Catalyst Chage Operation

GBH Enterprises, Ltd.
VULCAN VGP Series Purification

Catalyst / Adsorbents Operating Manual
Process Information Disclaimer
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the Product for
its own particular purpose. GBHE gives no warranty as to the fitness of the
Product for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability for loss, damage or personnel injury
caused or resulting from reliance on this information. Freedom under Patent,
Copyright and Designs cannot be assumed.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
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Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Contents
Section
1
Introduction
Process design and modification considerations
Health and Safety precautions
VULCAN VGP CATALYST containers and storage
VULCAN VGP CATALYST handling
VULCAN VGP CATALYST charging / loading
VULCAN VGP CATALYST discharge
Vessel entry
System start-up / Shutdown / Standby / Upsets
10
General considerations for liquid and gaseous systems
11
VULCAN VGP Sulfur guards
12
VULCAN VGP Mercury guards
13
VULCAN VGP Chloride guards
14
VULCAN VGP Arsine and other guards
15
VULCAN VGP Reduced materials
16
Reclamation or disposal of used absorbent
17
Treatment options with VULCAN VGP Series Catalyst Materials
Introduction
GBH Enterprises (GBHE) provide VULCAN VGP Series catalysts and

Absorbents for a wide variety of different applications in many industries.
There are a number of reasons why gas/liquid streams require purification. For
example, sulfur and chlorine compounds are particularly severe poisons for
nickel, iron and copper catalysts used in refinery applications, so their removal
using VULCAN VGP Series catalysts and Absorbents can prevent catalyst and
plant degradation.
Mercury and sulfur levels can be significant in raw gas feedstock, and need to be
reduced in order to meet tight sales gas specifications. VULCAN VGP Series
catalysts and Absorbents products can reduce these contaminants down to parts
per billion (ppbv) levels.
Hydrogen sulfide (H2S) and carbonyl sulfide (COS) removal from CO2 streams is
another area in which VULCAN VGP Series catalysts and Absorbents are well
proven.
VULCAN VGP Series catalysts and Absorbents products provide purification of
process streams using a well-established fixed-bed technology. The flexibility of
VULCAN VGP Series catalysts and Absorbents means that they can be effective
over a range of temperatures and pressures; they can be used in plants with
changing throughput for applications on-shore or off-shore.
This manual discusses how to handle and operate the VULCAN VGP Series
catalysts and Absorbents, for use in gas and liquid streams, in order to achieve
the optimum performance. Every VULCAN VGP Series catalysts and
Absorbents application is different, and the product selected is tailor made for
each situation. It is important to discuss any proposed changes with the GBHE
Technical Sales Manager, to prevent loss of product efficiency.
Every care is taken to make sure that all absorbents which are produced by
Haiso Technology Co., Ltd. leave our manufacturing site, and are transported
to the final destination, in the best possible condition. However, to get the best
service from any absorbent it must be handled and operated correctly after the
time it arrives at the users site. This means that the absorbent should be subject
to proper storage, charging and commissioning procedures and should be
correctly operated once the plant is on line.
Absorbent handling should be done with care and considered in detail at an early
stage. This will ensure that all equipment is available so that proper and safe
procedures can be followed. Guidance is provided in this document which will
allow the development of local operating procedures to ensure the safety of
operators during VULCAN VGP Series catalysts and Absorbents charging and
discharging operations.
Process operating instructions should also be developed before commissioning
of the VULCAN VGP Series catalysts and Absorbents and these should cover
the start-up, normal operation, shut-down and emergency procedures associated
with the use of VULCAN VGP Series catalysts and Absorbents products.
It is strongly recommended that the normal operating boundaries of the
VULCAN VGP Series catalysts and Absorbents are detailed and reviewed with
GBHE before commissioning of any VULCAN VGP Series catalysts and
Absorbents products. It is vital that any modifications to these operating
boundaries are discussed with GBHE before any changes to process operating
conditions are made on the plant. Failure to carefully review process
modifications may result in a loss of process efficiency and could cause a range
SHE issues.
2. PROCESS DESIGN AND MODIFICATION CONSIDERATIONS

VULCAN VGP Series catalysts and Absorbents are by their very nature active
materials. They remove small quantities of contaminants from a wide variety of
liquid and gas streams, with high efficiency and effectiveness. As a result of their
high activity, they are sensitive to changes in the composition of the process
stream.
At the project design stage it is therefore vital to consider any unusual or upset
process conditions as well as the normal operating conditions. Any major
differences in process conditions that could occur during start-up, shutdown, or
mal-operating conditions should be discussed with GBHE before commissioning.
On most new plants and many retrofits, a HAZOP, or Hazard and Operability
study will be carried out. GBHE recommend that the use of a Hazard and
Operability study is considered and that the VULCAN VGP Series catalysts and
Absorbents are only installed following the development of local operating
procedures.
It is particularly important that any possible interactions of the VULCAN VGP
Series catalysts and Absorbent reactors with all other units within the process
flowsheet are reviewed.
For sulfided materials the possible ingress of air (or pure oxygen) to the
VULCAN VGP Series catalysts and Absorbent reactors during trip situations on
other units is of particular importance. This situation should be avoided.
Furthermore, during the Hazard and Operability study it should be noted that the
VULCAN VGP Series catalysts and Absorbent may be chemically distinct in their
fresh and in their spent state and the absorbents may therefore be sensitive to
different components in the process stream at different stages of their life.
The various VULCAN VGP Series catalysts and Absorbents are sensitive to
different contaminants and GBHE will choose the most suitable VULCAN VGP
Series catalysts and Absorbents for each project based on an understanding of
the nature of the contaminants in each process stream.
Contaminants or components of particular interest are:

Hydrogen
Oxygen
Carbon monoxide
Unsaturated hydrocarbons
Aromatic hydrocarbons
Sulfur compounds ( H2S, COS, SO2, RSH, R2S, CS2)
Halogen compounds (HF, HCl, Cl2, RCl )
Nitrogen compounds ( NOX, NH3, HCN, Organo N )
Mercury
Metals
Arsine / Phosphine / Metal Carbonyls
The more detail that can be given about the gas composition the better.
GBHE will also need to consider the possibility of solid or liquid carry over into
the VULCAN VGP Series catalysts and Absorbent reactor and any significant
temperature and pressure changes which may be experienced during operation
of the absorbents. Therefore, at the design stage a detailed composition of the
normal running process stream should be supplied to GBHE and as much
information as is available about unusual operating conditions should also be
made available.
Process modifications
A distinctive and discrete design will be prepared for each VULCAN VGP Series
catalysts and Absorbent application. The choice of absorbent will be made to
provide the user with the most economically attractive purification process and to
ensure that the VULCAN VGP Series catalysts and Absorbents produces no
unexpected SHE hazards during loading, beneficial operation and unloading.
However, both the efficiency of the VULCAN VGP Series catalysts and
Absorbents and the SHE risk analysis associated with the use of the absorbent
can be compromised by uncontrolled process modifications.
During the design stage of the project GBHE should be made aware of as wide a
range as possible of likely operating conditions including those which could be
experienced during start-up, shutdown and emergency operations.
If any change to these conditions is expected to occur while the VULCAN VGP
Series catalysts and Absorbents on-line then GBHE should be made aware of
these changes before the modification is implemented.
The range of modifications which should be reviewed with GBHE includes, but is
not limited to:
- Impurity concentrations
- Operating pressures
- Temperatures
- Viscosity
- Flow rates
- Changes to the source of the process stream
- Changes to the levels of contaminants such as oxygen, hydrogen, carbon
monoxide, unsaturated hydrocarbons, Sulfur species and ammonia.
- The design conditions should also be confirmed against the actual operating
conditions to ensure that the bed is not exposed to unexpected challenges.
Other considerations that should be included at the design stage or as part of a

modification are:
-
Provision of suitable non-isolatable pressure relief systems

Isolation of vessels for maintenance and bed change out (Double block
and bleeds are the usual standard for vessel entry)
Access for change outs
Sample points and monitoring systems
Process control and analytical systems to achieve required outlet
specification
Provision of purge points and venting systems
Pipe layout
Fouling rates / liquid carry over
Provision of filters
Single phase or 2 phase / Dense phase operation
Up or down flow in the case of liquid treaters
Provision of hard standing areas for absorbent changeouts
Selection of absorbent loading system
Vessel inspection requirements
Corrosion rates
Impact of other unit operations
Examples of different modes of operation

VULCAN VGP Series catalyst and Absorbent purification beds can be arranged
in numerous different combinations, depending on the stream and the target
contaminant.
Single beds
Lead lag beds
Parallel beds
Process control
Pressure drop minimization
Phased installation
Beds used in combination with other processes
Vessel drawings
Vessel drawing of 2 or 3 typical vessels showing details of standard collector and
distributor arrangements.
Note, the collectors and distributors are individually sized for each case.
It is important to ensure that the ceramic support balls are larger than the slots or
holes in the collector
Monitoring of beds
It is recommended that the beds are monitored on a regular basis to assess
ongoing operational performance
Many plants have DCS type systems which record process flows,
temperatures and pressures but there are other variables which should
also be recorded.
A typical list would include:
- Inlet impurity concentration
- Outlet impurity concentration
- Pressure drop
- Flow rate (Typical, average and peak)
- Temperature
- Pressure
- Any changes in stream composition
- Any operational issues
- Bed status lead / lag, parallel, bypass etc.
This information is very useful if there are any issues with the bed as it allows a
picture to be built up of the operation over an extended period.
It is very helpful if these records can be forwarded to the relevant GBHE contact
person as it is the best way of improving the understanding of the particular
process stream and operation.
Health, Safety and Environmental Precautions
3.1
Working Practice Guidelines
Operators should be aware of the hazards associated with the use of absorbents
and draw up the appropriate safety measures.
The Material Safety Data Sheet supplied by GBHE should be consulted for
information on specific absorbents.
The key areas to address include, but are not limited, to:
3.1.1 Training
All personnel involved in absorbent handling should be instructed in the potential
occupational health and safety hazards associated with both fresh and used
absorbent, and the appropriate precautions to be taken.
3.1.2 Site Preparation

The absorbent handling area should be roped off to exclude unauthorized
personnel. The restricted area may have to be adjusted, depending on the wind
strength and direction. Provision will have to be made for the access of forklift
vehicles and dust extraction equipment etc. where necessary.
3.1.3 Ergonomics & Personal Protective Equipment

Physical hazards arise from the handling of drums, materials and lifting
equipment. Personnel should be aware of these, and appropriate precautions
taken.
Personnel working with the absorbent loading, unloading, screening, sealing
drums, cleaning up spills etc. should wear protective overalls, goggles, hard hat,
gloves, boots and appropriate dust masks.
3.2
Dust Control
It is essential to control the inhalation of absorbent dust to levels below the

appropriate occupational health exposure limits. Engineering methods should be
employed as the primary means of controlling exposure to dust whenever this is
reasonably practicable. If dust cannot be controlled to safe levels, suitable
approved respiratory protection must be worn.
All the activities involving absorbent dust must be assessed to gather information
about health hazards, to evaluate the risks and to specify controls.
The hazards associated with absorbents depend on the composition of the
absorbent, and the Material Safety Data Sheets provided by GBHE should
always be consulted. The potential short and long term health effects are
described in these data sheets. It should be noted that the Material Safety Data
Sheets apply to the unused absorbents. Absorbents discharged after use will
usually have different physical and chemical properties and these properties will
vary with the plant operating conditions.
3.2.1 Dust Masks

The type of respiratory protection to be worn depends on the dust levels
generated, and the exposure limits for the materials involved. However,
experience suggests that personnel involved in charging and discharging
operations inside a vessel should wear approved full-face air supplied breathing
apparatus. If there is a danger of loss of consciousness or asphyxiation,
powered respirators with high efficiency filters must be used. It is preferable to
use positive pressure rather than demand systems.
Personnel involved in other activities such as the screening of absorbents, filling
socks and cleaning up spillages are advised to wear suitable dust masks. The
maintenance of equipment that has contained catalyst/absorbent may also
necessitate the wearing of suitable dust masks. All personnel required to wear
respiratory protection should be instructed in its proper use, and limitations.
A DUST MASK IS NOT A BREATHING APPARATUS AND MUST NOT BE
USED AS PROTECTION AGAINST TOXIC GASES, OR IN AN ATMOSPHERE
DEFICIENT IN OXYGEN ( <19.5%).
3.2.2 Monitoring
Periodic air monitoring can be carried out to determine personal exposure levels
to airborne dust. These monitoring results can be used to assess the
effectiveness of the dust control measures and respiratory protection. An
assessment of the performance of any local exhaust ventilation that is installed
should be carried out.
Monitoring should also be considered for other fugitive emissions and releases
such as hydrocarbons, aromatics, mercury vapor or any other contaminants of
the process stream.
If an issue is identified, the work should be stopped until a safe way forward has
been agreed amongst the parties involved
3.2.3 Housekeeping
All absorbent spillages should be cleaned up promptly using methods that do not
produce airborne dust e.g. with a vacuum cleaner with a high efficiency filter, or
by wet mopping. Dry sweeping should be avoided.
All sweepings and other debris should be disposed of in a suitable way. They
should not go into the domestic waste.
3.2.4 Personal Hygiene

To prevent the ingestion of absorbent dust, no eating, drinking or smoking should
be allowed in the absorbent handling area.
Personnel working with absorbents should practice good personal hygiene and
wash their hands and faces prior to eating, drinking or smoking, and washing
hands before using toilet facilities.
3.3
First Aid Measures
In the event of direct exposure to absorbents, the following first aid measures
should be taken:
Eye Contact - flush the eyes with clean water for at least 15 minutes. If any
irritation persists, medical attention should be obtained.
Skin Contact - wash off immediately using soap and water.
Ingestion - obtain medical attention. Give 250 ml of water to drink. DO NOT
give anything to an unconscious person. Do not induce vomiting.
See Material Safety Data Sheet for the specific recommendations for particular
products.
Check suitability of these generalized first aid measures
3.4
Entry into Inert Gas Atmospheres
Operators should never enter an absorbent vessel filled with an inert gas unless
they are fully trained in inert entry procedures.
Without an approved breathing apparatus, the operator would lose
consciousness within a few seconds and die soon afterwards. There have been
a number of double fatalities when somebody outside a nitrogen filled vessel has
entered without breathing apparatus, to assist a colleague already in difficulties.
Even looking closely into the open manhole of a nitrogen filled vessel can be very
dangerous without approved breathing apparatus.
Openings into a vessel blanketed with inert gas should be kept closed, except
when work is going on inside, and there should be prominent warning notices to
alert everyone to the potential hazard. All personnel working in the area should
be made aware of the nature and dangers of asphyxia, and should know how to
attempt the rescue and resuscitation of anybody who may be overcome.
If entry into a nitrogen filled vessel is unavoidable, it is essential to use a fully
integrated life support system with adequate back up. There are a number of
specialized companies that have teams of fully trained staff available for this type
of work.
See also diagram and references in section 8

3.5
Discharge of catalyst/absorbent
It is important to note that spent material may be contaminated with process fluid
as well as any debris/contamination that has accumulated on the bed.
The spent absorbent will also be chemically different from fresh material, so
different handling precautions will be required.
Issues associated with particular absorbents are detailed in the discharge section
and the safety data sheet.
3.6
Discharge of Self-heating Absorbents
Some VULCAN VGP Series catalyst and absorbents will be discharged in a

self-heating state.
In these cases the effect of oxidation on the absorbent can cause a significant
temperature rise.
There are 2 main potential causes of this,
3.6.1 Sulfided material

Some sulfided materials may react with air to produce heat. In extreme cases,
some decomposition may occur, releasing SO2.
It is essential that the discharged absorbent is kept separate from flammable
materials.
The material should be discharged into approved UN drums so that it can be
shipped to a reprocessing facility as a self-heating material.
Appropriate local regulations should be adhered to for this activity.
3.6.2 Reduced material

Some reduced materials may react with air to produce heat. In these cases local
stabilization/re-oxidization of the material may be possible.
It is essential that the discharged catalyst is kept separate from flammable
materials. Transport of such absorbent should be in enclosed metal skips or
enclosed metal-sided trucks. Dumps of the absorbent should be within easy
reach of water hoses so that any overheating that occurs can be controlled.
High temperatures can build up in heaps and it may be a prudent precaution to
spread the absorbent thinly over the ground until oxidation is complete.
This should be done in a banded area, to prevent any contaminated water going
to drain. Under no circumstances should personnel be allowed to walk over the
absorbent until it has been fully stabilized.
3.7
Discharged Spent Sulfur Absorbents
The discharged absorbent contains sulfides and should not be stored near acids.
Accidental contact of the spent absorbent and acid would result in the evolution
of hydrogen sulfide (H2S).
Similarly, accidental mixing of sulfided material with oxidizing agents could result
in release of SO2
3.8
Discharged Spent Chloride Guards
As with discharged sulfur guards, spent chloride guards should not be stored
near acids or oxidizing agents, as accidental mixing could result in the release of
HCl.
3.9
Ancillary Equipment
For some applications, filters may be installed, either on the process stream or as
part of the vacuum handling system. Due care should be taken when changing
filters as dust contamination can be a source of self-heating. Used filter bags
should be put into a sealed metal container, for disposal.
3.10
Environmental precautions
Care should be taken to ensure that fresh or spent absorbents do not enter the
environment.
It is particularly important to note that sulfided absorbents oxidise to sulphates in
air. Sulphates are much more soluble than sulfides and will readily enter water
systems. Some absorbents contain components which are significant marine
pollutants if discharged to water system and may affect fish or effluent treatment
facilities
For further information contact your local GBHE representative or:
4. VULCAN VGP SERIES CATALYST CONTAINERS AND STORAGE

Drums
GBHE most commonly supplies VULCAN VGP Series catalyst and absorbents
in steel drums with polythene liners. The drums can be banded on pallets to
allow easier movement. The full drums weigh between 80 and 250kg (175 and
550lb) depending on the density of the product. The absorbent drums should be
inspected on arrival on site for damage, so that any insurance claim can be
substantiated.
Drums should not be stacked on their sides, or stacked more than four drums
high, even when supported on pallets. Taller stacks tend to be unstable, and the
lower drums can be crushed. If the drums are to be stored on site, they should
be kept under cover and away from damp walls and floors. The lids should be
left on until just before the absorbent is to be charged. If lids are removed for any
reason, e.g. to permit inspection, they should be replaced as soon as possible to
prevent any contamination of the absorbent.
Figure 1. Stacked drums on pallets in a 40 CT Container
IBCs
GBHE absorbents can also be supplied in VULCAN Box containers on pallets.
Typically, an VulcanBox will contain about 1m3 (35ft3) of absorbent.
The absorbent is actually stored within the VULCAN Box in a Flexible
Intermediate Bulk Container (FIBC or, commonly, a big-bagor supersac)
which allows easy handling of the absorbent during lifting and transferring
operations. If absorbents are supplied in VULCAN Boxs then time can be
saved by avoiding the handling of a large number of drums during a shut-down
period. VULCAN VGP Series catalyst and absorbents can be stored for long
periods in VULCAN Boxs, provided they are suitably protected. Indoor storage
is preferable.
Figure 2 : Picture of VULCAN Box
By special arrangement some absorbents can also be supplied in big bags

without a VULCAN Box, 2m3 IBC hoppers or 25m3 bulk containers.
Unless otherwise stated, GBH Enterprises VULCAN VGP Series Catalyst and
Absorbents are not affected by extremes of temperature from -50C to +50C (60F to +120F) provided that they are kept dry. In extremely humid conditions it
may be necessary to store the absorbents in an air-conditioned building. Prereduced absorbents can overheat at temperatures above 100C (212F) and
should therefore be stored below 50C (122F).
These materials should be kept out of direct sunlight, away from other sources of
heat and away from combustible materials.
Consideration should be given to the storage of other chemicals in the same area
as GBHE VULCAN Series catalyst and absorbents.
It is particularly important that acids are not stored in the presence of sulfided
materials, as accidental mixing could release toxic H2S.
Oxidizing agents may cause the release of SO2
Similarly, spent chloride guards should not be mixed with acids or oxidizing
agents as this may cause the release of HCl
Detailed information regarding product hazards are contained in the Material

Safety Data Sheets.
5. VULCAN VGP SERIES CATALYST HANDLING

Drum handling
VULCAN VGP Series Catalyst drums are supplied on pallets for ease of
handling and to reduce the likelihood of damage in transit. A suitable fork-lift
truck and a paved area are required to move the pallets.
The fork-lift truck to be used for dismantling the pallets
should be fitted with rim or body clamps to avoid
damage to the drums. Standard fork-lift trucks must
not be used to lift individual drums under the rolling
hoops, as this inevitably damages the drums and
absorbent.
VULCAN VGP Series Catalyst drums should be handled as carefully as possible.
If a mobile crane or suitable equipped fork-lift truck is to be used, a smooth
paved area is desirable to facilitate movement.
When drums are to be lifted to the charging manhole, it is usually more
satisfactory to use a mobile crane rather than the individual lifting beam on the
vessel. A crane can lift drums from a wide area, and this avoids multiple
handling.
Drums must not be rolled. If manhandling is unavoidable, suitable drum barrows,
upending levers and skids should be used.
More importantly, proper equipment is essential for the safety of the operators
particularly when larger or heavier drums are involved.
VULCAN Box / Big Bag handling
Big bags, also known as IBCs, typically contain 1m3 of absorbent. As a result
they weigh around 1 tonne, and need to be moved by a suitable forklift truck.
When the bags are being lifted to the top of the vessel for loading, spreader bars
or extended hooks are required. If all 4 loops of the bag were fitted into a single
crane hook, this applies excessive force on the bag which may result in a split
bag.
Use of Cranes
If a crane is to be used for catalyst/absorbent loading an appropriate lifting study
should be carried out.
Although these are not particularly big lifts, there can be a large number of small
lifts in a short period of time.
Use of forklift trucks
Where forklift trucks are used, the work
area should be cordoned off.
For some sites, all terrain forklift trucks are
required; otherwise a smooth paved area is
preferable for the handling of drums and
IBCs.
The zoning restrictions and control of
sources of ignition in the work area should
also be considered. It may be necessary to
use diesel fork trucks, or fork trucks with
flame arrestors in some process areas.
Other equipment, such as tractor units for articulated lorries may need to operate
under hot work permits.
Control of work and risk assessments.

Handling and loading operations should be controlled by local work permit
systems.
Where appropriate, a risk assessment may be required. This operating manual
should answer most of the questions raised by a risk assessment, but if there are
further questions, GBHE should be contacted to ensure that all issues are
resolved.
6. VULCAN VGP SERIES CATALYST CHARGING / LOADING

6.1 Pre-charging Checks
Before the VULCAN VGP SERIES CATALYST absorbent is charged, it is
important to check the internal condition of the vessel. ln particular, checks
should be made on the condition of the exit distributor, the absorbent support grid
and any inert support material such as ceramic balls. Faults at these points
cannot easily be rectified after the absorbent has been charged.
If there has been any evidence of high pressure drop,
or any operating problems, it may be worth removing
any ceramic balls from the vessel head to remove any
dust or scale. Dust accumulations in the ceramic balls
can significantly raise the pressure drop across a
vessel.
The vessel should be clean, dry and free from loose
scale and debris. It is important that the charging level
is clearly defined to make sure that the correct volume
of absorbent is charged. The required final level can
be marked with chalk, before charging is started.
A useful additional check can be made at this time by
warming up any thermocouples, to make sure that the
expected indication is being given on the control
panel, and to check that any sample points are clear
and undamaged.
For vessels where a long bed life is expected, it is also worth checking that any
vessel inspections are up to date, and doing any statutory internal inspections
that are required while the vessel is empty.
Some form of light metal grid or spider should be inserted into the discharge
manhole to prevent inadvertent absorbent discharge when the manhole cover is
eventually removed for discharging the vessel.
The manhole should be securely tightened before the vessel is loaded, although
it may not be necessary to fit all the bolts at this stage.
6.2 Charging Vessels
6.2.1 General Issues

A layer of heavy inert material (ceramic lumps or balls) or sometimes metal hold
down grids should be placed on top of the absorbent, to prevent movement of the
absorbent pellets by the incoming gases.
A layer of inert material can be
useful in trapping
contaminants in the gas before
they reach the absorbents.
VULCAN Series Catalyst and Absorbents Reactor Loading

Grading Material Loading Diagram
ID = 7' 0"
design
actual
design
Dist Tray
The VULCAN Series A ST

range of materials provides
particularly good performance
on those duties where
occasional fouling may be an
issue.
26 ft3
active support, high void cylinder 16 mm
active support, hollow cylinder
catalyst
catalyst
19 ft3
active support, ball
6.4 mm
1/10"
actual
8'
Baskets are out
9'
9'
9'8"
9'8"
13'2"
12'
8"
2'4"
2'6"
1/10"
7"
14'10"
15'1"
8.0 mm
6"
15'4"
15'5"
Supp. Grid
15'8"
Top of Supp. Grid

Filled up dump chute
Quench
w ith 1/8" support
Collector tray
Most absorbents produce

some dust during the charging
process. Therefore, suitably
approved full-face air supplied
breathing apparatus, or
powered respirators, with high
efficiency filters must be
provided for all operators
entering the vessel.
Internals between the

two beds are to be
Perforate tray
Dist Tray
19 ft3
active support, high void cylinder 16 mm
21'4"
21'4"
Support beams extend 6"
21'10"
21'10"
to 8" below tray.
6"
22'4"
22'4"
19 ft3
6.4 mm
6"
22'10"
23'3"
19 ft3
4.8 mm
6"
23'4"
23'4"
272 ft3
catalyst
30'5"
30'3"
19 ft3
active support, ball
10 ft3
support balls
1/10"
8.0 mm
1/2"
Elephant stool
85"
6"
30'8"
30'9"
Top of stool
31'8"
31'11"
Btm of stool
Bottom dump chutes w ere packed w ith kaow ool
Sphere 8.0 is the metric size

Gear/Water w heel shape 16 is the metric size
Hollow cylinder 6.4 and 4.8 are the metric sizes
Trilobe
Protection against dust is particularly important if the absorbent has any toxic
properties.
It is essential that the atmosphere in a vessel is checked before allowing entry.
There are two important general rules for charging VULCAN VGP Series
Catalyst absorbents into vessels:
The absorbents must not have a free fall of more than 50- 100 cm (20 - 40
inches).
The absorbent must be distributed evenly as possible as the bed is filled.

The distance that an absorbent pellet can fall without serious damage depends
on its strength and shape. A hard spherical granule will withstand a fall better
than a soft angular pellet or extrudate. Recent work indicates that some
absorbents can be charged satisfactorily using a pneumatic conveyor, and this
technique can shorten the charging time substantially.
Generally, the absorbents and catalysts should be loaded via suitable hoppers
and a loading sock. The materials should not be loaded via a vacuum system as
this may lead to significant deterioration of the absorbent.
In some cases, vacuum loading has been used, but use of this option should be
discussed with GBHE before loading commences.
6.2.2 Loading procedures

The absorbent must not be poured into the vessel at one spot, even if the
resultant heap is raked level. This is because the particles tend to segregate as
shown in Figure 3. Any small particles and dust stay mainly in the centre of the
heap, while large pieces roll to the edges. This can lead to uneven distribution of
the gas flow during plant operation.
Care should be taken to ensure that the top of the absorbent bed is level after
charging has been completed. If the bed is wide, and access is through a side
manhole it can be difficult to get the absorbent distributed across the vessel
without raking. However, raking is generally undesirable as it can lead to a
concentration of fines near the manhole.
Figure 3: Particle Segregation during Charging
In practice, this type of maldistribution is most likely when the absorbent has
been allowed to fall into one spot just beneath the charging manhole. This type of
problem can occur also when operators walk on the absorbent bed, or vibrate it
unevenly. When it is necessary to walk on the absorbent bed, the load should be
spread as much as possible by using charging boards on top of the absorbent.
The following equipment is required for manual absorbent charging:
1
Safe access to charging manhole - side or top as appropriate.
Crane, or local lifting beam, with suitable hoist.
Metal hopper or tundish plus section of flexible plastic tubing for top entry
manhole.
Canvas or plastic sock and rope - both of sufficient length to stretch from
the charging manhole to the lowest level of the absorbent.
MANUAL ABSORBENT LOADING

For outdoor installations it is recommended that manual absorbent charging is
not carried out in heavy rain or high winds. The performance of the absorbent is
not hindered by small amounts of water entering the reactor during absorbent
charging. It is recommended that temporary weather protection is provided
around the charging manhole.
A hopper/tundish is usually supported above the charging manhole. The loading
procedure should insist on the hopper/tundish being supported 1 m above the
manhole to allow viewing access to the reactor. This can typically be done using
temporary scaffolding.
Ensure the absorbent support system has been installed as defined in the
mechanical data sheet. This may require insertion of a wire mesh grid, ceramic
balls or absorbent support material - see section 'Reactor Preparation'. Ensure
the absorbent support system is horizontal and the top surface is free of debris.
The absorbent charging procedure is as follows:
Empty the absorbent into the hopper or tundish and fill the sock with absorbent.
The absorbent will flow into the reactor in a controlled manner. The rope
attached to the free end of the canvas sock can be used to guide the sock so that
it does not always discharge at the same point. As the level of the absorbent bed
rises towards the free end of the absorbent sock, the reactor filling rate will be
reduced. When this is observed the sock should be emptied of absorbent and
shortened. This is most easily done by raising the free end of the sock with the
rope and cutting 1 m off the sock with a knife.
When the absorbents have been charged to the correct height, the absorbent
surface should be levelled using care. The ceramic ball loading should then be
loaded as defined in the reactor mechanical data sheet.
On completion of absorbent and ceramic ball loading, replace the charging
manhole cover.
If there is any delay during absorbent charging, the reactor manholes should be
securely covered to prevent the ingress of water or other absorbent contaminants
from the air.
Once the reactor is boxed-up and mechanically complete GBHErecommend
maintaining the reactor at pressure under an inert gas to prevent ingress of
potential absorbent contaminants - see section 'System Startup/Shutdown/Standby/Upsets'.
A deep narrow bed is the easiest shape to charge satisfactorily, as irregularities
are more likely to be evened out along the direction of the gas flow. Extra care is
required with wide beds because it is more difficult to distribute the absorbent
evenly over a large area. Radial flow beds are particularly susceptible to irregular
packing and uneven gas flow.
6.2.3 Loading Problems

Uneven packing of the absorbent and breakage during charging can seriously
affect the gas distribution and the effectiveness of the absorbent bed. The
degree of packing in the absorbent bed has a marked effect on the voidage.
Even in a bed of regular pellets, the voidage can vary by +/-10%. If the particles
are not all the same size, then the voidage variations can be considerably
greater. The effect of packing on pressure drop is very marked.
To a first approximation the pressure drop is inversely proportional to the cube of

the voidage and a +/-10% variation in voidage can result in a +/-30% variation in
pressure drop. Furthermore, it is possible that a loosely packed bed will settle in
use and the pressure drop may increase by up to 50% as this occurs.
The effect of packing variations on the distribution of gas flow is more
pronounced at low flow rates, because the flow becomes less turbulent, although
the performance of the absorbent at low flow rates (when the inlet flow rate of
contaminant is likely to be lower than the design value) may be less critical.
VULCAN VGP SERIES CATALYST Discharge
Drawings of typical arrangements to be included in these sections

Introduction
The safe discharge of absorbent can be the most challenging phase in the life
cycle of a bed.
The absorbent will have changed its chemical composition, will be saturated in
the process fluid and may have picked up other significant contaminants.
As a result, this activity should be carefully considered and subjected to
appropriate risk assessments
Contamination
Depending on the duty, other contaminants may have accumulated on the bed.
These can include, mercury, aromatic hydrocarbons, oils, wax, metals, and iron
sulfide among others.
These contaminants can site or duty specific and will vary from case to case.
Where necessary the bed should be sampled before discharge to ensure that
appropriate PPE is worn.
Where this is not possible, a higher level of PPE may be required for the job to
ensure that the operators are not exposed to unacceptable levels of potentially
harmful compounds.
In such cases a COSHH (control of substances hazardous to health) assessment
may be appropriate.
In general, the hazards associated with contamination of the bed will be similar to
the hazards associated with a normal break in to the process lines. However,
because of the high surface area of the absorbent, the concentrations may be
higher than have been seen elsewhere in the process.
Self Heating Materials.

Materials which are either supplied in the sulfided form, or become sulfided in
use can be self heating on discharge.
In these cases the material should be
discharged under nitrogen.
Appropriate precautions for monitoring the
nitrogen content of the work are and the
provision of breathing apparatus should be
considered.
In some duties it is also possible for pyrophoric iron to accumulate on the top of
the bed. This is scale which has become sulfided, broken off the inside of the
pipe and washed down onto the bed
Non-self heating materials
Materials for the removal of chlorides are not generally self heating and do not
usually need to be discharged under nitrogen once the vessel has been
thoroughly purged
There are three ways of discharging absorbent from a reactor:

-
By gravity
By vacuum
Manually
Before discharge
The following precautions should be taken before discharging the absorbent:
1
Ensure the reactor is isolated and purged with nitrogen for a suitable period.
This reduces the quantity of any adsorbed hydrocarbons on the absorbent and
eliminates potential for forming an explosive mixture with air. Purging is best
achieved by repeated pressurisation and depressurisation.
It is recommended that the nitrogen specification should include a clause for an
oxygen level of less than 0.1% (mol).
Experience of VULCAN VGP Series Catalyst materials has shown that

pyrophoric iron sulfide can accumulate in the bed from the process due to the
long life of the absorbent.
Furthermore, the spent absorbents are themselves deemed liable to self heating
in contact with air therefore DO NOT PURGE WITH AIR. Given enough oxygen
and enough time the copper sulfide within the spent material will eventually
oxidise giving off heat.
The discharged absorbent should be sealed in the drums, to avoid ingress of air.
Although the spent VULCAN VGP Series Catalyst material is not in itself
pyrophoric, it is still recommended to handle it under inert conditions. Any inert
entries into vessels must be undertaken with breathing apparatus and all
appropriate precautions.
See section 'Absorbent Handling' for absorbent handling precautions.
See section 'Reactor Entry' if reactor entry is required.
7.1
ABSORBENT DISCHARGING USING GRAVITY
The vessel should be under a nitrogen purge to prevent ingress of excessive

amounts of air. As a result, operators working in the vicinity should be protected
with appropriate PPE.
Gravity discharge is the most common method. Manual discharge is usually only
used as a last resort for small or part absorbent reactor volumes.
In this particular case, the reactor is designed with a conical section in the
bottom. This should allow complete absorbent discharge into the spent absorbent
handling system.
If there is sufficient headroom under the vessel, it may be possible to discharge
direct into drums using a conventional double headed drum filling unit.
If there is not sufficient room, it may be necessary to install a vacuum unit to
transport the material to the area where it will be drummed up.
The following equipment is required:
1
Container(s) for 'used' absorbent - empty metal drums

2
Tundish
Either plastic chutes/tubing or specialist vacuum equipment.
Drumming unit with dust extraction
Set-up the absorbent discharging equipment - see figure for typical arrangement.
A slip plate fitted in the discharge chute can control the rate of absorbent
discharge.
When the majority of the absorbent is discharged it may be necessary to remove

the following by hand or with specialised vacuum equipment :
1
2
Any remaining absorbent.
Ceramic balls plus associated wire mesh (if present) which were originally on top
of the absorbent. Ceramic balls can be reused if their condition is satisfactory.
The side manhole should be removed and any absorbent, which is against the
manhole, can be removed through the spider.
Rotate discharge manhole spider to control absorbent flow:
Spider webs horizontal - no absorbent discharge
Spider webs vertical - maximum absorbent discharge rate
7.2
ABSORBENT DISCHARGING USING VACUUM EQUIPMENT
Vacuum discharge may be carried out under nitrogen to avoid the risk of the
used absorbent self-heating. Alternatively, several discharges have been
successfully carried out with the vessels under nitrogen blanket, and air used as
the fluid carrier only.
The following equipment is required:
1
Safe access to the discharge manhole.
Specialised vacuum equipment with sufficient length of flexible plastic tubing to

reach the lowest level of absorbent. A long length of rope attached to the free
end of the tubing.
Container(s) for 'used' absorbent - may be combined with specialised vacuum

equipment, otherwise empty drums, or container.
Remove the discharge manhole cover.
Set-up the absorbent discharging equipment - see figure for typical arrangement.
Remove the ceramic balls that may be on top of the absorbent by hand and/or
specialised vacuum equipment.
Discharge absorbent using specialised vacuum equipment using rope(s) to

control flexible plastic tubing as necessary.
In certain circumstances it may be necessary or more convenient for an operator
to enter the reactor to direct the flexible plastic tubing of the vacuum equipment see section 'Reactor Entry'.
Since there is likely to be self-heating material present, a vacuum discharge is
likely to be the most appropriate option.
These operations should be carried out under inert conditions. It is possible to
recycle the inert gas back into the reactor if required, although this is a more
complex procedure.
VESSEL ENTRY
Drawings of typical arrangements to be included in these sections

Operators should never enter an absorbent vessel filled with an inert gas unless
they are fully trained in inert entry procedures.
Without an approved breathing apparatus, the operator would lose
consciousness within a few seconds and die soon afterwards. There have been
a number of double fatalities when somebody outside a nitrogen filled vessel has
entered without breathing apparatus, to assist a colleague already in difficulties.
Even looking closely into the open manhole of a nitrogen filled vessel can be very
dangerous without approved breathing apparatus.
Openings into a vessel blanketed with inert gas should be kept closed, except
when work is going on inside, and there should be prominent warning notices to
alert everyone to the potential hazard. All personnel working in the area should
be made aware of the nature and dangers of asphyxia, and should know how to
attempt the rescue and resuscitation of anybody who may be overcome.
If entry into a nitrogen filled vessel is unavoidable, it is essential to use a fully
integrated life support system with adequate back up. There are a number of
specialized companies that have teams of fully trained staff available for this type
of work.
Extreme caution must be exercised prior to reactor entry. Ensure that the permit
to enter the reactor has been issued and signed, confirming that the reactor is
positively isolated. If the reactor contains an inert (e.g. nitrogen) or toxic
atmosphere then operators should be protected by an integrated life support
system with an appropriate back up - specialist firms can be recommended by
GBHE C2PT.
If the reactor atmosphere is confirmed to be air and non-toxic GBHE
recommends that operators wear suitable protective clothing - body clothing,
gloves, goggles and dust mask. If there is the potential for absorbent dust
generation such as during absorbent loading or discharging then
GBHErecommends breathing sets. If breathing sets are used external back-up
operators should monitor operators within the reactor at all times with spare
breathing set(s) readily available.
Please note that spent absorbents may contain adsorbed combustible or toxic
components, which may not be completely removed during nitrogen purging. If
there is any doubt about the presence of adsorbed combustible or toxic
components GBHE recommends an inert gas entry using a specialist firm.
Points to consider before vessel entry:
Work permit / entry permit
Risk assessment
Rescue / Escape plan / Communication methods
Purging plan
Positive isolations line breaks or slip plates on all process and service
lines
Full isolation of electrical drives, heating, radioactive sources, stirrers etc.
Continuous atmosphere monitoring LEL, O2 concentration, concentration
of toxic compounds, temperature
Breathing apparatus
Harness / Lifelines
Lifting tripod and winch
Lighting
Suitable tools
Standby man
Rest periods and ongoing review of risk assessment
Training and instruction of personnel
Qualified / experienced personnel
If a vessel entry is to be carried out, additional PPE includes

Breathing apparatus
Safety harness
Rope or wire to allow operator to be lifted out if required
Tripod and winch
Disposable overalls
SYSTEM START-UP / SHUTDOWN / STANDBY / UPSETS
The following comments are prepared as recommendations for the operation of

the unit.
Operating companies should incorporate these recommendations as appropriate
into the overall plant procedures.
9.1
SYSTEM PURGING
The VULCAN VGP Series Catalyst process should be purged with nitrogen prior
to the introduction of process feed, prior to absorbent discharge or prior to
system maintenance.
GBHE recommend that the VULCAN VGP Series Catalyst process is initially
purged using a once through method followed by a number of repeated
pressurisations / depressurisations to achieve the desired purge specification.
Local instructions relating to the standard of purging should be followed, but
typically the purging process is continued until the outlet stream is below 5% of
the LEL (lower explosive limit)
9.2
SYSTEM STANDBY
Whenever the VULCAN VGP Series Catalyst process is not in use it should be
maintained at pressure with either the feed or an inert gas such as nitrogen so as
to prevent ingress of any contaminants from the atmosphere.
Dedicated pressure relief that cannot be isolated is required for each vessel.
For longer shutdowns (greater than one month) it is worth considering purging
the vessel with nitrogen so that it is ready for restart when required.
If the VULCAN VGP Series Catalyst process is connected to other high-pressure
systems it is necessary to ensure no ingress of contaminants from these sources
preferably with a positive isolation - slip plate or double block and bleed.
Suitable non-isolatable pressure relief is required for all isolated pressurised
systems.
9.3
SYSTEM START-UP
The VULCAN VGP Series Catalyst process should only be operated within the
agreed design conditions. If operation outside of these conditions is required,
GBHEshould be consulted for advice.
It is recommended that the system is pressurised at rates of not greater than 1
bar per minute below 10 barg and 10 bar per minute above 10 barg.
This normally achieved by the use of small bypass valves. More details are
included in the section describing vessel change over.
Fresh absorbent will contain some water adsorbed in the pores from the
atmosphere, which will be slowly released into the process fluid.
Sulfur guard Shutdown

SYSTEM SHUTDOWN
The H2S removal vessels should be depressurised at a rate not exceeding
10 bar/minute above 10 barg or 1 bar/minute below 10 barg.
The vessels should be purged with nitrogen until the purge gas is free of
hydrocarbon. A heated nitrogen stream may allow the purging to be completed
over a smaller time period. This should begin at the earliest stage that the
shutdown procedure allows and will enable any hydrocarbons, which may be
adsorbed onto the VULCAN VGP Series Catalyst, to vent off. During this period
the operator will regularly monitor the vessel for signs of hydrocarbons in the
purge stream.
The vessel will be kept under a nitrogen blanket during discharge.
9.5 UPSETS
The VULCAN VGP Series Catalyst process is very robust but care should be
taken to ensure that the process:
i
is not subjected to significant flow variations (> 30%) above maximum design,
which can cause deterioration in flow distribution.
ii
is not subjected to significant water or liquid carryover.
iii
is not subjected to undesirable poisons.
iv
is monitored regularly to allow a record of normal reactor performance to be builtup.
10
General considerations for liquid and gaseous systems

Brief descriptions of the main points to consider in the operation of VULCAN
VGP SERIES CATALYST beds, including:
Blow down
Isolations
Double block and bleed
Draining
Upflow / downflow
Purging
Filling liquid vessels
Gas locks
Connection to relief system
Different duties
Control flow on outlet valves to avoid JT cooling effects
VULCAN VGP SERIES CATALYST materials are used on both liquid and
gaseous streams for the removal of Sulfur compounds, chlorides, mercury and
arsine.
These duties are individually considered depending on the customers process
stream and the process conditions.
11
Sulfur guards
Although this section repeats information that is available in other sections, it is

included here to summarize the most important issues related to Sulfur guards
on a single prompt sheet.
If you dont read anything else,
read this if you have a Sulfur guard.
Sulfur guards
Sulfur guards are supplied as metal oxides and they react to form metal sulfides.
Sulfided materials will release H2S or SO2 on contact with acids or oxidising
agents
Self-heating, Air and oxygen

The absorbent will change from a metal oxide to a metal sulfide in use.
Metal sulfides are self-heating, i.e. they heat up if air or oxygen is blown through
them. Some absorbents are more self-heating than others
DO NOT purge the bed with air, or allow air / oxygen to pass through the bed at
any stage of the process operation.
Nitrogen for discharges
As the absorbent is self heating it should be discharged under nitrogen
The nitrogen used should be at least 99.9% pure.
Nitrogen from membrane units is unlikely to be of sufficiently high quality.
The hazards associated with working with nitrogen must also be considered to
ensure that operators are protected from any oxygen deficient atmosphere
Vessel entry
Vessel entry into an inert atmosphere should be avoided if at all possible
If this is not possible, full breathing apparatus will be need, a full vessel entry and
rescue plan should be prepared and the local work control procedures should be
followed.
Metal containers
As the spent material is self heating it should be discharged into suitable metal
containers and sealed.
Seal able UN drums or approved seal able IBCs are usually used
Transportation
Spent absorbent should be shipped to a suitable disposal site in accordance with
local shipping regulations.
These self heating materials would normally be orange list and are subject to
UN shipping regulations and transfrontier shipping regulations
MSDSs
Discharged material must be shipped under an MSDS which represents the
material itself. GBHE can assist in the analysis of the discharged material so that
an appropriate MSDS can be prepared.
Small samples can be sent by DHL, Federal express and similar companies who
are familiar with the shipment of samples.
Generic MSDSs can be supplied for the shipment of samples to GBHE for
analysis.
Disposal
Spent absorbent should be disposed of at a suitable outlet. Different regulations
apply to different products and a number of different options are available.
Contamination
It is important to note that beds may also be contaminated with other impurities
such as mercury or benzene that are present in the stream in small quantities
Other contaminants or foulants in the stream can adversely affect the

performance of the material
PPE
Recommended personal protective equipment for handling fresh material
includes:
Suitable dust masks, Overalls, Gloves, Safety glasses, Safety boots
For discharges the level of PPE required will be determined by the extent of
contamination on the absorbent.
For example, if benzene has accumulated on the bed, benzene filters will be
required on gas masks and the other PPE requirements should be carefully
reviewed.
Vessel entry
If a vessel entry is to be carried out, read section 8
Loading
Absorbent must be loaded using a sock to minimize breakage.
Correct loading is vital to ensure the correct operation of the bed.
Fresh Sulfur guards can be loaded in air.
Water / liquid carry over
In operation, it is important to avoid water and / or liquid carry over on a bed that
is in a gaseous duty
Steaming for purging will solidify the bed
If a bed is steamed to purge it, as is done for some materials, a VULCAN VGP
Series Catalyst bed is likely to solidify and it will then be very difficult to remove.
HAZOP
It is recommended that a hazard and operability study is conducted on all
processes which include a VULCAN VGP SERIES CATALYST bed.
It should be noted that fresh and spent materials are chemically different and are
sensitive to different process conditions
Work control
In order to ensure that all operations associated with the beds are conducted in a
safe manner, local work permit systems, risk assessments, lifting studies,
COSHH assessments, and disposal regulations should be observed.
12
Mercury guards

included here to summarize the most important issues related to Sulfur guards
read this if you have a mercury guard.
Mercury Guards
Mercury guards are supplied in either a sulfided or an un-sulfided form (if H2S is
present in the stream)
Sulfided materials will release H2S or SO2 on contact with acids or oxidising
agents

The absorbent will change from a metal oxide to a metal sulfide in use, or it will
be supplied as a metal sulfide
Metal sulfides are self-heating, i.e. they heat up if air or oxygen are blown
through them. Some absorbents are more self-heating than others
Nitrogen for charging
Sulfided material must be loaded under nitrogen.
Vessel entry
followed.
Metal containers
Transportation
UN shipping regulations and transfrontier shipping regulations
Special disposal routes will bed required for mercury containing materials
MSDSs
analysis.
Disposal
Contamination
such as organo-mercury compounds or benzene that are present in the stream in
small quantities.
PPE
includes:
reviewed.
Vessel entry
Loading
Absorbent must be loaded using a sock to minimise breakage.
Sulfided mercury guards must be loaded under nitrogen.
Un-sulfided mercury guards can be loaded into air.
HAZOP
processes which include a VULCAN VGP SERIES CATALYST bed.
Work control
13
Chloride guards

included here to summarise the most important issues related to chloride guards
read this if you have a chloride guard.
Chloride Guards
Chloride guards are mixtures of metal oxides which react to form metal chlorides.
They are not usually self-heating, although nitrogen should still be used for
purging to avoid the formation of flammable mixtures.
Spent chloride guards will release HCl or Cl2 on contact with acids or oxidising
agents
Sometimes it is necessary to discharge under nitrogen if the hydrocarbon content
of the material is very high and it is difficult to achieve less than 5% of the LEL
(lower explosive limit).
Vessel entry
followed.
Metal containers
The spent material is not generally self-heating, but it should be discharged into
suitable metal containers and sealed.
Transportation
Spent materials may be corrosive on contact with water and are subject to UN
shipping regulations and transfrontier shipping regulations
MSDSs
analysis.
Disposal
apply to different products and a number of different options are available
Contamination
such as or benzene that are present in the stream in small quantities
PPE
includes:
reviewed.
Vessel Entry
Loading
Sulfided mercury guards must be loaded under nitrogen.
Un-sulfided mercury guards can be loaded into air.

HAZOP
processes which include a VULCAN VGP Series Catalyst bed.
Work control
14
Arsine and other guards
15
Reduced materials

included here to summarize the most important issues related to reduced
material on a single prompt sheet.
read this if you have a reduced material.
Reduced materials
Reduced materials are supplied for a number of different duties.
Depending on the material, they can be pyrophoric in air, i.e. they can burst into
flame on contact with the oxygen in air.
Special procedures are required for loading and handling these materials, and
they are very specific to the particular operating conditions.
Some materials are supplied as a metal and have to be reduced in-situ.
Other materials are supplied in a pre-reduced form and need to be activated for
the material to perform correctly.
These guidelines some of the general issues associated with reduced materials
and operating procedures for a particular process will be agreed with the plant.
are self-heating, i.e. they heat up if air or oxygen are blown through them. Some
absorbents are more self-heating than others
Nitrogen for charging

material must be loaded under nitrogen.
Vessel entry
followed.
Metal containers
Transportation
UN shipping regulations and trans-frontier shipping regulations.
Special disposal routes will bed required for mercury containing materials
MSDSs
analysis.
Disposal
Contamination
such as organo-mercury compounds or benzene that are present in the stream in
small quantities
PPE
includes:
reviewed.
Vessel entry
Loading
-
must be loaded under nitrogen.

can be loaded into air.

HAZOP
processes which include a VULCAN VGP Series Catalyst bed.
Work control
16
Reclamation or Disposal of used absorbent
The value of discharged VULCAN VGP Series Catalyst absorbents depends on

the type of absorbent involved, prevailing metals prices, and on the location of
the plant. Some absorbents (notably those containing nickel or copper) usually
have a small positive value. Others (particularly those based on iron) have
negative values, because the combined cost of freight and processing exceeds
the value of the constituent metals. GBHE can assist in the environmentally
friendly disposal of discharged VULCAN VGP Series Catalyst absorbents by
recommending a number of metal recovery smelters who may be able to assist
with metal recovery.
Absorbents to be disposed of must be made safe for handling. In most cases this
means that any VULCAN VGP Series Catalyst absorbents which are discharged
in a potentially self-heating state must be made stable by exposure to air before
they are moved from the factory site.
Disposal of spent materials
A list of suitable disposal outlets can be supplied on request.
This list is not published here to ensure that the most up to date information is
provided when the material comes to be discharged
Transportation of spent absorbents

Local regulations should be followed for the transportation of spent absorbents to
the selected disposal outlet.
Some discharged materials will be classified as hazardous for various different
reasons.
Any such material need to be transported in accordance with the UN
recommendations on the transportation of dangerous goods, also known as the
Orange book.
These regulations vary, but in Europe it is required that the material has a safety
data sheet specific to that batch of spent material.
This means that the material needs to be discharged into suitable containers,
sampled and stored on site for several days while the analysis is completed and
the associated paperwork and permissions are prepared.
GBHE are able to assist with the analysis of samples of discharged material if
required.
Samples of discharged material
In order to generate a safety data sheet for the transportation of the discharged
material, it will be necessary to send a sample for analysis to GBHE C2PT.
These samples can be sent by freight forwarding companies such as Federal
Express and DHL who have experience in handling such materials.
There are requirements to send samples in UN approved containers with
appropriate documentation. GBHE can supply a suitable MSDS for a small
sample on request.
Whenever possible samples should be taken which are representative of the bed
profile.
This is easy if the bed is being vacuumed out from the top of the vessel.
If the bed is being discharged from the bottom, a grab sample from the top of the
bed before the bed is discharged is very useful as it gives an indication of the
highest absorbent loading and highest impurity concentration on the bed.
In either case, samples every 10% of the bed are usually enough to give a good
indication of the reaction profile down the bed.
In cases such as mercury guards where high concentrations of an important
impurity may be observed, it is worth taking samples at a higher frequency and
retaining for later analysis if required.
17
Treatment options with VULCAN VGP Series Catalyst materials
Impurities that can be removed by VULCAN VGP Series Catalyst processes,

including precious metal catalyst options
Sulfur compounds ( H 2S, COS, SO2, RSH, R2S, CS2 )
Halogen compounds (HF, HCl, CL2, RCl )
Carbon monoxide
Unsaturated hydrocarbons
Aromatic hydrocarbons
Nitrogen compounds ( NOX, NH3, HCN, Organo N )
Mercury
Metals
Arsine / Phosphine / Metal Carbonyls
Hydrogen
Oxygen
Streams that can be treated by VULCAN VGP Series Catalyst processes

Natural Gas
Carbon dioxide
Associated gas
Synthesis gas
Liquid hydrocarbons ( LPG, naphtha, Kerosene, NGLs )
Industrial gases (H2, N2, CO2, CO, He )
Chemical feedstocks (propylene, ethylene)
Air
Obviously it will not be possible to remove every impurity from every stream,
however, if is a stream with an impurity in it, drop us a line as we may be able to
help.

Catalyst Chage Operation

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GBH Enterprises, Ltd.

VULCAN VGP Series Purification

Process design and modification considerations

Health and Safety precautions

VULCAN VGP CATALYST containers and storage

VULCAN VGP CATALYST handling

VULCAN VGP CATALYST charging / loading

VULCAN VGP CATALYST discharge

System start-up / Shutdown / Standby / Upsets

General considerations for liquid and gaseous systems

VULCAN VGP Sulfur guards

VULCAN VGP Mercury guards

VULCAN VGP Chloride guards

VULCAN VGP Arsine and other guards

VULCAN VGP Reduced materials

Reclamation or disposal of used absorbent

Treatment options with VULCAN VGP Series Catalyst Materials

GBH Enterprises (GBHE) provide VULCAN VGP Series catalysts and

2. PROCESS DESIGN AND MODIFICATION CONSIDERATIONS

Contaminants or components of particular interest are:

Other considerations that should be included at the design stage or as part of a

Provision of suitable non-isolatable pressure relief systems

Examples of different modes of operation

Health, Safety and Environmental Precautions

Working Practice Guidelines

3.1.2 Site Preparation

3.1.3 Ergonomics & Personal Protective Equipment

It is essential to control the inhalation of absorbent dust to levels below the

3.2.1 Dust Masks

3.2.4 Personal Hygiene

First Aid Measures

Entry into Inert Gas Atmospheres

See also diagram and references in section 8

Discharge of Self-heating Absorbents

Some VULCAN VGP Series catalyst and absorbents will be discharged in a

3.6.1 Sulfided material

3.6.2 Reduced material

Discharged Spent Sulfur Absorbents

Discharged Spent Chloride Guards

For further information contact your local GBHE representative or:

4. VULCAN VGP SERIES CATALYST CONTAINERS AND STORAGE

By special arrangement some absorbents can also be supplied in big bags

Detailed information regarding product hazards are contained in the Material

5. VULCAN VGP SERIES CATALYST HANDLING

Control of work and risk assessments.

6. VULCAN VGP SERIES CATALYST CHARGING / LOADING

6.2 Charging Vessels

6.2.1 General Issues

VULCAN Series Catalyst and Absorbents Reactor Loading

The VULCAN Series A ST

active support, high void cylinder 16 mm

active support, hollow cylinder

active support, ball

Baskets are out

Top of Supp. Grid

w ith 1/8" support

Most absorbents produce

Internals between the

active support, high void cylinder 16 mm

Support beams extend 6"

to 8" below tray.

active support, hollow cylinder

active support, hollow cylinder

active support, ball