Contact Section - Converter - Catalyst Loading
January 18, 2003

Introduction Safety Equipment and Supplies Procedure

Associated Links Catalyst Unloading

Introduction

After catalyst removal and screening or in a new installation, the quartz pebbles and catalyst must be loaded into the converter.  This operation is more labour intensive than removing the catalyst since catalyst must be hoisted to the level of the bed manway, loaded through the manway, and distributed across the converter.  Multiple manways in the converter will speed up this operation to a great extent.  The following provides a general procedure for the loading of catalyst and quartz into the converter.  The user must adapt the following procedures to their specific situation.

Safety

Vanadium pentoxide catalyst dust is toxic and special safety precautions are required for all personnel involved in the loading operation.  Material Safety Data Sheets (MSDS) should be reviewed prior to commencing the operation.

Personnel shall wear as a minimum dust respirators, protective goggles, gloves and disposable protective clothing.  Externally supplied breathing air is highly recommended for those personnel working in the converter.

Standard vessel entry procedures should be followed at all times.  This should include as a minimum:

• Routine testing of oxygen levels inside the converter
• A person stationed outside the converter manway to monitor the workers inside the vessel.  This individual should be equipped with rescue gear and an independent air supply.

Equipment and Supplies

The following equipment will be required:

• Rakes and shovels
• Plywood sheets
• Measuring tape and chalk/markers
• Lifting equipment (i.e. crane or hoist)
• Conveyor

Procedure

1.       Ensure that the converter is safe to enter and all vessel entry procedures are in place and all required safety equipment is provided.

2.       Inspect the converter for cleanliness and remove any debris.

3.       Mark the expected level for the first layer of quartz pebbles (typically 2"), and the catalyst layer around the entire inside wall of the converter.  These marks will be used as a guide by the installers to level the layers and to determine the amount of quartz and catalyst that must be added.

4.       Install the first layer of quartz rock across the entire catalyst bed.  Use the marks on the converter wall as guide for leveling the quartz pebbles.

5.       Install the catalyst beginning at the far side of the converter working back towards the manway.   Use the marks on the converter wall as a guide for leveling the catalyst.  Avoid walking directly on the catalyst.  Use plywood sheets or boards laid on top of the catalyst if access is required across the top of the bed.

6.       Keep a log of the quantity and type of catalyst loaded into the bed.  This will ensure that the proper amount of catalyst has been loaded into the bed.

7.       Once the proper amount of catalyst has been installed, level the entire bed using the marks on the converter walls as guides.

8.       Install the hold-down layer of quartz rock across the entire catalyst bed.  Use the marks on the converter wall as a guide for leveling the quartz pebbles.

9.       Remove all equipment, plywood, bags, etc. from the converter and inspect for left over debris.

10.   Install the manways after final inspection.

• Catalyst loading operations should be halted if there is a possibility of exposing the catalyst to any form of precipitation (rain, snow, etc.)
• Catalyst samples should be taken to be analyzed for activity.