PREPARING YOUR PLANT FOR A CATALYST CHANGEOUT

A PRACTICAL GUIDE BY DGC AFRICA

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

Catalyst changeouts are high-stakes operations that directly affect plant throughput, environmental compliance, and overall asset performance. When properly executed, they restore process efficiency and maximise catalyst life. When poorly managed, they can lead to extended downtime, equipment damage, or even environmental breaches.

At DGC AFRICA, we understand that successful catalyst handling begins long before our team arrives on-site. It starts with detailed planning, cross-functional alignment, and safety-first thinking. This guide offers a step-by-step approach to help you prepare your plant for a smooth and successful catalyst changeout.

1.     DEFINE THE CHANGEOUT SCOPE AND OBJECTIVES

Every catalyst job must begin with clarity. Take time to define the scope of work and what success looks like. Is this a full catalyst removal and reload? Are you conducting a mid-cycle screening campaign to recover active catalyst and remove fines? Or is it a partial top-up in response to performance deviation?

Understanding the catalyst volume, age, contamination level, and plant performance trends allows us to tailor the right solution. Equally important is alignment on your shutdown window, available manhours, and re-commissioning requirements.

2.     CONDUCT A JOINT PLANNING SESSION

Catalyst handling is not a solo act. It requires careful coordination between operations, maintenance, HSE, engineering, and external contractors like DGC.

We recommend a formal pre-planning session that includes:

• A technical review of the reactor layout and access points

• Identification of all safety constraints and confined space entry protocols

• Discussion of site sensitivities (e.g., flammable vapours, heat zones)

• Agreement on waste handling, catalyst layering strategies, and reporting expectations

This session helps align everyone around a shared execution plan that reduces delays and surprises once work begins.

3.     PREPARE YOUR EQUIPMENT AND UTILITIES

Inadequate infrastructure readiness is one of the most common causes of delay. A catalyst changeout may involve vacuum units, mobile screening equipment, lighting rigs, and dust extraction systems — all of which require specific utilities.

Ensure that the following are available, tested, and easily accessible:

• Power supply (480V or 525V / 50Hz) for mobile screening and vacuum units

• Water access for cooling and vacuum pumps

• Scaffolding or platform access to manways and vessel tops

• Lighting for internal inspections and night shift continuity

• Compressed air- for use in various pneumatic equipment, including but not limited to dust filtration systems, for optimal dust separation to ensure higher quality output in screening

When this preparation is done well, mobilisation becomes plug-and-play.

4.     COMPLETE A PRE-JOB SAFETY ASSESSMENT

No catalyst changeout should begin without a comprehensive risk review. This is especially true for operations involving high dust loads, confined space entry, or potentially pyrophoric materials.

DGC works with your HSE team to develop a full safety package, including:

• A job-specific HSE plan

• Review and alignment of all relevant MSDS documents

• Confined space entry permits and atmospheric monitoring strategies

• Emergency response protocols for catalyst exposure or equipment failure

Proactively reviewing these controls ensures both team readiness and compliance with legal and internal standards.

5.     CLEAN AND SECURE THE WORK AREA

The work zone must be properly isolated, cooled, and cleared before any equipment is brought in.

This includes:

• Verifying that all valves are locked and tagged out

• Confirming zero pressure and acceptable temperature inside the vessel

• Purging with nitrogen or air as required by the process

• Installing barricades and hazard signage to restrict access

Safety starts with a clean and controlled work zone. When we arrive on-site and see it prepared, it’s a signal that we’re working with a plant that shares our standards.

6.     PRE-MOBILISATION MEETING WITH DGC AFRICA

We recommend a final coordination meeting 24–48 hours before mobilisation. This ensures all parties are aligned on sequencing, safety responsibilities, and communication.

Topics typically include:

• Arrival and offloading of DGC’s mobile equipment

• Staging areas for hoses, screens, and disposal drums

• Confirmation of working hours and rest schedules

• Review of PPE compliance and special site requirements

This session ensures we arrive ready to execute from the first hour.

7.     INSPECTION AND DOCUMENTATION

Proper documentation makes the difference between assumptions and accountability. Before and after catalyst handling, we recommend recording:

• Reactor and bed conditions pre-unloading

• Internal inspection photos

• Catalyst weight and volume estimates

• Screening mesh selection and rationale

• Spent catalyst classification and waste plan

DGC AFRICA will compile and submit a detailed post-job report including screened volumes, dust quantities, catalyst loss rates, and quality notes.

8.     CONFIRM SITE READINESS WITH A FINAL CHECKLIST

Before initiating work, a structured readiness check is essential. Even a well-planned operation can be undermined by a missed permit, a disconnected utility, or a miscommunication.

The following checklist provides a practical tool for supervisors and coordinators to verify that everything is in place before catalyst handling begins:

SITE READINESS CHECKLIST:

• Reactor cooled, purged, and isolated

• Utilities connected and tested (power, water, air)

• Entry permits and safety documents signed off

• Catalyst handling equipment staged and inspected

• Lighting and scaffolding in place

• PPE issued and safety protocols reviewed

• Stakeholder teams briefed and roles confirmed

When all boxes are ticked, the team can proceed with confidence, knowing the work environment is safe, compliant, and operationally ready.

CONCLUSION

Catalyst changeouts are not just about equipment or chemistry. They are about leadership, preparation, and commitment to precision. When your site is well-prepared, the entire operation flows more smoothly, safely, and efficiently.

DGC AFRICA stands ready to support your team from planning to execution. Our regional teams in Zambia and the DRC are experienced in navigating complex shutdowns and delivering results on time, every time.

Catalyst Unloading Checklist for Plant Managers.pdf

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

To schedule a pre-shutdown planning session, contact us at: contact-us@dgc-africa.com

 

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