A new generation of catalyst deactivation, removal and loading technology in the liquefied natural gas industry
Marko L. Draca A C and Stephanie Tyszta BA Santos, 60 Flinders Street, Adelaide, SA 5000, Australia.
B Santos, 32 Turbot Street, Brisbane City, Qld 4000, Australia.
C Corresponding author. Email: marko.draca@santos.com
The APPEA Journal 60(2) 628-632 https://doi.org/10.1071/AJ19221
Accepted: 7 April 2020 Published: 15 May 2020
Abstract
In 2019, Santos applied an innovative, world first technology for catalyst changeout at Gladstone Liquefied Natural Gas (GLNG) Plant which eliminated 900 crane lifts, reduced confined space entry work by 145 h and reduced catalyst loading duration compared with traditional methods. Removing and replacing adsorbent media or catalyst in the LNG industry is a high risk activity that often drives the critical path of shutdown events. Traditional methods require confined space entry in an inert environment, with a worker required to manipulate a vacuum hose or loading sock while wearing an air supplied mask inside a vessel. Air temperatures inside can exceed 40°C and the risk of trapped pockets of hydrocarbons is difficult to eliminate. For the GLNG Train 1 2019 Major Shutdown, Santos awarded the catalyst changeout scope to EnerMech to deliver on innovations designed to eliminate the key risks of traditional media changeout operations. New technologies, techniques and processes for the decontamination, unloading and loading of adsorbent media were developed to mitigate the risks of traditional media handling through; (1) Ensuring adsorbent media is hydrocarbon free and deactivated before unloading; (2) Waste minimisation during decontamination of the media; (3) Effective remote unloading of adsorbent media; (4) Predictable outcomes through immunity to adverse weather conditions; (5) Limited cranes, flow bins or bulk bags required for loading; (6) Continuous adsorbent media fill at high rates; (7) Ability to maintain media moisture content during loading; (8) Flexibility and scalability in vessel loading; (9) Minimise media attrition through reduced media handling; (10) Significant safety benefits through the elimination of inert entry; and (11) Effective environmental and schedule upsides. The paper details the actual performance data of the technology as delivered at the GLNG Train 1 Shutdown.
Keywords: adsorbent, adsorber, decanting media, decontamination, loading of catalyst, loading of media, media attrition, media changeout, molecular sieve, sieve, steam, steam deactivation, steam decontamination, unloading of catalyst, unloading of media, ZymeFlow.
Marko Draca is a Chartered Engineer with 15 years of experience in oil and gas. Marko has worked in Australia and West Africa in the fields of subsea and pipeline infrastructure design, maintenance and repair, pipeline construction and shutdown management. Marko has a passion for building and leading high performing teams. Marko’s current role as Shutdown Superintendent for Santos allows him to apply and approach to shutdown management that has a proven track record of excellent safety performance, low cost delivery and industry leading innovation. In 2019, Marko was the Execution Superintendent on the GLNG Train 1 Major Shutdown and contributed to the design, testing and use of the new catalyst handling equipment. |
Stephanie Tyszta is a Process Engineer with 7 years of experience in the LNG and gas processing industry, working for Santos. Stephanie currently provides daily plant support to GLNG with a recent focus on Major Shutdown Support. Previously Stephanie has worked in Process Safety, contributing to the LNG Plant Major Hazard Facility in-house safety assessment. Prior to this Stephanie provided plant support to Moomba Gas Plant and Port Bonython Liquids Plant. In 2019, Stephanie contributed to a new technology for catalyst handling which was applied at GLNG during the Train 1 Major Shutdown. Stephanie holds a Bachelor of Chemical Engineering and Bachelor of Finance from the University of Adelaide. |
References
EnerMech (2020). Catalyst handling services. Available at https://www.enermech.com/services/industrial-services/catalyst-handling-services [verified 3 April 2020].ZymeFlow Decon Technology (2020). Chemistries. Available at http://www.zymeflow.com/refinery-chemistries.html [verified 3 April 2020].
