve the catalyst’s performance. This reduces energy consumption, extends lifespan, and increases production capacity.  

Nitrogen is often used during catalyst replacement. Catalyst removal under nitrogen is primarily done for safety and process-related reasons. However, in this specific project in Finland, the client’s safety policy did not permit the use of nitrogen, requiring an alternative approach.

The solution

In consultation with the client, Mourik applied the ‘Waterflood’ method. In this technique, a controlled flow of water is directed upward through the reactor. This prevents contact between the catalyst and the outside air, reducing the risk of spontaneous combustion.  

For this process, one of our latest vacuum trucks was connected to a special waterflood hopper. Through this hopper, the catalyst was safely packed into designated bins. The combination of winter cold and the use of water made this task particularly challenging.

The result

Our team worked in day and night shifts and, thanks to smart preparation, managed to complete the project ahead of schedule. The client was so satisfied that a request for a follow-up project was submitted immediately.