Catalyst Dense Loading

Catalyst loading is increasingly critical. Whether installing single or multiple layers of catalyst, achieving perfect loading amounts and profiles is essential to prevent channeling and unnecessary coking.

Catmasters, LLC developed the Hyperloader™, a catalyst dense loading machine, to address issues with existing loading technologies identified by our engineers and customers. This truly innovative solution provides catalyst loading services to oil refining, petrochemical, gas, and chemical processing facilities globally.

Catmasters trains dense loading personnel operating from locations in the Gulf Coast, Midwest, Northeast, Caribbean, and Europe, with selected partners in other regions. Using the Hyperloader™ guarantees that loads are completed according to specifications.

The Hyperloader™ is a key component of Catmasters catalyst technology.

Fixed Bed Loading – Hyperloader™

Catmasters developed and patented the Hyperloader™ to mechanize the catalyst loading process, significantly reducing manual operation of dense loading machines.

The Hyperloader™ can be installed on a tray or mounted to the Catascope™. It dispenses catalyst gently using airflow while slowly rotating its dispensing nozzle. The Hyperloader™ crew adjusts the air or nitrogen flow, ensuring that as the bed rises in the reactor, the catalyst is dispensed at the correct rate and within 18 inches of the tray.

A unique control system and catalyst dispersion pattern enable both uniform and area-targeted loading. Therefore, the Hyperloader™ can be used to load axial and radial flow reactors.

Figure 1 Axial flow reactor loading, Fixed Wave loader

Fixed Bed Loading – Hyperloader™ with Catascope™ – Coming Soon

Dense loading performed by the Hyperloader™ mounted on the Catascope™ ensures that operators remain outside the reactor during loading.

The Catascope™ is currently in the final testing stage and is scheduled to launch in September 2025.

Figure 2 Axial flow reactor loading, Fixed loading distance

Radial Flow Reactors

The Hyperloader™ is the most effective system for loading radial flow reactors. The radii of the loading waves are self-adjusted, ensuring no shadowing or catalyst breakage occurs during loading.

Figure 3 Radial flow reactor loading

Figure 4 Load Wave (top view)

Reformers and Furnaces

To load reformer and furnace tubes more effectively, Catmasters is designing and developing a fully automated catalyst loading system to be introduced in the near future.

Tubular Reactors

Loading tubular reactors presents two major challenges: productivity and accuracy. Catmasters is designing and developing a fully automated catalyst loading system to be introduced in the near future.