Remote Telescopic Arm for Catalyst Removal in Fixed Bed Vessels
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Solution Overview
Problem
Current methods for removing catalysts from fixed bed vessels pose occupational hazards due to exposure to pyrophoric and explosive materials, oxygen-deficient atmospheres, and the risk of explosions, requiring manned entries into confined spaces with hazardous conditions.
Innovation Solution
A remotely controlled telescopic system with a telescopic arm is mounted to the top of the vessel, allowing for the deployment of tools to access and remove the catalyst without human entry, using a tool changer to adapt to different tasks such as removing manway elements, vacuum collection, and size reduction of agglomerated catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual entry into the vessel is used for load removal, then workers can directly access and remove the catalyst, but personnel are exposed to pyrophoric and explosive materials, oxygen-deficient atmospheres, and confined space hazards
Solution Approach 1:
A remotely operated robotic system serves as an intermediary between the operator and the hazardous environment. The robotic arm with various end effectors can manipulate the catalyst and perform removal tasks without human personnel entering the confined space, thus eliminating exposure to pyrophoric materials and oxygen-deficient atmospheres while maintaining operational capability
2Reliability
If the vessel is purged with inert gas to prevent spontaneous combustion, then catalyst safety is improved, but personnel are subject to asphyxiation from nitrogen gassing
Solution Approach 1:
The robotic system acts as an intermediary that can operate within the inerted atmosphere without compromising personnel safety. Since the robot performs the load removal tasks remotely, personnel do not need to enter the nitrogen-purged environment, thus preventing asphyxiation while maintaining the necessary safety measures for catalyst handling
3Productivity
If workers manually break up and extract agglomerated catalyst, then complete load removal is achieved, but workers are exposed to flammable and explosive atmospheres
Solution Approach 1:
The robotic system with specialized end effectors serves as an intermediary to perform the dangerous task of breaking up and extracting agglomerated catalyst. The robot can manipulate the catalyst material without human personnel being exposed to flammable and explosive atmospheres, while still achieving complete load removal from the vessel
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
This method significantly reduces operational risks and time spent by workers near the vessel, eliminating the need for manual entries and minimizing exposure to hazardous conditions by enabling remote access and removal of the catalyst.
Implementation Method 1
skimming off said portion; and/or removing by gravity, through the drain pipe, the portion of the load which is capable of flowing freely
Implementation Method 2
removing by gravity, through the drain pipe, the portion of the load which is capable of flowing freely
Data Source
Figure 1~3
Figure 4~6
Figure 7~8B
AI summary
The present invention relates generally to a method for removing a load from a load fixed bed vessel that eliminates all worker entries for the removal of the load, namely for extracting the free flow catalyst by gravity or by a vacuum collection system, or for manually breaking up or extracting by vacuum collection the agglomerated catalyst. In the method of the invention, these tasks are realized by a remotely controlled telescopic system comprising a telescopic arm. The telescopic arm deploys tools into the vessel to provide access to the load and to remove it.