COURSE OVERVIEW:

Catalysts are the fundamental drivers of chemical transformations in refinery and petrochemical units, but their effectiveness depends heavily on proper handling and loading techniques. This course provides a detailed examination of the procedures and safety protocols required to manage catalyst life cycles, from initial procurement to final disposal. Participants will explore the physical and chemical properties of different catalyst types, including beads, extrudates, and powders, to understand how mechanical stress and environmental exposure can impact their catalytic activity.

The scope of this training focuses on the rigorous technical requirements for reactor loading and unloading operations. Attendees will learn about "dense loading" versus "sock loading" techniques and how to achieve uniform bed distribution to prevent channeling and pressure drop issues. The course emphasizes the importance of internal inspections and the correct placement of support media, ceramic balls, and distributors to ensure optimal fluid dynamics within the reactor vessel.

Safety is a primary pillar of this curriculum, particularly concerning the handling of pyrophoric and toxic catalysts. The course details the passivation and neutralization processes required before unloading spent catalysts to prevent spontaneous combustion or hazardous gas release. By integrating best practices for nitrogen blanketing, personal protective equipment, and specialized handling equipment, this course prepares personnel to execute catalyst changeovers efficiently while minimizing unit downtime and protecting worker health.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Identify different catalyst geometries and their susceptibility to attrition.

2.  Explain the safety hazards associated with fresh and spent catalysts.

3.  Execute proper storage and inventory management for sensitive catalyst materials.

4.  Differentiate between sock loading and dense loading methodologies.

5.  Utilize loading diagrams to ensure correct placement of catalyst and support media.

6.  Perform pressure drop tests and bed density checks during the loading process.

7.  Implement nitrogen blanketing and inert entry procedures for reactor vessels.

8.  Manage the unloading of spent catalysts using gravity or vacuum systems.

9.  Execute passivation and "oiling" procedures for pyrophoric materials.

10.  Identify signs of catalyst poisoning, fouling, and sintering during inspection.

11.  Sample catalysts safely for laboratory activity testing and analysis.

12.  Ensure compliance with environmental regulations for catalyst disposal and metal recovery.

13.  Develop a detailed catalyst changeover schedule to minimize unit downtime.

TARGET AUDIENCE:

Maintenance Engineers, Operations Supervisors, Catalyst Technicians, and Safety Officers involved in reactor turnarounds and catalyst management.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.