Remote Catalyst Removal Device for Refinery Reactors
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Solution Overview
Problem
Catalyst unloading in the oil refining and petrochemical industry is hazardous due to the risk of pyrophoric scale, requiring inert conditions and manual handling, which increases the risk of injury and death, and existing methods like water flooding are inefficient and costly.
Innovation Solution
A robotic or remotely controllable solids removal device with a frame structure, propulsion and turning mechanisms, and a vacuum head connected to a power unit, allowing for safe and efficient removal of catalysts from vessels without confined space entry, adaptable to various vessel types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual catalyst unloading is performed by personnel entering the vessel, then the catalyst can be handled and removed, but the risk of injury and death increases due to pyrophoric scale exposure, asphyxiation, and falling hazards
Solution Approach 1:
A robotic device with remote control capability serves as an intermediary between operators and the hazardous catalyst unloading environment. The device includes a mobile platform with vacuum system, manipulator arm, and remote control unit, allowing operators to control the unloading process from a safe distance outside the vessel while eliminating direct personnel exposure to pyrophoric scale and confined space hazards
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system. The robotic device incorporates a vacuum head with variable geometry suction opening, remote-controlled manipulator, and automated navigation capabilities, substituting human physical labor and exposure with mechanical automation that can be controlled remotely
2Object-affected harmful factors
If full reactor water flooding is used to eliminate inert entry requirements, then personnel safety is improved, but catalyst re-use is prevented, unloading time increases, and water handling costs increase significantly
Solution Approach 1:
The robotic device acts as an intermediary that enables safe operation in inert atmospheres without requiring water flooding. The remote-controlled platform can navigate and operate within nitrogen-purged vessels, maintaining catalyst integrity for potential re-use while eliminating the need for water flooding and associated productivity losses
Solution Approach 2:
The patent is specifically designed to operate in inert atmospheric conditions using a mobile robotic platform with sealed components and explosion-proof electronics. The system maintains operational capability in nitrogen atmospheres, allowing catalyst unloading without water flooding while preserving catalyst quality and reducing unloading time
3Ease of operation
If multiple personnel with breathing apparatus are required for catalyst vacuuming, then the catalyst can be unloaded, but the complexity of the operation increases and the probability of death or injury increases
Solution Approach 1:
The robotic device is self-propelled and self-navigating within the vessel. The mobile platform autonomously moves to positioning locations using its drive system, and the vacuum system automatically operates to collect catalyst material, reducing the need for complex manual coordination and multiple personnel interventions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces personnel exposure and risk of injury during catalyst unloading, improves efficiency by minimizing unloading time, and eliminates the need for hazardous material handling, while being adaptable to different vessel configurations.
Implementation Method 1
a vacuum head connected to a discharge end of the frame structure. The vacuum head has a suction end and a discharge end connectable to a vacuum hose
Data Source
AI summary
Methods and apparatus are disclosed for removing catalyst, absorbents and other materials from a reactor, guard bed, or other refinery or petrochemical vessel via a robotic or remotely operated device. A vacuum hose is connected to the device for removing the material from the vessel for ex-situ regeneration or disposal. The device moves around on the surface of the catalyst using motorized screws that grip to the catalyst material. The device is powered by hydraulic, pneumatic or electric motors attached to the frame of the device with supply and return hoses extending in and out of the vessel in line with the vacuum hose.