DGC CATALYST HANDLING BEST PRACTICES GUIDE

Catalyst handling is a specialised field that requires technical precision, environmental awareness, and unwavering commitment to safety. At DGC AFRICA, we bring over a century of industrial service experience to ensure catalyst changeouts are executed flawlessly — minimising downtime, protecting your equipment, and extending the life of your catalysts.

This guide presents our comprehensive best practices for catalyst handling, covering the full lifecycle: unloading, screening, and loading. It is designed to support both operational teams and client stakeholders seeking reliable, cost-effective, and compliant handling solutions.

1.     PLANNING AND PRE-JOB PREPARATION

Successful catalyst handling begins long before the first vacuum hose is connected. Planning is critical to performance, safety, and regulatory compliance.

At DGC, every project starts with:

• Collaborative Planning: We engage client teams in detailed pre-job meetings to understand reactor specifications, process sensitivities, and timeline expectations.

• Site Assessment: Our engineers inspect access points, utilities, environmental risks, and any logistical constraints.

• Equipment Matching: Based on catalyst type, volume, and operational conditions, we configure the most appropriate combination of vacuum systems, screening units, and loading tools.

• Safety Protocols: A job-specific HSE plan is prepared, aligned with both MSDS requirements and site-specific safety procedures.

2.     CATALYST UNLOADING BEST PRACTICES

Unloading spent catalyst must be done with absolute care to prevent structural degradation, cross-contamination, or dust exposure.

Our approach includes:

• Layer Integrity: We separate catalyst layers based on activity levels, size, and age, ensuring no cross-blending or quality loss.

• Controlled Vacuumation: Using rubber-lined hoses and adjustable vacuum pressure, we protect fragile catalyst particles and minimise breakage.

• Special Barriers: Where required, we install baffles or containment barriers inside vessels to maintain material separation.

• Skilled Personnel: All unloading work is conducted by certified, highly trained catalyst technicians.

• Dust Management: Localised dust extraction units are positioned to capture airborne fines at the point of entry.

3.     CATALYST SCREENING BEST PRACTICES

To restore catalyst performance and remove unusable fines, we use a state-of-the-art mobile Catalyst Screening Unit designed for high throughput and safe onsite operation.

Key features of our screening process:

• Initial Inspection: Visual and manual checks assess catalyst contamination, size variation, and moisture content.

• Advanced Screening: Our mobile unit processes 8,000–10,000 litres per hour, with interchangeable mesh screens to accommodate 19 mm, 6 mm, and fine catalyst separation.

• Dust Extraction: Twin cyclone separators and a bag filter unit capture process dust and ensure clean discharge.

• Custom Mesh Selection: We select screening mesh based on historical plant data and actual batch composition.

• Output Monitoring: Every batch is documented for screened volume, recovered catalyst, and discard percentage.

4.     CATALYST LOADING BEST PRACTICES

Proper loading is essential to achieving uniform flow distribution, avoiding channel formation, and maintaining reactor efficiency over time.

We follow these loading principles:

• Technique Adaptation: Depending on project requirements, we use either sock loading or dense loading to optimise bed structure and flow.

• Uniform Distribution: Special attention is paid to layering, with operators trained to spread catalyst evenly throughout the vessel.

• Environmental Protection: Moisture, oxygen, and dust exposure are tightly controlled through sealed transport and dry transfer environments.

• Verification Tools: Probes, cameras, or level sensors are used to validate bed height and confirm loading accuracy.

• Client Sign-Off: Final inspection is conducted jointly with client representatives to validate loading integrity.

5.     SAFETY AND COMPLIANCE

At DGC, safety is not negotiable. Every catalyst handling operation is planned and executed with strict adherence to health, safety, and environmental protocols.

Our safety framework includes:

• MSDS Protocols: All materials handled in accordance with MSDS documentation and plant-specific safety requirements.

• Personal Protective Equipment: All crew members wear gloves, safety goggles, anti-static clothing, and respiratory protection.

• Incident Response Plans: Each project site has a documented emergency response procedure covering spills, exposures, and equipment failures.

• Environmental Stewardship: Used catalyst fines are contained, classified, and disposed of according to regional environmental laws and best practice.

6.     DOCUMENTATION AND REPORTING

Transparent, standardised reporting is central to how we work. Our clients receive complete visibility into the catalyst handling process.

We provide:

• Job Cards & Checklists: Operational steps are tracked using standardised forms and checklists.

• Quality Control Reports: Final reports detail catalyst volumes, screening yield, fines percentage, and anomalies.

• Digital Recordkeeping: Where permitted, we use digital data logging tools to enhance traceability and future performance benchmarking.

• Client Sign-Off: All reporting is reviewed and signed by both DGC supervisors and client representatives.

7.     CONTINUOUS IMPROVEMENT

We continually refine our approach to deliver the highest standards of catalyst handling service.

Our commitment includes:

• Post-Project Reviews: Lessons learned are shared internally to improve future project planning.

• Client Feedback Loops: Client input is actively solicited and integrated into operational adjustments.

• Ongoing Training: DGC technicians receive continuous upskilling in the latest technologies, safety techniques, and process optimisation.

CONCLUSION

Catalyst handling is more than just a technical task — it is a critical link in the chain of safe, efficient, and cost-effective plant operation. By adhering to these best practices, DGC AFRICA enables our clients to maintain operational excellence, reduce emissions, and maximise return on catalyst investment.

For consultation, mobilisation, or technical support, please contact: contactus@dgcafrica.com

DGC AFRICA - Over a Century of Trusted Service.

Committed to Safety, Quality, and On-Time Delivery.

 ABOUT OUR COMPANY, HISTORY, AND PARTNERS

Dickinson Group of Companies (DGC) was founded in 1910. Please visit our website for comprehensive information about Our Company – History, Vision & Values, Strategy, Global Alliances, Africa Footprint, Commitment to Safety, Anti-Corruption Policy, References, and Industrial Solutions.