Softard logo Japanese

Softard's Catalyst Change Out Technology



Up to now, we have been striving for safety, speed, and reliability. We have developed catalyst replacement technology for reaction towers, a bottleneck in regular maintenance work of petroleum refining plants (many patents related to catalyst replacement). Industrial plant design (software) and construction and maintenance (hardware) must be very closely related like the wheels of a car. In order to realize this philosophy, experienced engineers from various fields have gathered at our company. We have a number of patented technologies that satisfy our customers' advanced requirements and provide internationally competitive know-how and technology.

Refinery maintenance business

1.Safely catalyst unloading technology under air atmosphere

The Catalyst Passivation Method (KS-767 method) prevents direct contact between the catalyst and air by forming a strong oil film on the surface of the catalyst, preventing oxidation and heat generation of the catalyst. Conventionally, in the catalyst replacement work, in order to suppress the oxidation and heat generation of the catalyst, nitrogen was sealed in the reaction tower and a method of sending people into the nitrogen gas was adopted. However, the KS-767 construction method developed by our company enables work in an air atmosphere and is a wet extraction method, which solves the problem of dust scattering. Also, KS-767 allows construction to be carried out safely and economically. This technology has many achievements not only in Japan but also widely overseas (more than 500 achievements in Japan and overseas) and has been highly evaluated. These patented technologies have been researched and developed over many years in the process of extracting catalysts from reaction towers in petroleum refineries.

Construction results of KS-767 (CATnap)

Applied process

Waste catalyst extraction volume results

Unloaded volume of catalyst

2.Consolidated catalyst excavation method by robot

The catalyst excavation method (catalyst excavator MARK series) using a robot developed by our company has solved the conventional dangerous work at once, also, it possible to reduce the cost of on-site work.

Japanese patent No. 2065261

3.High-dense catalyst loading machine

A loading machine designed to prevent drift and caking of the catalyst in direct residue desulfurization equipment. It is also possible to easily create a flat loading surface by reversing the impeller.

触媒充填機 SPM
Japanese patent No.6383679
US patent US 9586189 B2

4.Dust remover device for catalyst particle

A device that removes fine particles generated by crushing the catalyst during loading. Particles that adversely affect the operation of the reactor can be preliminarily removed while loading catalyst.

触媒粉除去装置 ダストリムーバー
Japanese patent No. 7025015 US patent US 9586189 B2

5.Unloading technology for catalyst regeneration

The RALS (Reductive Attrition Loss Separator) method developed by our company extracts the catalyst so that it can be reused. In recent years, the prices of catalysts have soared due to the soaring prices of rare metals. In addition, stricter regulations for sulfur in gas oil and other products have significantly increased the number of catalysts required. There is also a demand for effective utilization of limited resources. This RALS (Reductive Attrition Loss Separator) method makes it possible to recover catalysts that were previously discarded as renewable catalysts.

Japanese patent No. 5072643
US patent US 7959870 B2

6.Continuous separator

A separator that can be extracted continuously without stopping the suction work of the catalyst. When the catalyst is drawn out by suction from the reactor, the suction is normally stopped each time the catalyst is discharged from the separator. However, the continuous separator can suck continuously without stopping the suction as the name suggests. This prevents the catalyst from clogging the suction hose, which is 30m or longer, and enables efficient removal of the catalyst.

Japanese patent No.5893998
US patent US 7959870 B2

7.Crude oil tank sludge removal technology

Technology for removing sludge deposited on the bottom of a crude oil tank during open inspection. The deposited sludge is dissolved by circulating from various directions using highly soluble solvents and chemicals. It is also possible to process crude oil sludge, which was previously treated as industrial waste, by dissolving it.

Japanese patent No.5997587
US patent US 10130978 B2

8.No Man Entry, Reaction Tower Catalyst Extraction Technology

A technology for extracting the catalyst from the reactor without requiring workers to enter the reactor. A worker extracts the catalyst from the top stage of the reactor by operating an extraction pipe. As a result, more than 98% of reactor catalyst withdrawal

Japanese patent No. 5956235

9.Energy-saving design technology

In addition to the processing design of conventional plants, we have developed the latest energy-saving design with a focus on sustainability and technology aimed at reducing environmental pollution.

10.Other technologies