(2a) The Future Is Here: Robotic Catalyst Removal

WorleyParsons has been developing new technology using vacuum catalyst removal from refinery and petrochemical vessels via a remote-operated vehicle. The development of CAROL^TM (Catalyst Amphirol) responds to increasingly stringent requirements to reduce human risk in inert confined-space entry. It is the culmination of a three-year development effort from conception and design to prototyping and testing and represents a potential game-changer in the industry.

A rough estimate of the number of worker days of risk exposure due to confined-space entry during catalyst unloading exceeds 10,000 days per year. Current practices for catalyst removal from each of these vessels pose a risk to safety and/or the environment. The CAROL^TM robot/ROV provides an alternative that minimizes risk to workers.

CAROL^TM was recently used at a commercial facility for the first time. At an LNG Plant in Australia CAROL was successfully used to remove more than 1750 cubic feet of molecular sieve catalyst from a dehydration bed under inert conditions. The unloading was completed without requiring manned entry until the vessel was opened to air, achieving a catalyst unloading rate of up to 240 cubic feet per hour.

The initial unloading with CAROL^TM exceeded expectations. Because of this the work scope was increased. As a result unloading time was significantly reduced compared to previous turnarounds.

This presentation showcases the challenges associated with current catalyst removal techniques, and the inherent safety advantages that CAROL^TM has shown. The presentation includes video of the test vehicle operating characteristics and discussion on industry acceptance progress, preliminary test results and lessons learned.