EO REACTOR

CATALYST
REPLACEMENT JOB
 2
Ethylene Oxide

Ethylene oxide is an organic compound with the formula C ₂H ₄O.

Ethylene oxide is a colorless and flammable gas with a faintly
sweet odor.

Ethylene oxide (EO) is produced in large volumes and is primarily

used as an intermediate in the production of several industrial
chemicals & Alcohols, the most notable of which is ethylene
glycol. Ethylene Glycol is used as raw material in the manufacture
of polyester fibers and for antifreeze formulations.

EO is also used as a fumigant( pesticide) in certain agricultural

products and as a sterilant for medical equipment and supplies.
 HAZARDS OF EO

 Extremely Flammable Gas. May form explosive mixture with

air.

 May cause skin and eye irritation

 May cause an allergic skin reaction

 May cause respiratory irritation

 May cause generic Defects

 May cause cancer

 May damage fertility or the unborn child

 Causes damage to nervous system, kidneys through

prolonged or repeated exposure
 EO Manufacturing process
Gas containing ethylene, oxygen, methane, nitrogen,
and argon is entering the reactors. The reaction
between oxygen and ethylene occurs under a pressure
of approximately 20 bars and a temperature of
approximately 250°C over a silver catalyst.
C2H4 + ½ O2 → C2H4O
This is exothermic reaction which means that heat is
produced. The heat is removed with circulating boiling
water on the shell side of the reactors. Some of the
circulating water is evaporated to steam which is used
in other processes
Vertical flow shell-and-tube reactors are used for the
system
We came across Removable dome type reactors like IGL
Kashipur, Reliance Jamnagar & fixed dome type EO
Reactors like Reliance Hazira & Dahej
 Steps involved in EO Reactor Job
1. Equipment mobilization
2. Site set up
3. Mechanical activities
4. Preparation for confined space entry
5. Bottom spring removal ( Parallely top spring also if they are present)
6. Unloading of catalyst from thermocouple tubes by fish taping
7. Unloading of catalyst from tubes by Air lancing method
8. Grit blasting of tubes , tube sheet , top& bottom domes , man way covers
and nozzles
9. Swab and mole insertion
10. Swab Blowing
11.Installation of bottom springs
12.Placement of template or inserts
13.Loading set up
14.Catalyst loading
15.Outage correction
16.DP Measurement
17.DP Correction
18.Loading of thermocouple tubes
19.DP measurement & correction of thermocouple tubes
20.Final cleaning and box up
 POINTS TO BE CONSIDERED DURING EO REACTOR JOB EXECUTION

Even though execution of EO reactor job seems to be very simple, we need to

give importance to very minute details as project schedule is very tight. Normally
EO Reactor catalyst replacement job is in critical path of shutdown.

Some important points to be considered areas follows

Team work , Patience & alertness is the basic necessity of EO reactor Job.
Without teamwork , it is impossible to execute the job within stipulated duration

We should plan sufficient back of equipment as there is no time available for

trouble shooting and repair

As job entirely depend upon manpower , we should plan sufficient manpower for
the activity

We should plan minimum 2 steps ahead in terms of planning during execution.

All materials , manpower , execution details should be ready minimum 2 steps
ahead

We should execute all the activities perfectly in first execution itself. Any repeat
work due to mistake during execution will delay the job significantly.
 Equipment & Manpower mobilsation

All the CR equipment to be mobilsed atleast seven days in advance as it

will take lot of time in equipment set up due to space constraint in
execution area

Manpower mobilsation should start early in batches of 30 people as gate

pass process take around 3 days & one day each for Confined space
medical test at client medical center & plant specific training

Air compressors , receivers , Dehumidifiers with AC units to be mobilsed

3 days prior to the shut down.

Care to be taken for provision of PPES for contract workers.

 Equipment set up
Vacuum equipment set up – Vacuum units , cyclone hopper ,
dust bag house , vacuum manifold & Testing

Electrical panel set up & connection

Dehumidifiers AC unit installation & testing

Air compressors , dryers , Air receivers , air manifolds set up &

leak test.

Mock set up of loading template at ground

Spring removal tool set up & testing

Air lancing arrangement set up

Screening machine set up

Planning for Loading arrangement & its preparation

Key equipments / materials required
for EO Catalyst replacement Job
FOAM:
7 cm DIA X 12.7 cm LONG X WHITE
COLOR.
[ Density = 30 + 1.25 Kg/M3 ]

SCRUB BRUSH:
Nonwoven multiple layer (5 layers) Industrial scrub
type Abrasive with OD: 39-40mm x ID4-5mm &
overall length 70mm
This will be held by 1Nos M4xCSK MS Screw(73-
75mm length) with Nayloc Nut & guided by 2Nos MS
plated washer Having 20mm approx. OD and 5mm
ID on either side
Air lancing accessories
Grit Blasting Dust filtration unit
Machine Air compressors

Air
recivers

Air Dryers

Hopper knife
gate system
with PLC
Control
ATLAS COPCO OIL FREE COMPRESSOR
AIR DRYER
 Preparation for confined space entry

Gas test to be performed

Rigid ladder to be installed

Serration protection cover to be installed in all manways

AC ducts , air blowers to be installed

Trained confined space attendant to be present

 Bottom spring removal
After receiving the permit , already prepared spring removal pneumatic
tools , manual tools and hooks to be taken inside. Around 30 persons to
take confined space entry

Springs to be brought down till tube sheet level

After inspection , springs to be completely removed

Springs have to be brought down to ground level and to be stored inside

drums
Catalyst unloading by Air Lancing method
 All the preparations to be completed parallel with Bottom spring
removal

 Proper layout to be made to prevent converging of lancing team

 All the vacuum hoses to be laid in systematic manner to prevent

entanglement inside reactor

 Free access to escape to be maintained.

 Lancing to be done in systematic manner

 Marking of catalyst height to be done on lances

 Once the unloading completes , capping to be done

 Care to be taken to avoid physical damage to lances

 Utmost care to be taken regarding all safety aspects

 Grit blasting

SET-UP GRITBLASTING EQUIPMENT AND TEST

OPERATION
- Layout plot, hose with nozzle and dead man’s
switch
- Compressed air set at 7 bar
- Set timer next and test for operation/accuracy
TEST BLASTING REACTOR TUBES
- Identify selective tubes for testing and set timing
- Grit blast selective tubes and inspect for
cleanliness
- Client/Catalyst Rep/CR Asia PM will determine
duration

GRITBLASTING THE REACTOR TUBES AND

SHELLS
- Work in orderly fashion, capped after completed
- Sweep blast reactor shell
- Wipe fines grit from shell and vacuum at the
bottom
 Swab insertion and blowing
INSERT FOAM SWAB INTO TUBES
- Insert in orderly fashion, row numbering and capping
- Foam push down using air stick or swab master machine
INSPECTION AND BOROSCOPING
- Verify all foam swab removed from
tubes
- Caps problem tubes and make
correction.
- Boroscope tubes shall necessary
INSTALL BOTTOM SPRING

- Compressing the springs in the clock-wise

direction into the tubes
- The depth of the spring is secured with a
special stopper on the spring-rod-device
- Install all the springs till bottom tube sheet
level
- After inspection , place push the springs up
to desired depth
- Inspection of spring depth using
measurement sticks
 Loading set up and preparation
This activity need to be done parallel with bottom
spring insertion
Loading hopper ( dedusting hopper ) to be placed
at the top portion. We need connect 4” or 6”
ductron hoses.
Scaffolding platform to be erected to pour
catalyst to the dedusting hopper
Loading template installation and alignment
- Remove caps at designated loading quadrant
and remain caps for thermocouple

- Assemble template in correct alignment

- Cover other quadrant which not designated

to be load with rubber mats
 Insert loading method
In insert loading method we are using
designed insert tubes instead of
template

Normally we will use 50% insert tubes

We need to use sliding metallic dams to

prevent disperse of catalyst

Normally inserts are marked with upper

and lower outage specifications

While removing inserts , we need to

cross check whether desired outage
attained or not

Properly designed inserts give correct

outages. Very less correction required

We are procuring inserts from Tube

master
DUST REMOVAL TECHNIQUES DURING FILLING

- Provide mesh screen with minimal vacuum

suction hopper at top of reactor
- Provide sufficient length of hose which lays over
on the template

SWEEPING CATALYST INTO GUIDE TUBES

- Softly sweep the catalyst into tubes and minimize
sweeping of catalyst
- Do not walk on the template

REPEAT THE SAME METHOD FOR OTHER QUADRANT

ONCE COMPLETED LOAD ALL CATALYST

TUBES,REMOVE TEMPLATES
HEIGHT CHECK
- Measured using PVC tube with designated
marking on required height
- Any over/under load tubes will be mark with
colored caps

CORRECTION
- Vacuum excessive catalyst for over load tubes.
Screen the vacuum catalyst.
- Top up under load tubes
DETERMINE DUST-BLOW PROCEDURE

- Visual observation in the bottom head

during the air blow of the first few tubes
- CR Asia, Catalyst vendor & client will
determine correct dust blow procedure for
time and pressure

DUST BLOWING ALL TUBES

- Keep a vacuum hose in the bottom to

remove dust.
- Remove only a few rows of caps during
process. Change color caps after dust blow
DP MEASUREMENT

We are using tube master DP measurement

devices

Initially all DP measurement devices are

calibrated using their calibration kit

All DP measurement devices are connected to

laptop

All DP measurement devices to be calibrated at

regular intervals specified by Tube master
Engineer

Place the stick correctly in a tube – row- and

tube number will be indicated on the display of
the stick
 DP Correction

All tubes needs to be an average pressure drop of

+/– 3% of that average. Each tube beyond this range
should be identified, by different colored caps.

CORRECTIVE ACTIONS

If > Than 3%;

- Extra blowdown
- Vacuum to maximum outage

If < Than 3%;

- Top up catalyst to minimum outage

If none of above works, empty the catalyst tubes and

reload
THERMOCOUPLE CATALYST LOADING

• Each catalyst thermocouple tube is packed with

new catalyst to an outage equal to the average
outage of the non-thermocouple tubes.
• Slowly load manually to avoid Dp out of range.
• Tap thermocouple continuously to avoid bridging

DUSTBLOW THERMOCOUPLE TUBES

DP MEASUREMENT THERMOCOUPLE TUBES

• Thermocouple tube should have a pressure drop
equal to the
highest pressure drop of all regular tubes of the
complete bed including top fill
THERMOCOUPLE INERTS LOADING

• Slowly pour manually to avoid and tap

thermocouple continuously to avoid bridging

MEASURING AND CORRECTING

THERMOCOUPLE TUBE PRESSURE DROP

• Measured from bottom tube sheet

• The correction factor for thermocouple tubes is
calculated
• If the pressure drop is not in the target range,
adjustments should be made to increase or
decrease the DP until it is correct