CATALYST HANDLING SERVICES Introduction Dickinson Group of - PowerPoint PPT Presentation

CATALYST HANDLING SERVICES

Introduction Dickinson Group of Companies was founded in 1910 followed by the establishment of its furnace service business in 1928. The company has 90 years experience in providing Specialist Furnace and Industrial Services to the mining, metals smelting, mineral processing, thermal power generation and petrochemical refining industries. VISION Dickinson Group of Companies’ Vision is to be a Leading provider of Furnace and Industrial Services MISSION Dickinson Group of Companies’ purpose is to provide an integrated and multidisciplinary “ One Personalised Solution ”, by offering essential furnace and industrial services, which increase productivity and performance together with reducing costs for our customers. CERTIFICATION Dickinson Group of Companies is certified to OSHAS 18001

Dickinson Geographic Footprint Office Locations • South Africa • Zambia • Mauritius • Tianjin, China • Egypt • Namibia Business Operations • Democratic Republic of Congo Business Experience • Russia Business Alliance Locations • Brazil

Dickinson Head Office & Workshops 14,000 m 2 Total land area: Total buildings (including offices, workshops & warehouses): 8,500 m 2

Safety Policy  Dickinson Group of Companies operates according to international best practices to achieve the highest practical levels of Safety, Health, Environmental Control and Quality , and adheres to BS OHSAS 18001:2007 accreditation.  The safety of our employees and contractors is an integral part of our business, with the goal of ZERO HARM.  The Group strives to:  Demonstrate strong leadership and direction in all conceivable SHEQ issues.  Ensure a consistent approach to the management of SHEQ in all locations.  Consult and communicate with all employees and stakeholders.  Educate the workforce in risk management, safety, health and environmental principles.  Respect the right of all staff to work in an environment where they know that risks are adequately controlled.  Promote the health and wellbeing of all its staff.  Measure SHEQ performance.

Industries we serve  Aluminium Smelting  Glass  Platinum & Nickel  Iron, Steel & Coke Making  Copper & Cobalt  Ferrochrome & Ferromanganese  Heavy Sands  Nickel  Power Generation  Cement & Lime  Chemical & Petrochemical  Ceramic  Refractory Manufacturing  Food & Beverage Manufacturing  Fertilizer Manufacturing  Water & Municipal Services  Telecommunications

Furnace Solutions Industrial Solutions

CATALYST HANDLING SERVICES

Background  Catalysis has significantly increased the viability of many industrial processes and continues to permit industry to sustainably meet the ever increasing demands for different industrial products.  By definition catalysis involves an agent promoting a chemical reaction, without being consumed by the reaction itself.  The use of catalysts has grown to be an indispensable part of modern industry, in fact catalysis is presently employed in about 90% of all commercially produced chemical products.  Despite the fact that the catalyst is not consumed in the reactions, in the continuous industrial processes, phenomena of catalyst surface poisoning and surface area impairment are observed, giving rise to the need for catalyst handling services.

Safety Aspects  Catalyst handling is a highly specialized science that requires very specialized skills and equipment with adherence to highly strict safety, health and environmental requirements and procedures .  With the correct partner, manufacturers may be assured of peace of mind even as the delicate tasks are performed.

Quality Aspects  Quality monitoring, control and assurance take centre stage in all Dickinson Group of Companies' activities. Strict quality controls are observed . We aim at zero error and satisfying our client.  Use of state of the art industrial vacuumation and screening equipment to meet the technical needs of this specialized catalyst unloading, screening and loading service.  With all its equipment, experienced, trained and specialized manpower, the client is assured of a professional and timely job delivery .

Industries The company has undertaken large projects across the complete range of mining, metals smelting, mineral processing, chemical and refining industries with a particular emphasis on the following:  Sulphuric acid plants  Chemical plants

Catalyst Handling Services  Dickinson Group of Companies offers an extensive range of catalyst handling services coupled with a wide range of support services.  The company stands out as a service provider of choice; anchored by over 90 years of experience in providing the specialist furnace and industrial services to mining, metals smelting, mineral processing, thermal power generation and petrochemical refining industries.

Scope of Services  Catalyst Unloading  Catalyst Screening and Materials Handling  Catalyst Loading  Reactor & Maintenance Works  Catalyst Supplies  Strategic Stocking of Catalysts  Reactor Maintenance Works  Corrosion Protection Services  Acid Resistant Brick Linings and Anti-Corrosion Coatings

Catalyst Unloading  Through excellent project planning, monitoring, control, communication, coordination and management, Dickinson Group of Companies ensures that catalyst layers are separated according to age and (or) type without cross contamination, harm to personnel and endangering the convertor structural integrity.  Special barriers are constructed inside convertors for personnel movements while vacuuming to avoid catalyst damage. Vacuumation suction pressure and catalyst velocity are also carefully controled by our team of experts to avoid catalyst breakage. In addition the team ensures that all ceramic ball layers are vacuumed separate from the catalyst.

Catalyst Unloading

Catalyst Screening and Materials Handling  Catalyst screening eliminates process dust, catalyst fines and small catalyst particles that are generated over time and tend to affect catalyst reaction surface area as well as other process parameters.  The Screening is considered a critical factor to the success of an entire catalyst handling job as catalysts may easily be damaged by errors in the choice of equipment or settings.  Our highly competent technical and field teams have successfully conducted several screening campaigns.

Catalyst Screening and Materials Handling  Plant data is collected prior to the works and proper screens mesh selection is done offsite. Continuous monitoring of screening conditions is observed in order to consistently ensure quality in every bag or drum.  The team ensures that accumulations in the divisional plates under the grids are removed completely from pass to pass. Where meshes are employed, their condition is also closely and continuously monitored  Misplacement of bags or drums may have detrimental effects, as such, every screened or collected catalyst bag or drum from the different passes and layers of the convertor is well labelled and stored/stacked in well- defined locations.

Catalyst Loading  Dickinson Group of Companies performs both sock and dense catalyst loading. Like in every other stage of the catalyst handling process, quality assurance is given a critical attention.  Given the hygroscopic nature of catalysts, exposure to the environment is minimized at all costs ..

Catalyst Loading  Throughout the loading process, an even distribution of ceramic balls and catalysts on each bed in accordance with the loading diagram is closely monitored and ensured.  The loading team puts in place all necessary measures to minimize catalyst breakages, channeling and high pressure drops due to loading errors.

Haldor Topse Agency  Dickinson Group of Companies has been appointed exclusive agent for Haldor Topsoe to promote, sell and strategically warehouse the dominant catalyst manufacturer‘s full range of VK Sulphuric acid catalysts in Namibia, Zambia and the Democratic Republic of Congo.  Haldor Topsoe is a world leader in catalyst manufacturing and technology . The company was founded 1940 with a vision to tap the potential of catalysis and scientific results and apply this to industry; this still stands and remains the backbone of the company.  Haldor Topsoe A/S enables establishments in the chemicals, oil & gas industries to get the most out of their processes and products, using the least possible energy and resources.

Catalyst Supplies Product Range The Group supplies the following range of performance catalysts for Sulphuric acid production:  VK38  VK48  VK59  VK69VK-WD  VK-WH  VK-WL  VK-WSA  VK-WSX

Reactor Maintenance Works Proper maintenance and repairs are critical to a successful plant shutdown, the company is in a position to assist with all necessary works that have to be undertaken before catalyst loading is done. These include the following reactor and maintenance works:  Assembly and de-assembly of vessels  Convertor or reactor internal works  Surface cleaning and preparation  Weld inspections  Internal convertor or reactor inspections