Bucket Elevator for Catalyst Processing

General Description

Catalysts are essential for speeding up chemical reactions that convert crude oil into more valuable, usable products. The process is called cracking and heavy hydrocarbon molecules are broken down into smaller ones for the production of gasoline, diesel fuel, light olefins and other products. Eurecat US, Inc. is a global leader in catalyst activation, rejuvenation, and recycling services, supporting refineries and petrochemical facilities throughout the world.

The Pasadena, Texas operation handles large volumes of spent catalyst that must be conveyed, dried, and processed with strict control to ensure safety, efficiency, and product consistency. As part of a system upgrade, Eurecat required a reliable method to vertically transfer spent catalyst from a vibratory feeder up nearly 50 feet to a surge hopper feeding an industrial spiral vibrating dryer.

The application demanded a robust, dust-tight, and continuous-duty conveying solution capable of handling abrasive catalyst material while operating in a 24/7 processing environment. Equipment longevity, process accuracy, and consistent material flow were essential to the success of the operation.

KWS Bucket Elevator Transports Spent Catalyst Vertically

Design Parameters

Product Type: Spent Catalyst
Material Density: 23 to 55 Lbs per Cubic Foot
Conveyor System Capacity: 131 Cubic Feet per Hour
Duty: 24 hours a day, 7 days a week

KWS Advantages

KWS supplied a continuous style bucket elevator specifically engineered for abrasive spent catalyst and the unique layout of Eurecat’s process line. Continuous elevators are ideal for fragile or abrasive materials because buckets overlap and allow bulk materials to flow gently from bucket to bucket, reducing wear and minimizing dust generation. To meet the project requirements, KWS incorporated heavy-duty components, precise tolerances, and a rugged design to ensure long equipment life.

KWS Special Features

The KWS continuous duty bucket elevator was constructed using abrasion-resistant components and a heavy-duty boot and head assembly designed for the demanding characteristics of spent catalyst. Dust-tight intermediate and inspection housings sections minimized airborne particulates and improved plant safety. The inlet was engineered for smooth, controlled feeding from the vibratory feeder, while the discharge section with adjustable throat plate ensured uniform material flow into the surge hopper for accurate metering into the industrial spiral vibrating dryer.

A Dodge TAII high-efficiency shaft-mounted gear reducer was supplied and well suited for tight space constraints. A V-belt drive allows simple speed adjustment and easy maintenance.

Hardened tooth sprockets and heavy-duty engineering class chain contributed to long service life and reliable 24/7 operation. Maintenance-friendly access points and OSHA-compliant guarding simplified inspections and ensured operator safety.