A new generation of catalyst deactivation, removal and loading technology in the liquefied natural gas industry

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.