Tubular Reactor Catalyst Change-out

A tubular reactor contains thousands of tubes, and every tube needs to behave the same. How evenly the catalyst is loaded determines flow distribution, conversion and run length. What happens during the shutdown shows up months later, in the performance of the reactor.

Two risks are easy to miss at handover. Fines and uneven packing create pressure-drop differences between tubes, which can lead to hot spots and uneven catalyst ageing. When unloading, cleaning and loading are split across several parties, the handovers between them cost time and blur responsibility.

That is why we see a catalyst change-out as the start of the next run, not the end of the shutdown.

We take on the full scope in up to four connected stages:

• Catalyst unloading, with the M-Lance where the reactor design allows
• Tube cleaning, where required, with a method defined before execution
• Catalyst loading, with our proprietary MIDC equipment and multiple dedusting points
• dP measurement, tube by tube, at a controlled airflow and recorded digitally

[Visual: the four stages as a simple process bar]

At handover you receive a loading report with tube-by-tube dP results, spread, deviations and any corrective actions. The raw data is yours, so it can be reviewed by your team, the catalyst supplier or the licensor, and compared with future runs.

[Visual: dP chart per tube, showing mean, spread and outliers]

Over [XX] years, our catalyst handling teams have completed [XX] tubular reactor change-outs worldwide, across EO, acrylic acid, PA, MA, VAM, formaldehyde and methanol service. We execute with our own people and equipment, or together with a selected local contractor under our supervision. The same standards apply in both models.

[Quote from a client or licensor, with name, role and plant]

Read more about our [Catalyst Handling] and [Industrial Cleaning] services.