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Precautions and safe practices

UOP handling guidelines for


ADS-120/ADS-130 adsorbents
Table of contents

The nature of adsorbents and their operations 1

Loading fresh adsorbent 1


Preparation 1
Loading 3
General loading instructions 3

Start-up and operation of adsorption systems 4

Preparing spent ADS-120/ADS-130 adsorbent for unloading 5


General nitrogen purging instructions 5

Unloading and handling of spent adsorbent 6


General unloading instructions 6

Disposal 8

This brochure is intended as a general discussion and it may not be


applicable to particular operations. Operating conditions and equipment will
vary from unit to unit, and actual operating experience with a unit should be
considered before implementing guidance from this document. Owners and
operators remain at all times responsible for the proper operation and
maintenance of their units.

In addition, this document is intended for trained workers and assumes a full
understanding of how to safely and lawfully perform the tasks referenced
herein. Persons should not rely on this information as a substitute for
professional training or for practices and procedures designed to ensure
compliance with all applicable legal, industry and other requirements. This
material does not constitute a warranty, express or implied, of results in any
specific application or fitness for a particular purpose, and it does not create
or modify any agreement with UOP.
The nature of adsorbents and their operations

UOP ADS-120/ADS-130 adsorbents exposure to air and moisture must


are high capacity non-regenerative be minimized. The spent adsorbent
adsorbents used for sulfur removal should not be exposed to mineral
from various hydrocarbon gas and acids, flame or an ignition source or
liquid streams. Fresh, unused adsor- temperatures above 190°C since
bent is stable when dry, and can be toxic vapors such as sulfur or
loaded with appropriate protective hydrogen sulfide may form.
equipment and appropriate confined
space entry procedures. However, Additional product safety information
once exposed to hydrocarbon on the products are available in UOP’s
streams containing sulfur, MSDSs, which are available by
adsorbents form metal sulfides that contacting your UOP representative.
have limited stability and any

Loading fresh adsorbent

Proper handling and storage Preparation


UOP ADS-120/ADS-130 products are
is important to ensure that
bound metal oxides. In their fresh,
the adsorbent does not unused state, these products present
become contaminated with minimal handling risk when appropriate
protective equipment is used.
water which could delay Appropriate protective equipment
startup and result in loss includes gloves, long sleeve shirts and
pants or coveralls to protect against
of production time. In
skin exposure; safety glasses, goggles
addition, it is critical that or face shield to protect the eyes; and UOP ADS-120/ADS-130 adsorbents
safe procedures are used dust masks or respirators if dust might are normally shipped in airtight, non-
be generated. When exposed to returnable steel drums. To help prevent
to protect personnel. water, the heat of adsorption can damage to the drums, always store
cause the adsorbents to get quite hot. them upright on pallets and do not
Care should be taken to avoid contact stack them over three (3) pallets high.
with moist skin, mucous membranes Individual drums should be moved by
and eyes.

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mechanical means such as fork lift • Removing hazardous materials from • Having notification and response
trucks equipped with drum rim or the vessel prior to entry. procedures in place for emergency
body clamps. Take care when moving situations such as injury or loss of
• Isolating the confined space from
adsorbent containers. Proper lifting consciousness to personnel within
sources of hazardous materials or
techniques and equipment should be the confined space.
energy by installing blind flanges to
used. Full drums can weigh more than
inlet and outlet nozzles and decou- • Equipping personnel entering the
350 pounds and full bags more than
pling pumps and instrumentation. vessel with the appropriate safety
2,100 pounds.
equipment, which may include the
• Providing adequate ventilation to
use of safety harnesses and/or
Drums are shipped under a slight prevent accumulation of flammable
self-contained breathing apparatus.
vacuum to ensure product integrity, materials, combustible dusts, toxic
so it is important that drum seals are contaminants or an environment that • Training personnel authorized to
maintained prior to use. Drum lid is oxygen deficient or excessive. work as safety attendants, rescue
bands and vent screws should remain personnel or persons entering the
• Testing for oxygen, flammable gas,
tight when stored or moved and confined space.
and suspected toxic materials prior
drums should not be handled in a
to entering the vessel. • Conducting pre-job discussions
manner that could puncture or dent
with personnel involved with the
the containers. The vent screw on the • Using safety attendants outside the
work about the potential hazards
lid should only be loosened immedi- vessel to monitor and communicate
of the confined space work.
ately prior to loading the adsorbent with personnel in the confined space.
into the vessel.

Drums and bags should be stored in


dry conditions and away from sunlight.
For temporary storage, drums should
be stored on pallets and both the drums
and bags should be covered with
tarps or other material to protect them
from sunlight and/or precipitation. For
longer term storage, drums and/or bags
should be stored in a warehouse or
similar climate-controlled environment.

In situations where entry to the vessel


is required, confined space safe work
practices must be followed. Many
countries have specific regulations
for confined space work. Personnel
should review these regulations and
other precautions and practices, and
ensure that they are followed. The
required precautions and practices
include, without limitation, the following:

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Loading • Isolating the area under the lifting The ideal way to load ADS-120 or
Minimize exposure of the adsorbent path using ropes or signs and ADS-130 adsorbent to obtain these
to moisture by loading in dry weather keeping personnel clear of the area. conditions is at such a rate and in
and not leaving open containers such a manner that the adsorbent
• If pneumatic trucks are used to
exposed to the atmosphere. beads fall uniformly over the surface of
transfer adsorbent into the vessel
the adsorber bed, and that each bead
through a hose, keeping the hose
If flammable vapors such as settles into place before another bead
outlet pointed away from personnel.
hydrocarbons are present in the falls on it. This provides a uniform,
loading area, grounding is especially • Making sure that the transfer and maximum packed density and
important to avoid discharge of the receiving systems are electrically pre¬vents settling of the adsorbent bed.
static electricity that could cause an grounded to help dissipate any static
explosion or fire. Even conductive charge, since static electricity can Prior to placing the loaded vessel into
footwear and conductive walking build up during transfer operations. service, flush air from the vessel with
surfaces may not prevent electrostatic high purity nitrogen (minimum 99.9%)
• Using tag lines on loads that must
buildup on the human body. As one and leak test the flanges opened
be guided into position or where
example, removal of outer garments during the loading procedure.
load movement can be potentially
in low humidity conditions can hazardous.
generate sparks. Before introducing any hydrocarbon
• Opening the vent screw on the stream into the adsorbent bed,
Take care when moving adsorbent drum lid before removing the drum displace the air using a high purity
containers. Proper lifting techniques lid band just prior to loading the nitrogen purge. Since a rate that will
and equipment must be used, since adsorbent into the vessel. ensure good nitrogen distribution in
containers must normally be lifted to the vessel is seldom available, use
the top of the vessel using hoists or General loading instructions alternate purging with number of
cranes. Proper lifting techniques must pressurization and depressurization
The objectives of the loading
be performed in accordance with steps in the downflow direction to
operation are to:
government regulations and/or other enhance air removal. Continue the
precautions and practices including, process until less than 0.5% oxygen is
• Obtain a uniform, maximum
without limitation, the following: present in the outlet. At the end of the
packed density
purge, leave a nitrogen blanket on the
• Minimize settling and migration adsorbent vessels until startup.
• Conducting a visual inspection and
of adsorbent
functional check of hoisting and
lifting equipment prior to its use to • Keep adsorbent bed layers level,
identify any defects. not cone shaped

• Keeping loads within the load limits • Obtain uniform gas flow through
of the lifting equipment. each adsorber by loading all
adsorbers in the same way.
• Training operators in proper
operating and inspecting procedures.

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Start-up and operation of adsorption systems

For gas phase systems, increase For liquid systems, increase to filled, close the flare line and bypass
pressure slowly down flow with feed operating pressure by slowly introducing line (if used) and open the feed line.
(less than 50 psi/minute) to operating feed at ambient temperature into the Use a bypass line if available or crack
pressure by cracking open the inlet bottom of the vessel at less than 25 open the outlet line to increase pressure
(top) valve or small pressure change psi/minute by cracking open an inlet in the downstream system. Once the
bypass valve. When the vessel is at or bypass valve. When the vessel is at outlet system is pressured up, open
feed pressure, open the inlet valve fully feed pressure, open the inlet or bypass the outlet line, close the bypass line
and crack open the outlet (bottom) valve fully then slowly open the flare (if used) and establish normal flow.
valve to slowly increase pressure line valve to start filling the vessel up
downstream. For ADS-120/ ADS-130 flow. Open the flare line valve so that * Note: In the unlikely event that
adsorbent, if the feed gas tempera- the rate of filling is about 50% of the the outlet temperature increases
ture is higher than 50°C AND the design feed rate. Typically a sight to more than 100°C during filling,
hydrogen level in the process gas is glass at the top of the vessel is used immediately stop the flow, drain
expected to be above approximately to determine when the vessel is full. the vessel and purge with high
10 vol%, special start-up procedures Do not allow the liquid to enter the purity nitrogen to flare. Contact
may be necessary to minimize the flare line. Some temperature rise* is your UOP representative for
impact of an exothermic reaction expected due to adsorption of the assistance.
that may occur. Contact your UOP carrier stream. Once the vessel is
representative immediately to
determine if special procedures
need to be followed. Once the
downstream is pressured up, establish
flow at near design rates through the
vessel by opening fully the outlet valve.

Some temperature rise* is expected


due to adsorption of the carrier stream.

* Note: In the unlikely event that


the outlet temperature increases
to more than 100°C when flow
is established, immediately stop
the flow, depressurize the vessel
and purge with high purity
nitrogen to flare. Contact your
UOP representative for assistance.

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Preparing spent ADS-120/ADS-130 adsorbent for unloading

Read and understand this To help minimize the presence and 4. Vent purging gas to flare to destroy
reaction of these other trace contami- hazardous compounds.
section thoroughly before nants, it is essential that certain
5. Note that the amount of available
opening a used adsorbent precautionary practices be employed
nitrogen is typically inadequate to
prior to and during unloading the
system to the atmosphere. provide the gas at velocities needed
adsorbent from the vessel. Importantly,
for effective flow distribution within
the bed must be completely purged
the adsorbent bed. To improve the
with high purity nitrogen prior to
effectiveness of the nitrogen purge
unloading to remove trace contaminants
step the following is recommended:
and create an inert atmosphere free
of oxygen and water. An inert • Repetitive pressuring and depres-
atmosphere must also be maintained suring of the bed with nitrogen can
during unloading operations to improve the effectiveness of the purge
ensure that any remaining trace step. It is best to pressure up and
contaminants do not become depressurize down flow through
displaced or react with oxygen and the bed to avoid lifting the UOP
moisture contained in ambient air to adsorbent and/or support balls. If
create a hazardous atmosphere. downward flow is not possible for
the purge step, contact your UOP
When used as intended, ADS-120/ General purging instructions representative for specific
ADS-130 adsorbents react with sulfur to prepare the adsorbent bed
recommendations.
for unloading
compounds contained in the process
1. Isolate the vessel containing UOP • Continue to pressure and
stream to form copper oxides and
adsorbent and drain any liquids and depressurize the vessel to flare
sulfides. These compounds are
depressurize it. with nitrogen until the outlet mixture
generally stable under ambient
contains less than 10% of the lower
condi¬tions as long as they are not 2. Install blind flanges on all inlet and
explosive limit (LEL) for any flamma-
exposed to oxygen, and a high purity outlet lines except the flare line.
bles and no toxic compounds. The
(minimum 99.9%) nitrogen purge (with Connect a nitrogen source at the
LEL in air of several common fluids
less than 100 ppm(m) oxygen) must opposite end of the vessel.
is shown in Table 1.
be used during unloading. However, in
addition to these components, other 3. Purge with nitrogen with a Table 1
trace contaminants from the process minimum purity of 99.9% containing LEL of Some Common Fluids
stream may be adsorbed by or less than 100 ppm(m) oxygen. Fluid Volume % in Air
deposited on the adsorbents. These Alternatively, the vessel can be Benzene 1.4
other trace compounds can become Ethane 2.9
steamed out downflow with low
concentrated on the adsorbent during Hydrogen 4.0
pressure steam at a temperature
its use and may cause the spent Methane 5.0
below 190°C (375°F), ensuring that
adsorbent to exhibit toxic, flammable n-Butane 1.6
the flow is lined up from the bottom
Propane 2.1
or unstable characteristics. Among of the vessel to a safe location. The
the contaminants of greatest concern steaming step may be continued for If you encounter any difficulties or
are hydrogen sulfides, iron sulfides 8-12 hours to drive off light have questions using the above
(from metal scale in the vessel), hydrocarbons. Steam-out must be procedures, contact your UOP
arsenic and/or mercury, and residual immediately followed by a cold representative immediately.
hydrocarbons. 5
nitrogen purge.
Unloading and handling of spent adsorbent

Read and understand Therefore, the area around the vessel


Note: Due to the possible
must be isolated and safe procedures
this section thoroughly for working in a hazardous/inert
presence of sulfur, arsenic, or
mercury and/or other contaminants,
before opening a used atmosphere must be implemented.
the spent UOP adsorbent is likely
ADS-120 or ADS-130 to be considered a hazardous
Furthermore, hazardous materials may
adsorbent system. be released during unloading of spent
waste by most governmental
authorities when generated (i.e.
adsorbent that could create a toxic,
removed from the vessel). Other
flammable or reactive environment.
hazardous characteristics of the
Be prepared for these situations.
material may also affect waste
Test the area around the unloading
classification. Packaging, storage,
operations to establish a safe
transport, treatment and disposal
perimeter and restrict access within
of hazardous waste are strictly
that perimeter to individuals who are
controlled by governmental
outfitted and trained to work in a
regulations. The facility owner
hazardous atmosphere. Implement
and operator should review these
standard grounding procedures and
regulations before initiating
have firefighting equipment available.
unloading activities, and should
incorporate all regulatory
Personnel involved with the unloading
requirements into the unloading
operation that are working outside
UOP recommends that UOP procedures.
the hazardous atmosphere perimeter
ADS-120 or ADS-130 adsorbent
should wear gloves, long sleeve shirts
unloading be conducted with high
and pants or coveralls to protect General unloading instructions
purity nitrogen (minimum 99.9%
against skin exposure, safety glasses,
with less than 100 ppm(m) oxygen). UOP recommends that purging be
goggles or face shields to protect the
UOP recommends that a nitrogen conducted with high purity nitrogen
eyes, and dust masks or respirators
blanket be maintained on the vessel (minimum 99.9% with less than 100
if adsorbent dust might be generated.
during unloading operations as trace ppm(m) oxygen). After completion of
hazardous contaminants can remain the repetitive purges described above,
Due to the hazardous nature of the
on the adsorbent, even after nitrogen start the nitrogen purge from the
spent material, UOP recommends that
purging. Always assume that some bottom of the vessel and open the
materials be immediately offloaded into
hazardous contaminants remain on loading port at the top of the vessel.
containers approved for transportation
the UOP adsorbent. In addition, always Properly trained personnel should
of hazardous/dangerous goods per
assume a hazardous atmosphere monitor the oxygen and LEL at the top
appropriate United Nations and other
exists within the vessel. Do not enter of the vessel to help ensure the vessel
requirements. Selection of the specific
the vessel unless confined space entry has an inert atmosphere.
container should be established
procedures that include provisions for
beforehand in consultation with the
safe entry under inert/ hazardous Properly trained personnel can then
disposal/treatment/ transportation
atmosphere are followed. vacuum out the inert balls on top of
company who will be receiving the
the bed into transport containers
spent material.
UOP recommends that the adsorbent located at the drumming station on
be unloaded under inert conditions. the ground.
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There should be a stainless steel 3. Vacuum out any remaining balls into 3. Once most of the adsorbent has
screen on top of the UOP adsorbent separate containers until no adsorbent been removed from the vessel, remove
bed under the inert balls. To make is observed under the floating screen the inert bed support material into
unloading easier, secure the screen to or metal bed support screen. Remove separate containers. Vacuuming the
the top of the vessel. This usually can the inert entry person and shut off the ceramic material from outside the
be done without entering the vessel. nitrogen purge. vessel may be the easiest way to
The screen can normally be secured accomplish this step. Check from
using a harpoon-type tool with a long UOP spent adsorbent manual outside the vessel to ensure that no
handle. If this approach is unsuccessful removal option through the adsorbent is under the floating screen
or unavailable, trained personnel may bottom port: or on the top bed support screen, and
enter the vessel under confined space then shut off the nitrogen purge on
procedures and secure or remove 1. UOP recommends that top loading the vessel.
the screen. shipping bins or totes capable of
holding four (4) drums of adsorbent be 4. After all of the adsorbent has been
UOP spent adsorbent vacuuming used for emptying vessels through the removed, prepare the atmosphere in
removal option: bottom port. Use of larger bins will the vessel for safe entry. Remove the
speed up the unloading operation as nitrogen purge line and attach an air
1. The adsorbent is typically removed the adsorbent will likely free-flow by mover so that air is expelled out of the
through the top manway by trained gravity at a fairly quick rate. If a bin will bottom of the vessel below the bed
personnel from outside the manway. not fit under the dump port, dumping support. The air will carry any remaining
The product should be discharged will have to be done into nitrogen vapors out of the vessel and away
into clean, dry and sealable nitrogen purged drums. All containers should from personnel. Monitor for the
purged U.N. approved transport be maintained with a nitrogen purge presence of any hazardous contami-
containers. (A nitrogen purge is also and be plastic-lined. Again, please nants as well as the oxygen level in
required on the dust collector.) note: UOP ADS-120 or ADS-130 the vessel and at the outlet of the air
adsorbents SHOULD NOT be mover to ensure that the nitrogen and
Note: UOP ADS-120 / ADS-130 unloaded into non-metallic containers hazardous contaminants have been
adsorbent should not be removed. Once safe levels have been
unloaded into non-metallic 2. Position trained and equipped established, personnel can access the
containers. personnel and open the dump port vessel under appropriate confined
at the bottom of the vessel to allow space entry procedures. Always leave
2. Once the adsorbent is removed to flow into the nitrogen purged shipping the air mover on while personnel are in
below the bottom port, the bottom container. Personnel should be the vessel and periodically monitor the
manway/(dump) port can be opened equipped with garden-type hoes to vessel atmosphere to ensure safe
and trained personnel can enter under help remove the adsorbent from the levels are maintained.
inert space procedures through the vessel. Take care not to dislodge or
top manway and use the vacuum hose damage either the floating screen in 5. For the inert bed support, vacuum
inserted through the bottom entry to an inert bed support system or the top or remove by buckets the remainder
remove any remaining adsorbent. screen in a metal bed support system. of the inert bed support material and
The bottom port flange can be used proceed to internal vessel inspection.
control or stop the flow of product out
of the dump port when changing bins 6. For a metal bed support system
or drums. proceed to internal vessel inspection.

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Disposal

The spent adsorbent is hazardous and In the unusual case where the ADS-120
should be disposed of or reclaimed in or ADS-130 products may be contam-
accordance with all governmental inated with mercury you may contact
requirements. It is feasible to reclaim UOP for assistance in placing ADS
the active copper component in the adsorbent users in contact with spent
adsorbent and, where applicable mercury guard processing facilities.
regulations permit, the reclaimed
copper may be returned to the open
As a reminder, due to the possible presence of sulfur, arsenic and other
market. When disposing the spent
potential contaminants such as mercury, the spent UOP ADS-120 or
adsorbent, condsider:
ADS-130 adsorbent is likely to be considered a hazardous waste by
most governmental authorities. Other hazardous characteristics of the
• Completing a detailed character-
material may also affect waste classification. Packaging, storage,
ization of the spent adsorbent for
waste classification purposes. transport, treatment and disposal of hazardous waste are strictly
controlled by governmental regulations.
• Selection of treatment and disposal
companies that are licensed for
mercury and sulfide containing
wastes.

• Selection of transportation
companies licensed to transport
hazardous waste.

• Selection of disposal containers


approved for transportation of
hazardous goods per appropriate
U.N. protocol. Consult with the
company handling the disposal,
treatment, and/or transportation
about the container type prior to
their receipt of the spent material.

• On-site storage and management of


spent material prior to shipment.
Emergency Assistance - 24 hour Emergency Telephone Numbers:
• Execution of regulatory paperwork
associate with safe transport and Medical or release emergencies (PROSAR) : + 1-800-498-5701 or
disposal, such as the use of + 1-651-523-0309
manifest and prior consent
Transportation (CHEMTREC) : + 1-800-424-9300 or
documentation, if the spent material
+ 1-703-527-3887
is to be exported.

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Find out more
For more information, contact your local
UOP representative or our Des Plaines office.

UOP LLC, A Honeywell Company


25 East Algonquin Road
Des Plaines, IL 60017-5017, U.S.A. UOP5746
Tel: +1-847-391-2000 February, 2012
Printed in U.S.A.
www.uop.com © 2012 UOP LLC. All rights reserved.

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