CATALYSTHANDLING &
NEW TECHNOLOGIES
THE RIGHT LOADING METHOD & KNOW-HOW ENSURES EFFICIENCY
The catalyst replacement service has been part of our range of services since many years. We act according the highest Safety, Health & Environment standards.
Zero accident policy is our highest priority!
CATALYST HANDLING SERVICE
UDL Uniform Density Loading 2.8 ®
Ammonia converter technologies for revamps
Digital dP Measurements
Video Inspection
Dense Loading for Fixed Bed Reactors
TubeCleaner inside
TubeCleaner outside
UDL Uniform Density Loading
When loading cracking furnaces, it is crucial that every tube is loaded with exactly the same amount at the same speed and that a virtually consistent density is achieved. If the reactor is loaded using the conventional sock-loading method, hot spots will develop in certain circumstances due to an unequal gas flow rate, following which tears in the tubes may occur due to overheating. The degree of efficiency is also not optimum due to the widely differing density of the individual pipes. In the case of sock loading, the loss of pressure is approx. +/- ≤ 10%. Furthermore, prior to the works, the exact measured amount of catalyst must be prepared which means loading the catalyst into socks so that each tube can be identically loaded. Our UDL uniform density loading technology - which we use in either its manual or automatic version - is easier, faster and better. The reactor loading carried out by using UDL manual loading guarantees a consistent and good loading result. For the even more efficient and consistent automatic loading of all tubes, we recommend using UDL automatic. You save up to 20% more time and the loss of pressure is just +/- ≤ 3%.Neuer Text
Digital dP Measurements
IKR Richter Technology GmbH uses digital systems for pressure drop measurements which cannot be outdone in terms of precision.
The devices do not just stand out for their light weight and their ease of use. A safety appliance automatically cuts off the device in the case of excess pressure so that a high degree of occupational safety is guaranteed.
You can be assured that you will obtain the best measurements during every work phase.
We measure the pressure drop:
after emptying the tubes to see whether a free flow-through exists,
per catalyst layer and type change and
after the end of the work to determine whether the same pressure drop is found on all tubes.
Video Inspection & Checking of the remaining lifetime
After the reactor is emptied, all of the tubes are checked first of all. It is verified whether residual catalyst exists, whether the tubes are polluted with carbonates, which act as an isolator, and whether the support grid at the bottom of the reactor is free or damaged. Further measures are derived at short notice from the results.
We have a procedure that stands out as being time-saving and efficient. Video recordings of the individual tubes are continuously saved onto SD cards. While the first recordings are surveyed by site management, customer and catalyst manufacturer on a separate playback device, the IKR Richter Group technicians continue to gradually deliver the further recordings. In this way, further decisions may be made and promptly implemented without interrupting the works.
In cooperation with MP Magnetische Prüfanlagen, IKR Richter Technology has developed a tool which means that we can carry out an expansion measurement on every single tube. This means that the diameter is continuously measured, and the smallest deformations caused by hot spots can be recognized. Compared to traditional external gauging, internal measurement delivers more accurate measurements which make a decision with regard to the possible tube replacement easier for our customers.
Dense Loading for Fixed Bed Reactors
Many years of experience with the Dense Loading Machine ensures, that the catalyst material is dispersed in the reactor in a consistent, gentle and low dust way. This gives the required uniform and dense storage of the individual catalyst particles with a significantly higher loading volume. The continuously variable regulation of feed quantities, the rotational speed of the loading motor and the length and design of the flexible, star-shaped product deflectors placed on several levels guarantee gentle and economic loading for any reactor bed size. The high quality theoretical training and practical on-the-job training are consistently implemented for all reactor technicians – as we are well aware: the more adept the technician, the better the loading result. Our customers receive a well-engineered technical service without royalties.
