CATALYSTS
Remote, robotic removal
of catalysts from reactors
C. JANSEN, WorleyParsons, Brisbane, Queensland, Australia;
and A. W. SLOLEY and S. SCHROEDER, Advisian (WorleyParsons Group), Houston, Texas
In the 1970s, the first commercial
remote-operated vehicles (ROVs) for the
offshore oil and gas industry were devel-
oped. Prior to these, underwater inspec-
tions and maintenance operations were
performed by personnel wearing heavy
underwater suits equipped with breath-
ing apparatus. A catalyst handling techni-
cian faces a similar scenario when enter-
ing vessels filled with nitrogen (N2) to
vacuum the spent catalyst material. The
number of fixed-bed catalytic vessels in
the global refining and petrochemical
industry is estimated to exceed 50,000
(average of 50–60 vessels per facility),1
and yet the process for catalyst removal
has remained essentially unchanged for
the past 75 yr.
In 2018, the industry’s first commer-
cial robot for catalyst unloading was used
to remove molecular sieve adsorbent
from a dehydrator at an LNG plant in
Australia. The development of a new, re-
motely operated robotic catalyst removal
systema responds to increasingly strin-
gent requirements to reduce human risk
in inert, confined-space entry. It is the
culmination of a 3-yr development effort
from conception and design to prototyp-
ing and testing, and it represents a poten-
tial game-changer in the industry.
This article showcases the challenges
associated with existing catalyst removal
techniques, as well as the inherent safe-
ty advantages that the new system has
shown in its pilot operations. One case
study demonstrates the system’s elimina-
tion of the need for confined-space entry
under inert conditions during adsor-
bent unloading from a dehydrator. The
second case study examines the use of
the system on a wet catalyst bed under
water flood conditions. The final case
study illustrates the use of the system in
removing material built up at an angle of
repose, at temperatures unsuitable for Fatalities have occurred in the catalyst
human entry. handling industry due to asphyxiation,
exposure to heat and fire, falling from
Traditional catalyst unloading. Based heights, pressure buildup and engulf-
on existing technology, a rough estimate ment under catalyst.4 A study conducted
of the number of worker days of risk ex- by the US Chemical Safety Board identi-
posure due to confined-space entry dur- fied 85 N2-exposure incidents in the US
ing catalyst unloading (FIG. 1) exceeds between 1992 and 2002, resulting in 80
10,000 d/yr globally (assuming cata- deaths and 50 injuries.5 While improve-
lyst removal every 5 yr with an average ments have been implemented, fatalities
confined-space entry duration of 1 d per continue to occur.
vessel).1 Catalyst removal is commonly In 2014, a catalyst handling worker
achieved by a worker standing on the cat- was killed at a refinery in Germany. The
alyst and manipulating the end of a high- worker was vacuuming catalyst from the
volume vacuum hose (FIG. 2). bottom of the vessel when he reported
The challenges faced by a catalyst hard sections of catalyst via the intercom-
handling technician are similar to that
of a deep-sea diver. The working condi-
tions require supplied breathing air to
sustain life, and one mistake can lead to
catastrophic consequences. While the
offshore industry has seen the develop-
ment of the ROV to greatly reduce the
requirement for underwater diving at oil
platforms, the safety improvements in the
catalyst handling industry have focused
primarily on improved personal protec-
tive equipment (PPE) and procedures.
Many vessels require inert conditions
throughout the catalyst unloading pro- FIG. 1. Worker entering a vessel.2
cess, typically because pyrophoric scale
on the catalyst can auto-ignite in the pres-
ence of oxygen (O2). Anti-panic helmets
have been developed that consist of a
clamshell design bolted to the occupant’s
head. The helmet cannot be removed by
its occupant—a design that has become
standard best practice—after fatalities
occurred due to technicians removing
their helmets in the vessel. It is likely they
had become claustrophobic and were not
thinking clearly, potentially influenced
by heat exhaustion. In operation, breath-
ing air is supplied to keep the helmet at a
FIG. 2. Worker vacuuming catalyst.3
slight overpressure.
Gas Processing & LNG | MARCH/APRIL 2019 37
CATALYSTS
FIG. 3. Robotic catalyst removal systema prototype development—clockwise from top left:
Versions 1.0, 2.0, 2.1 and 3.0.
FIG. 4. Robotic catalyst removal
system testing.
munication system. Ten minutes later,
the worker called for help and the safe-
ty crew initiated rescue activities. The
worker reported that a wall of catalyst
had collapsed on him and that he could
feel heat coming from within the catalyst.
Outbreathing from the helmet provided
enough O2 to cause pyrophoric scale on
38 MARCH/APRIL 2019 | GasProcessingNews.com
the catalyst to ignite. Communication
with the entrant gradually slowed, and
then stopped. The burned body was re-
covered only after 350 ft3 of catalyst had
been removed.
While fatalities present the ultimate
risk, the health impact on catalyst han-
dling technicians when performing man-
ual vacuum operations is also significant.
The ergonomic position taken by the
worker is to crouch over in hot protective
clothing while maneuvering a heavy vac-
uum hose around the vessel. They cannot
drink water while inside the vessel be-
cause of the air supply system. To get out
of the vessel for a break, they may need to
climb 40 ft of ladder to reach the manway,
which could be as narrow as 18 in.
Development of remote, robotic cat-
alyst removal system. Early attempts to
create a catalyst removal robot were made
by Greg Kraus and Ray Arnold of Cata-
lyst Services Inc. in Texas. With a patent
published in October 2008, the design
involved a vacuum line connected to an
articulating nozzle, supported against the
sides of the vessel using stabilizing arms.5
One of the key challenges the inventors
likely faced was achieving a catalyst re-
moval efficiency comparable to that of
a person. Catalyst changeouts are often
critical-path activities during a plant turn-
around, meaning delays are costly for the
operator. This challenge is likely what
prevented the robotic arm concept from
being commercialized.
The development team for the new
system took a different approach. The
aim was to develop a machine that sits on
the catalyst and vacuums it while moving
around. The “quicksand-like” characteris-
tic of the catalyst was the critical param-
eter to overcome. The amphirol (screw-
propelled vehicle) was selected (FIG. 3).
The development of the amphirol cat-
alyst unloading robot was adapted from
a technology that the manufacturer had
previously implemented for the red mud
lakes of alumina refineries. The technol-
ogy, which uses worm gear propulsion,
allows the device to move on a semi-
liquid substance. The combination of a
lightweight aluminum frame and large-
diameter screws provides a buoyancy ef-
fect on the catalyst (FIG. 4). The system
has been tested on the full range of media
density (40 lb/ft3–80 lb/ft3) and particle
size (0 in.–1 in.) encountered in catalyst
unloading.
The amphirol is controlled remotely
from the top platform or at grade (FIG. 5).
Movement around the catalyst bed is
achieved via remote-operated direct-
drive hydraulic motors. Meanwhile,
the vacuum head, which is connected
to the robot via a hydraulic cylinder,
can be raised and lowered remotely to
achieve an optimum catalyst-to-air/N2
efficiency. The system’s in-vessel electri-
cal equipment is rated for use in Zone 1
and Class 1 Division 2 hazardous areas
(ATEX, IEC Ex and AEx certification
on the entire system). The equipment is
operational up to a temperature of 167°F
(75°C). For manual unloading, the vessel
will be cooled to less than 100°F (38°C)
for human entry, and atmospheric pres-
sure is maintained. The system provides
productivity advantages since it can be
deployed while the vessel is still hot. It
can also operate continuously through-
out the shift, meaning the support crew
can have a staggered lunch break and
eliminate 12%–20% of downtime.
Risk mitigation is a critical aspect of
any project. The robotic catalyst removal
system team has approached the device’s
development using the same rigor as
would be applied on a major greenfield
 CATALYSTS

project. Examples of outputs from the

risk assessment process include hydrau-
lic oil low level trip to minimize potential
leakage from a broken hose; continu-
ous monitoring of vessel lower explosive
limit, oxygen content and temperature to
minimize the risk of fire and/or explo-
sion; and operating procedure with step-
by-step guidance and sign-off to ensure
effective operation of the equipment.

Case studies. The case studies present-

ed highlight the use of the new catalyst
removal system under a range of chal-
lenging circumstances typically encoun-
tered during catalyst unloading.
Dehydrator unloaded under inert
conditions. The system was used to
remotely remove adsorbent from a de-
hydration vessel, avoiding the need for
worker confined-space entry under inert
conditions.
The dehydration vessels, which re-
move water from gas before it is liquified,
consist of 2,000 ft3 of molecular sieve
adsorbent, which is low-density catalyst. FIG. 5. Robotic catalyst removal system operational setup.
When unloaded under an N2 blanket, the

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Gas Processing & LNG | MARCH/APRIL
CATALYSTS
catalyst is dry and free-flowing. When
unloaded manually, the technician’s boot
will sink into the material up to the knee.
The plant is located in a tropical climate
with temperatures in the vessel reach-
ing up to 120°F (49°C). The catalyst sits
between a lower and upper steel mesh
screen with ceramic balls at the top. The
vessels are of a large diameter, with no
gravity dump capability. The client was
seeking to eliminate confined-space en-
try under inert conditions.
The new system was used to unload
the dehydration vessels under inert con-
ditions, with no requirement for human
entry into the N2 environment. This was
the first time that the system had been
FIG. 6. Dehydrator vessel.
FIG. 7. Control station.
40 MARCH/APRIL 2019 | GasProcessingNews.com
used in an operating plant. The robot was
first deployed to remove 1-in. ceramic
balls from above the top mesh screen. The
screen was speared and removed from the
top manway. The system was then used
to remove the molecular sieve adsorbent,
navigating to all parts of the vessel, includ-
ing in and around the moisture probes lo-
cated toward the bottom of the bed. The
vessel was then opened to air so that the
bottom internals could be removed.
The system remotely removed more
than 95% of the molecular sieve adsorbent
from the vessel, including the ceramic
support material at the top of the bed. In-
ert conditions were maintained through-
out the process, and the requirement for
confined-space worker entry in the O2-
deficient atmosphere was eliminated.
Dehydrator unloaded under water
flood conditions. The system was suc-
cessfully used to remove wet material
from another dehydration vessel follow-
ing a water flood operation. This removal
took place in a portion of the same plant
as in the previous case study.
Some operators have sought to move
entirely away from confined-space en-
try under inert conditions. This can be
achieved by flooding the vessel with
water several times to flush away the re-
sidual hydrocarbons. In the case of pyro-
phoric material, the catalyst is kept rela-
tively wet by slowly lowering the water
level in the bed as the catalyst is removed.
Although the catalyst can then be vacu-
umed in an open-air environment, the
water introduces additional hazards for
the occupants, and full suits with breath-
ing apparatus are still required.
The system was used to vacuum the
wet adsorbent. The screws were effective
FIG. 8. Camera on robot.
in allowing the robot to maneuver on the
catalyst bed, thereby maintaining an even
level of catalyst during removal, which
was important because the catalyst was
not free-flowing.
The use of the system on the wet ad-
sorbent showed how the technology can
be used in tandem with the water flood-
ing method. The time at risk for confined-
space entry was significantly reduced.
Gas shift reactor unloaded post-
gravity dump. The system was used to
remotely remove built-up catalyst at an
angle of repose, with vessel temperatures
exceeding 120°F (49°C). This was the
first time that the system was used in a
live operating plant in the US.
Catalyst from the gas shift reactor
vessel was removed in the first instance
using a dump nozzle located at the bot-
tom of the catalyst bed. This allowed for
catalyst to be gravity-dumped from the
vessel; however, not all catalyst was re-
moved. The residual catalyst can be up
to 40% of the total vessel volume. Work-
ers are typically required to enter the
vessel to vacuum the remaining material
and must be wary of the built-up catalyst
around the vessel walls and the associat-
ed risk of being buried. The pyrophoric
material also tends to heat up if the N2
purge is insufficient to maintain inert
conditions. At this plant, the supply of
N2 was low and vessel temperatures were
difficult to control.
The system was used to unload the re-
sidual catalyst material (post-dumping)
in the gas shift reactor vessel. It was op-
erated in temperatures not suitable for
human entry. The system successfully
removed the catalyst until a hot spot
on the catalyst bed caused the plastic
prototype screws to melt. Hot catalyst
beds are not uncommon, and workers
will on occasion feel heat through their
boots, at which point they must get
to the ladder before the soles of their
shoes melt.
This use of the system demonstrated
that the robotic catalyst removal technol-
ogy can be used effectively, in combina-
tion with gravity dumping, to minimize
the time spent by workers inside con-
fined spaces during catalyst unloading.
The vessel temperatures following the
catalyst dumping operation were still too
high for human entry; however, the use
of the catalyst removal system allowed
the job to continue.

Although a set of screws was destroyed
due to a hot spot in the catalyst bed, this
incident highlighted the reason that ro-
botic catalyst removal is being introduced
as an alternative to manual vacuum un-
loading. A new set of 3D-printed alumi-
num screws are in production and are ex-
pected to withstand catalyst temperatures
of greater than 200°F (93°C).
Future work. In some cases catalyst
can be fused, normally as a result of a
process upset prior to the shutdown or
extended runs between changeout. Dur-
ing in-house tests, the system has broken
through a layer of crust created using a
mixture of carbon and mortar. The screws
on the unit are effective in catalyst condi-
tions with mild agglomeration or “shelv-
ing” (buildup of sticky material against
the walls after dumping). However, addi-
tional implements are being developed to
extend the capabilities to heavily agglom-
erated or coked beds, typically encoun-
tered in heavy oil applications.
The catalyst removal system’s robot is
now remotely operated using a joystick
and video camera footage from inside the
vessel. A joint industry project with a uni-
versity in Brisbane is underway to imple-
ment automation of the robot movement
around the bed. The goal is for the system
amphirol to automatically move around
the bed to maintain an even catalyst ser-
vice and to automatically adjust the vac-
uum head position to optimize catalyst
removal efficiency.
Takeaway. As the industry’s first com-
mercial, fixed-bed catalyst unloading ro-
bot, the robotic catalyst removal systema
aims to reduce the associated risk of plac-
ing people inside vessels. This could help
kickstart a robotics revolution for the on-
shore oil and gas industry, like that seen
with ROVs in the offshore industry.
The system has a straightforward
design with few moving parts. By using
screws for propulsion, it moves freely on
the surface of loose material. It is light-
weight and easy to maneuver inside the
vessel using a joystick and live video feed-
back. Additionally, the system facilitates
effective vacuum removal of catalyst with
no requirement for human entry during
the bulk catalyst unloading phase of ves-
sel changeout.
The system development team has chal-
lenged the status quo that catalyst unload-
CATALYSTS
FIG. 9. Robotic catalyst removal system
post-job.
ing must rely entirely on personnel. The FIG. 10. Control system trailer.
robotic catalyst removal system has the po-
tential to radically alter what has been done
the same way for almost 75 yr. GP
LITERATURE CITED
1
“2017 worldwide refining survey,” December 5,
2016, online: https://www.ogj.com/down-
l oad a b l e s / s u r v e y- d ow n l oad s / w o r l d w i d e -
refining/2017/2017-worldwide-refining-survey.
html
2
Mourik, “Catalyst handling services,” online:
http://www.mourik.co.uk/catalyst-handling-ser-
vices.php
3
Catalyst Handling, “Setting new standards,” online:
http://www.catalysthandling.com
4
Malewitz, et al., “A deadly industry,” 2015, online:
http://www.ehstoday.com/safety/deadly-industry
5
US Chemical Safety and Hazard Investigation
Board, “Hazards of nitrogen asphyxiation,” Safety
Bulletin No. 2003-10-B, June 2003.
NOTE
FIG. 11. Camera on top of vessel.
CAROL (Catalyst Removal Amphirol)
a
CHRIS JANSEN is Program Manager technology selection, best-practices implementation
at WorleyParsons in Brisbane, and reliability improvement. Mr. Sloley developed his
Queensland, Australia, and plant and technology knowledge through 40 yr of
co-inventor of Advisian Digital’s experience with operating, vendor, engineering and
consulting firms. He publishes extensively and
robotic catalyst removal
technology, CAROL™ (Catalyst participates in many API, AFPM and AIChE activities.
Removal Amphirol). He developed Mr. Sloley holds a chemical engineering degree
his plant knowledge and process safety experience as (hons) from the University of Tulsa and is a licensed
a chemical engineer at BP’s Bulwer Island refinery in Professional Engineer in the state of Texas.
Brisbane, Australia. He then joined WorleyParsons in
2014, where he soon set out to transform his idea of SCOTT SCHROEDER is Senior
robotic catalyst unloading from concept into reality. Technical Consultant at Advisian
He is now managing the global rollout and (WorleyParsons Group) in Houston,
commercialization of the technology. Mr. Jansen Texas. At Advisian, he is responsible
graduated with first-class honors from the University for gas processing and
of Sydney with degrees in chemical engineering petrochemical technology. His
and commerce. responsibilities include economic
evaluation, technology selection and operational
ANDREW W. SLOLEY is Principal excellence support. He has worked for more than 20
yr in cryogenic gas processing, LNG, gas purification,
Consultant at Advisian
(WorleyParsons Group) in Houston, refinery offgas processing, NGL fractionation and
Texas. He is responsible for several novel processes. Mr. Schroeder received his
consulting on refinery and BS and MS degrees in chemical engineering from the
petrochemical optimization and University of Nebraska. He is a registered Professional
refinery-petrochemical integration. Engineer in the state of Texas and the province of
He manages consulting projects that that range from Alberta. He is also the co-inventor on two patents,
unit optimization to entire complex integration, with a third patent pending.
Gas Processing & LNG | MARCH/APRIL 2019 41