RE: GWS Catalyst Handling Equipment As requested, I have included below some further information on our 50 Series Diesel Vacuum Machine, which is our most popular vacuum machine for catalyst removal. For your reference I have also included further information on the rest of our catalyst handling range. To give you some background GWS Engineers Ltd are the UK’s leading manufacturer of large industrial vacuum equipment. Part of our range is our specialist catalyst handling equipment. We pride ourselves on supplying robust, reliable, quality equipment that will provide long service. We supply our specialist catalyst handling equipment to companies worldwide from the UK and Europe to Australia, India and the Middle East such as Mourik, Buchen, Catalyst Technology etc. For catalyst work we normally supply our 50 Series 4” Diesel Vacuum Machine. The 50 Series is ideal for catalyst work as it unloads catalyst at around a barrel per minute from reactors, which is generally as fast as it can be processed. The 104 Series is the largest vacuum machine in our range. It can be used for catalyst recovery work if you require more speed or to vacuum multiple tubular reactors. If you would like further details on the 104 Series please advise. Our range of catalyst handling equipment includes: • • • • • 50 Series Diesel Vacuum Machine, fitted with Chalwyn Valve, Spark Arrester and Closed Loop recirculation system for use with Nitrogen. If required 50 Series can be mounted on a Site Trailer. Constant Discharge Valve (CDV) Filter Hopper or High Discharge Filter Hopper 2,400 Cubic Metre Gas Cooler Dust Free Catalyst Drum Filler Catalyst Hopper with Soft Flowing Characteristics The sketches show how the equipment works together. All the above vacuum equipment is designed to ship in standard containers or by lorry. 50 Series Diesel Vacuum Machine Our 50 Series Diesel Vacuum Machine is ideal for catalyst removal work. Its compact size is convenient for site but it produces a powerful vacuum performance and it fits inside a standard shipping container. The 50 Series comes with additional modifications for catalyst work which includes high temperature filter bags, engine over-speed protection, Spark Arrestor, closed loop system for use with nitrogen & High Pump Temperature shutdown. 50 Series Diesel Vacuum Machine Specifications Fuel Consumption - Tank holds 200 litres 2 gallons per hour or 10 - 12 litres Power JCB 444 Dieselmax/Ecomax engine Airflow 2,200 to 2,750 cubic metres per hour (1,300 – 1,618 cfm) Maximum Vacuum 525 millibars Vacuum Suction Line 4" - 5" Filtration The 50 Series is fitted with a bank of 20 No. Silicon impregnated filters with high filtration properties mounted on 20 individual frames. The filters will stop all material of 1 micron or above. It also has a highly efficient mechanical rapper filter cleaning mechanism. Noise The 50 Series engine and blower are fully enclosed in a sound proof enclosure, making it quieter than most 4” vacuum machines. To comply with European regulations governing noise emissions the Vacuum Machine has been tested by an independent notified body. The 50 Series is skid mounted as standard or can be mounted on a Site Trailer and towed about site. Constant Discharge Valve (CDV) The Constant Discharge Valve (CDV) works by removing the catalyst from the airflow by centrifugal force (cyclone). The cyclone should remain empty at all times. The catalyst is discharged by two 200mm valves working together. One valve is shut at any one time, batch feeding the product every 15 seconds. The equipment is powered by compressed gas, nitrogen if you are using it on pyrophoric material. The system breaks down to allow it to be transported via sea container and is erected on site via a fork truck, which gives a 2.5 metre working height below it. It is fully fitted with hand rails, making it safer for your workforce when working at height. If input exceeds output material will carry over to the vacuum producing equipment. We recommend that our Filter Hopper is used with the CDV. In Transit format Dust Free Catalyst Drum Filler The latest addition to our catalyst handling range is our Dust Free Catalyst Drum Filler. The Dust Free Catalyst Drum Filler will fill up to two drums per minute, without visible dust release and with minimum operator effort. The Drum Filler is normally sited either directly under the reactor for dumping operations or below the collection vessel. The Dust Free Drum Filler can also be used with our Constant Discharge Valve (CDV) also pictured which is a tangent entry cyclone with constant discharge, with a working height below the discharge of approximately 2,500mm. Refineries have been able to make savings of thousands of Dollars per turnaround by avoiding costly Catalyst Flo Bin Hire charges. Any delay or conflict in the schedule can send hire costs spiralling upwards. However, by filling directly into Drums, which are owned by the refineries, additional hire costs are removed, which can assist in budget planning and reducing unnecessary additional costs. Plus, as the dust release is minimised it protects not only immediate operators, but other site personnel and passers-by who are not wearing breathing protection. It reduces the exclusion zone around the catalyst unloading operation and creates a professional, safe working environment. You can view a short video of the Drum Filler working on YouTube: https://www.youtube.com/watch?v=juVyICvlWSo Filter Hopper We recommend a Filter Hopper is used after the Constant Discharge Valve. The Filter Hopper is also fitted with a bank of 18 No. Silicon impregnated filters with high filtration properties mounted on individual frames. The filters will stop all material of 1 micron or above. The Filter Hopper is fitted with a highly efficient mechanical rapper filter cleaning mechanism. The Filter Hopper will contain any carry-over from the CDV and produce a one-stop, dust free discharge point into big bags, flow bins or drums. High Discharge Filter Hopper Returned Gas Cooler If the air/gas is required to be recycled we have our Gas Cooler. The Gas Cooler is powered by cold water flowing through an internal matrix at a rate in excess of 20 Litres per minute. The maximum input water temperature is 20 degrees centigrade. Should you wish to reduce the returned air temperature further the volume of input water can be increased to 50 litres per minute or the water can be cooled lower than 20°C. We recommend our 50 Series as it unloads catalyst at around a drum per minute, which is an ideal speed for processing drums, moving full drums onto pallets etc, ensuring a smooth, continuous operation. Please see attached specification information for our 50 Series Diesel Vacuum Machine. The catalyst is vacuumed from the reactor and enters the Constant Discharge Valve’s (CDV) cyclone at a gentle tangent entry. As the name implies it is a constant discharge. The catalyst is discharged into a 2½mt space below it, where Flow / CHEP Bins, Drums and FIBC Big Bags can be filled. We also have a 200 litre Drum Filler that fits in this space that is operator friendly with virtually no dust release, which makes for a cleaner job. The Drums can be purchased outright as opposed to the CHEP Bins which are generally hired. CHEP bin hire costs can be high, as catalyst can be stored for reprocessing for a considerable time. However, as drums are purchased outright, it avoids CHEP bin hire costs, and the savings can be huge. Even without this saving the Drum Filler makes the operation easier for your staff and it produces environmental benefits, as it reduces dust release on site. Like all Cyclones there is no storage facility and you will need to use the Filter Hopper inline, which will stop any carryover and discharge it cleanly from one point. If you are vacuuming a pyrophoric catalyst under nitrogen you will need our Gas Cooler to recycle the nitrogen and recirculate this cooled gas back to the reactor. The advantages of this equipment are that is it a constant operation, filling drums at approximately one drum every minute. Being modular you can use all or any part of it, positioning it in the space available. Cooler 50 Series Diesel Vacuum Machine Filter Hopper Constant Discharge Valve (CDV) & Dust Free Drum Filler
