OPTIMISING HANDLING OF VANADIUM PENTOXIDE CATALYST IN SULPHURIC ACID CONVERTERS

PREPARED BY DGC AFRICA

Over a Century of Trusted Service — Committed to Safety, Quality and On-Time Delivery

At DGC AFRICA, we apply industry-leading standards for the handling, unloading, screening, and reloading of Vanadium Pentoxide (V₂O₅) catalyst within Sulphuric Acid Converter Beds. Our methods are based on OEM recommendations and international HSE compliance frameworks, ensuring both operator safety and process efficiency.

HANDLING METHODOLOGIES

• Pre-Mobilisation Preparation

• All personnel are trained in catalyst exposure protocols.

• Mandatory PPE includes respirators, gloves, and protective suits

• Catalyst is stored under cover to avoid moisture contamination.

CONVERTER BED PREPARATION

 

• Internal vacuum cleaning removes all dust and debris.

• Stainless steel mesh repairs are done where required after thorough inspections.

• Converter shell insulation is done in accordance with OEM design specifications to ensure Insulation effectiveness, including the use of Cerablankets as specified by some of our clients in the industry.

LOADING PROCESS (OEM STANDARD PRACTICE)

• Sock Loading technique is primarily used, minimising breakage and dust formation.

• Thermocouples are placed precisely between ceramic ball layers and catalyst beds.

• Catalyst is levelled using non-metallic tools and covered with ceramic balls (top & bottom layers).

• Walking on catalyst is strictly prohibited — wooden planks are used to distribute weight.

Catalyst Volume & Type may vary from process parameters, and selection depends on design, operational needs, emissions targets, and temperature constraints. Total height includes ceramic ball layers and catalyst as defined per bed specification in accordance with OEM standards.

Catalyst types we have successfully worked with include:

PROCESS CHARACTERISTICS FOR SOCK LOADING:

• Relatively simple and cost-effective

• Suitable for most reactor designs

• Faster loading rate.

• Lowers the risk of breaking the catalyst.

  
  

VANADIUM PENTOXIDE (V₂O₅) SAFETY COMPLIANCE

Vanadium Pentoxide is a hazardous substance and requires strict handling controls:

• Inhalation Risk: Can cause severe respiratory irritation and systemic toxicity.

• Contact Risk: Causes skin and eye irritation.

• Reactive: Avoid water ingress, which produces corrosive acidic solutions.

DGC AFRICA COMPLIES WITH ALL MSDS PROTOCOLS, INCLUDING:

• Real-time dust suppression measures during unloading/loading.

• Personnel medical screening and exposure monitoring

• Full compliance with local and international hazardous substance guidelines

DGC AFRICA RECOMMENDATION

At DGC AFRICA, we assess each project individually to determine the most appropriate loading method based on:

• Reactor design and service conditions

• Catalyst type and value

• Flow distribution requirements

• Safety and operational constraints

  
  

WHY DGC-AFRICA?

• Proven safety record with zero injury incidents across major shutdowns.

• Deep understanding of OEM standards and material-specific handling expertise.

• Seamless integration into client shutdown schedules, minimising downtime and optimising converter performance.

Contact our team at contactus@dgc-africa.com 

Or visit www.dgc-africa.com

to discuss the most effective catalyst handling solution for your operation.

DGC AFRICA - Enhancing Catalyst Performance Through Precision, Safety, and Innovation.

 

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.