An innovative pilot program successfully demonstrated the value of real-time catalyst monitoring for an oil and gas facility, paving the way for significant cost savings.
Challenge
The customer faced challenges in continuously monitoring catalyst activity within reactor beds for their alkylation and trans-alkylation system. They lacked the ability to accurately determine the remaining catalyst reactivity potential, hindering their ability to maximize the economic benefits of their catalysts. Existing methods for estimating the remaining useful life of the catalyst were lengthy, taking 6-8 weeks to complete as an offsite batch process. Consequently, the customer needed a way to visualize catalyst consumption in near real-time, predict deactivation rates, and access comprehensive catalyst information in a centralized location.
Solution
Arundo conducted a pilot program to demonstrate catalyst activity in each reactor bed at the facility. The pilot involved multiple analyses to pinpoint where reactions were occurring and the extent of catalyst deactivation. It provided a visual representation of deactivation over time, empowering the Plant Manager to optimize catalyst replacement during plant turnarounds.
Impact
The pilot clearly demonstrated significant financial savings in catalyst replacement costs. By enabling the loading of new catalysts based on the actual deactivation rate, rather than relying on a fixed schedule, the customer can realize considerable operational efficiencies and cost reductions.
