Catalyst handling works include:

• Unloading/Loading of pyrophoric catalyst under inert/toxic atmospheres:

  Unloading and loading pyrophoric catalyst: must be handled under inert or toxic atmospheres to prevent self-ignition upon exposure to air. The catalyst will be vacuumed out under nitrogen purging and closed loop nitrogen re-circulation which creates a safe environment for transferring the catalyst in and out of reactors or vessels, using specialized equipment to minimize oxygen exposure and ensure safety. The following equipment’s we have handled catalyst under nitrogen.

• Ammonia Convertor
• Hydrocracker Units
• DHT
• MHC- Mild hydrocracking Unit
• Hydrotreaters
• LTS Reactor
• HTS Reactor
• Isomer Reactors
• Methanol Convertors
• Methanators
• OT Convertors
• CCR
• Diolefin Reactors
• Butamer Reactor

• Screening of catalyst under continuous nitrogen purging:

  Screening involves separating particles of different sizes or removing impurities to enhance catalyst performance. The pyrophoric catalyst requires continuous nitrogen purging to maintain an inert atmosphere, preventing the catalyst from reacting with oxygen or moisture, ensuring the catalyst remains effective and uncontaminated throughout the process.
• Loading by licensed dense loading technologies and sock loading methods:

  These specialized loading techniques ensure the efficient and even distribution of catalyst within reactors. Dense loading technologies and sock loading methods are used to maximize catalyst bed density and improve reactor performance.
• Desiccant drier/molecular sieve bed replacements:

  Replacing desiccant driers or molecular sieve beds is crucial for maintaining the efficiency of drying or separation processes. This involves safely removing spent materials and installing new desiccants or sieves to ensure optimal performance.
• Repairs & internal modifications of reactors:

  Performing repairs and modifications inside reactors is essential for maintaining operational efficiency and safety. This can include fixing damaged components, upgrading internal structures, or making modifications to improve reactor performance.
• Tubular reactor catalyst replacement and delta-P measurements:

  Replacing the catalyst in tubular reactors and measuring the pressure drop (delta-P) across the reactor ensures that the catalyst bed is functioning correctly and efficiently, which is crucial for process optimization and safety.
• Reformer catalyst replacement and tube replacement:

  Replacing the catalyst and tubes in reformers is necessary to maintain efficient hydrogen production and overall process effectiveness. This involves safely removing spent catalyst and worn tubes and installing new ones.
• Reformer tube external & internal cleaning using automated tools:

  Cleaning both the exterior and interior of reformer tubes using automated tools helps maintain heat transfer efficiency and prolongs the lifespan of the tubes, ensuring the reformer operates at peak performance.
• Video inspection of internal work and documentation:

  Using video inspection technology to document internal work provides a detailed visual record of the condition of reactors and other equipment, helping to identify issues and ensure that maintenance and repair work meets the required standards.
• Reactor cooling & purging by cold nitrogen gas injection:

  Cooling and purging reactors with cold nitrogen gas is a critical step to safely lower the temperature and remove hazardous gases before maintenance or catalyst change-out operations, ensuring a safe working environment and protecting equipment integrity.

  Maintaining the highest priority on the training and safety of personnel in confined space work and inert entry operations, Kanooz has gained our customers' confidence and satisfaction. We have achieved prestigious milestones in handling critical catalyst replacement works safely for projects such as multibed hydrocrackers, ammonia converters, Catofin reactors, Parex chambers, CCR, reformers, etc.

  Kanooz's extra high-volume dry vacuum system with PLC-controlled continuous discharge cyclone hoppers plays a major role in unloading catalyst faster than conventional vacuum unloading equipment. All Kanooz vacuum systems are designed to recycle spent nitrogen by filtering and cooling it before returning it to the reactor under vacuuming. This process avoids air ingress-related pyrophoric catalyst heating and minimizes replenishing/purging requirements.

  Kanooz offers turnkey services for Catofin catalyst replacement on a 'blinds to blinds' basis, which includes pre-mixing of inert grains and catalyst material in a desired ratio, unloading large quantities of spent catalyst material using a high-output continuous unloading system, loading of the catalyst mixture, and separation of spent inert grains from spent catalyst using custom-built density/gravity separators.