YOUR RELIABLE PARTNER

FOR CATALYST - HANDLING

UNIDENSE TM

Technology GmbH
 D - 01987 Schwarzheide
Alexander - von - Humboldt - Str. 2

UNIDENSE TM Technology GmbH

Telephone: +49 - 35752 - 947814

Fax: +49 - 35752 - 947829

Website: www.unidense.com

E-mail: [email protected]

UNIDENSE TM

Technology GmbH
 TABLE OF CONTENTS

1. ABOUT US

2. OUR SERVICE

REFORMER SPECIALIST SERVICE

HISTORY

TECHNOLOGY

3. CATALYST HANDLING

4. SAFETY

5. CONTACTS

UNIDENSE TM

Technology GmbH
 1. ABOUT US

UNIDENSE™ Technology GmbH was establi- We serve our clients through a selective network
shed in 2005 and is located in the center of Euro- of global qualified contractors that use the UNI-
pe, Schwarzheide Germany. UNIDENSE™ Tech- DENSE™ technology under licensee. We are the
nologie was established when Mourik Internatio- specialist of fertilizer, petrolchemical and gene-
nal bought the UNIDENSE™ from Yara Interna- ral catalyst industry. UNIDENSE™ Technology
tional (previous Norsk Hydro Agri) on April 1st GmbH supports this network with supervision,
2005. At present the technology has over 600 technical support and quality control.
worldwide references. The technology has suc- It is our objective to work with you to ensure an
cessfully been used to load tubes with internal optimal reformer catalyst change - out which will
diameter ranging from 2.8“ to 6“ and all common make your production processes more reliable,
catalyst types and sizes have been loaded. more efficient and more predictable.

UNIDENSE TM

Technology GmbH
 1. ABOUT US

MOURIK INTERNATIONAL GLOBAL PRESENSE

UNIDENSE TM

Technology GmbH
 1. ABOUT US

Mourik International
Turnover per discipline

5% Dense loading
20% Tubular Reactors

15% Vacuum and HP

cleaning
50% General catalyst handling
10% Mechanical Work

Mourik International
Volumen pro Typ der Industrie

4% Other 3% Steel
8% Fertilisers
35% (Petro) chemical

50% Refining

UNIDENSE TM

Technology GmbH
 2. OUR SERVICE

UNIDENSE™ TECHNOLOGY AS SPECIALIST FOR PRIMARY REFORMER

The history of UNIDENSE™ loading technology

The UNIDENSE™ technology was developed

by Mr G. Ryntveit as employee of Yara Interna-
tional (previous Northst Hydro Agri). Develop-
ment took place at Hydro`s Research Center
in Porsgrunn, Norway, during 1991 in order to
improve the quality of the primary reformer ca-
talyst loading in ammonia plants within Hydro.
Test results and the result from the first loading
were presented at the AIChE conference in San
Antonio in 1992. Since then Hydro Agrihas been
utilizing the technology for all replacements of
primary reformer catalyst, and the technology
has since been made available for companies
outside of the Hydro group. G. Ryntveit was re-
sponsible for the UNIDENSE™ technology as
employee of Hydro until October 2001, until he
took early retirement. He gave other companies
the permission to use the license for UNDEN-
SE™ technology worldwide. As from April 1st
2005 UNIDENSE™ Technology GmbH with as-
sistance of G. Ryntveit is the owner of the UNI-
DENSE™ technology.

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

The UNIDENSE™ loading equipment con-

sists of the following basic components:

Funnels

The part of the funnel where the catalyst is flowing

in an angle into the tube. In the neck of the funnel
where the catalyst enters the tube slits are made
in order to remove some of the catalyst dust during
the loading. A rubber sheet where catalyst is
charged will reduce catalyst dust formation an
reduce the noise level during the loading.

Brushes

The brushes consist of a body of springs through

the centre. The springs are equally distributed to
cover the cross-section of the tube and are fixed
in the body. The number of springs is selected
according to the diameter of the tube and the size
of the catalyst particles to be loaded. Thickness,
length and stiffness of the steel springs are var-
iable. The springs shall reduce the speed of the
falling catalyst particles, but not stop them, so
that the catalyst is loading without the particles
being crushed.

Loading rope

The loading rope is made up with a weight in the

bottom connected directly to the first brush. The
3 brushes at the end make up the first part of the
rope; on the distance between remaining brus-
hes are approx. 1m. When 2 or more layers of
catalyst are to be loaded, the outage from the
top of the funnel to each layer is calculated and
„flags“ of thin steel plate are fixed to the rope in
order to let the rope act as a measuring tape.

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Technology

THE PRINCIPLE OF UNIDENSE™

TECHNOLOGY

The UNIDENSE™ technology is a catalyst loa-

ding method for primary reformer tubes which is
less complex and faster than the traditional „sock“
loading method. Catalyst is slowly filled into the
tube through a specially designed funnel and the
loading rope is gradually pulled out of the tube as
the catalyst layer builds up. The brushes with
flexible springs reduce the speed of the catalyst
particles so that breakage is avoided. With the
UNIDENSE™technology the catalyst particles
will have a free fall from the lowest brush to the
catalyst surface. This gives a „low intensity“ filling
and the particles will come to rest before being
interlocked by other particles. Hence, there will
not be any risk for bridging, and vibration of the
tubes is not necessary. The UNIDENSE™ tech-
nology ensures a filling without extra voids and
a high uniform density along the full length of
the tubes. The catalyst is loaded directly from
buckets and the time consuming and expensive
socking of the catalyst is avoided.
Weighing of catalyst loaded in each tube is not
necessary.

Several layers of catalyst

When more than one type of catalyst is to be loa-

ded in the tubes with the UNIDENSE™ techno-
logy the level for each type is easily adjusted by
marks on the loading rope, and frequent measu-
rement of loading outage is therefore not neces-
sary. We have experience from an emergency
loading with 5 different types (shapes and sizes),
including used and screened catalyst.

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Pressure drop variation

The guaranty for the variation in pressure

drop measurement of the loading is that
the final result shall be within ± 5% of the
average. However, a variation of ± 3% or
less is a realistic target when a careful loa-
ding has been made. The pressure drop
is normally measured with the plant`s own
equipment and personnel as a quality con-
trol, and is normally taken during night in
order to minimize variations in temperature
and atmospheric pressure.

High uniform density - Less settling of catalyst during operation

With the UNIDENSE™ technology it is often experienced that more catalyst (3 to 7%) is loaded
than with the „sock“ method and normal vibration. This is due to the uniform packing of the cata-
lyst. The increase in density does not result in increased pressure drop in the reformer as nor-
mally should be expected. The explanation to this is that „sock“ loading and vibration results in
spots with locally very compact and high density, causing increased pressure drop. The UNI-
DENSE™ loaded density is uniform all through the tube and high enough to avoid settling of the
catalyst during operation. Experience from one plant with many starts and stops, is that the sett-
ling of the catalyst was even and only a few inches in all the tubes.

„Sock“ loading method

The traditional“sock“ loading method results in a loose filling with large gaps between the cata-
lyst. When the catalyst flushes out of the sock this will be a „high intensity“ filling and the cata-
lyst particles may (will) interlock and from bridges. Vibration will remove some of the bridges and
increase the density. After the plant is started, the tubes will expand due to the heat and some
bridges may break and cause settling of the catalyst and possibly new bridges and hot spots.
When vibration is used on the top of the tube it is obvious that the effect of the vibration in the
lower/bottom part of the tube will be smaller. The experience is that settling of the catalyst after
a „sock“ loading has been to such an extent, that the catalyst level has been inside the heated
zone and resulted in overheating of the top part of the tubes.

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Benefits of the UNIDENSE™ technology:

Socking of catalyst and weighing of the socks prior to loa-

ding is time consuming and is avoided with the UNIDEN-
SE™ technology. However, the catalyst has to be brought
to the tubes, and there is a good experience with transfer
of the catalyst in bags or bucket with up to approx. 30kg.
Bagging of the catalyst is much faster than filling a large
number of socks and only a few bags need to be weighed.
Also there is very good experience by using hoppers and
charging the catalyst directly in buckets which is carried to
the tubes. The UNIDENSE™ technology is a fast loading
method. The actual time for loading a tube with UNIDEN-
SE™ varies depending on the tube dimensions and length
of the tube, e.g. a 4“ diameter tube will take approx. 10 mi-
nutes (one of catalyst type) including the final outage mea-
surement. A reformer with 300 to 400 tubes is normally com-
pleted in 3 to 4 shifts of 12 hours. The time it takes to com-
pete a reformer loading with the UNDENSE™ technology
is often less than half of the time for sock-loading. Often the
time to replace the primary reformer catalyst is the critical
itern in a maintenance plant stop and reducing to down time
is the owner‘s main goal. Even using less man-hour for ca-
talyst replacements is a great benefit. Pressure drop of the
tubes has proved to bewithin a narrow range with the ma-
jority within ± 2,5% variation of the average pressure drop.
Rarely tubes have pressure drop outside of ± 5%, and most
of the reformers have been completed without reloading of
tubes. Since reloading of tubes is avoided, less (no) expen-
sive catalyst is wasted. Often when a „sock“ loading is made
problems like losing a part, or a full sock into the tube hap-
pens. Sometimes the sock opens during lowering in tube
and catalyst falls freely causing catalyst breakage. The vi-
bration method used by various teams is variable which
leads to large variations in loaded density and pressure
drop. Adjustment of the loading by vibration and reloading
of tubes is time consuming and may delay start up of the
plant. Such or similar problems are avoided by the UNI-
DENSE™ technology, and therefore tubes don‘t need to
be emptied and reloaded very often. We only see positive
effects and no negative risks of using the UNIDENSE™
technology compared with the „sock“ loading method. The
even and stable pressure drop results in even tube wall
temperatures and the high uniform loaded density will
ensure a long life of the reformer tubes and allow for im-
proved conversion and increased throughput. Using the
UNIDENSE™ technology contributes to extend the opera-
ting period and maintenance intervals.

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Benefits UNIDENSE™ in summary

Fast reformer loading

No presocking of catalyst

No vibration of tubes

Uniform pressure drop

Less waste of catalyst

No bridging or extra voids

- minimizes hot spots

- reduces catalyst settling

High uniform density

- Lower tube wall temperature

- Prolonged tube life

- Increased reforming capacity

Different internal tube diameters

Some tubes have less internal diameter in the top part to give room for the top flanges. This tube
design may be difficult to load with „socks“ because the sock diameter must fit the smallest top
section. In the part of the tube with larger internal diameter the sock may easily open and catalyst
will fall freely resulting in breakage. By applying a special design of the loading ropes we have
successfully loaded a number of plants with such tube design by the UNIDENSE™ technology
and obtained excellent results.

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

UNIDENSE™ comparison with Spiraload™

UNIDENSE™ Spiraload™

Number of tubes 504 504

Tubes ID, mm 85 85

Loading height, m 10.1 10.1

Loading profile 60% 57-4 (bottom)// 60//20//20%

40% 25-4 (top) Standard 7 holes // K
doped and pre-reduced

Volume of catalyst loaded, m³ 28,9 28,9

Number of supervisors involved 1 3

(in total)

Work organization 11-12 hours daily shift Around the clock

Number of loading units used 4 ropes 2 spiraload units

PD measurement 3 times (empty tubes, 3 times (empty tubes, 60%

25-4 only and fully bottom loaded and fully
loaded tubes) loaded tubes

Dates and loading time 15-19/07/2003,4.5 22-29/2003,7.5

working days in total) working days in total

Man - hours spent for loading 16*11.5*4.5=828(100%) 8*24*7.5=1440(174%)

(roughly)

Number of tubes required 0 4 or 5 tubes required

reloading partial discharging (more
than 60% of the first
catalyst initially charged)

Claims: UNIDENSE™ takes 7 - 14 minutes per tube

Variation in UNIDENSE™ P is ± 3%

SPIRALOAD™ takes 15 - 30 minutes

Variation in SPIRALOAD™ P is ± 5%

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Result analysis

UNIDENSE SPIRALOAD

Vendor supervisors 1 3

Shift length 12 hours 24 hours

Loading results(504 tubes) ±4% 495 tubes similar

Total loading time 4,5 days 7,5 days

Total man hours 828 1440

Relative man hours 100% 174%

No. Reloaded tubes 0 4-5

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

UNILOADERTM
The UNILOADER™ is a machine to automatically load reformer tubes with catalyst by the
UNIDENSE™ principle. The Uniloader™ is a leading and proven technology used within the
SYNGAS industry to load Methanol, Hydrogen and fertilizer reformers with catalyst.

The UNILOADER™ brings extra benefits to the UNIDENSE™ technology. The possibility for
human error is eliminatd and the system works even more accurately. This results in a better
density and improves the average pressure drop to 3%. This improved performance is achieved
in combination with an even faster loading (up to two times) than the manual technique.

The UNILOADER™ technology is used for loading all common catalyst types and sizes. Re-
former tube designs with varying internal diameter, narrow or wide top section, have succes-
fully been loaded.

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Advantages UNILOADER™

... the UNILOADER™ takes over the assignment from 2 employees

... steady, continuous loading

... no emptying of loaded pipes is thereby necessary

... therefore less catalyst must be purchased

... the dust suction reduces the dust charge in the pipe
and the workplace

... by the closed coverage type there is no loss of catalyst

... every tube will be charged with the same weight in catalyst

... minimal spring break by steady and slow roll up of the

loading rope above the tube. Thereby there exists no con-
tamination danger and no damage to the springs can occur.

... by the reduced spring break less foreign bodies appear in the tube.

... 20% of quicker load with the UNILOADER compared with the normal
procedure can be reached.

... no human failure

... higher uniform density

... improvement of the average pressure

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

UNIDENSE X-LOAD

Following an initial patent application in 2005, The connectors of the dampening means are
BUCHEN-ICS GmbH and UNIDENSE™ Tech- aligned in an out-of-centre manner relative to
nology GmbH have agreed to further jointly co- the reactor tube. This allows for more free area,
operate n the development of „UNIDENSE X- when viewed in a vertical projection, for the par-
Load“ .The X-Load offers an important impro- ticles to pass trough. The angles between the
vement in the loading of smaller reformer tubes, dampening means should be chosen so that
i.e. up to 4 inch. UNIDENSE™ Technology GmbH no particles can pass through unhampered, yet
will offer this improvement to its UNIDENSE™ a steady flow of particles is allowed. For the
Licensees. same dimensions of connector and dampening
The X-loading System uses horizontally aligned means, a symmetrical alignment around the
damping means at various levels, spaced ap- tubes central axis creates a very stiff middle
prox. 1.0m apart and mounted together in a section, with hardly any free area for the flow
flexible way, allowing an easy lowering an hoi- of particles. Decreasing the size of connectors
sting up the damping means as the catalyst and dampening means is not always possible,
level inside the reactor tube rises. The damping but an out-of-centre positioning of the connec-
means slow down the fall speed of the catalyst tors with varying length dampening means al-
particles, effectively avoiding breakage and guar- lows for more free area with the same dimen-
anteeing a high density of the particles by al- sions of the various components, as illustrated
lowing each particle to settle in a stabile posi- in the figure below.
tion before the next one comes.

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Project: February 2009

Praxair Dormagen Germany

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Projeckt: February 2009

Praxiar Dormagen Germany

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Project: February 2009

Praxair Dormagen Germany

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

New equipment for outside reformertube

cleaning

Description:

Pneumatic driven brush system, which climbs up and down the heated side of
the tubes.

Reference:

NH3 Primary Reformer, YARA Sluiskil Netherlands, September 2006, 170 Tubes
with OD 146mm, Heated L, and 15 Mtr.

Results:

Removal of approximately 600 Kg pollution and scale which results in a better

transfer of heat.

Cleaning time:

Cleaning time per tube of approx. 18 min including the time taken to reset the
brush for the next tube.

Advantages:

As it reaches the bottom of the furnace there is no need for scaffolding.

More info:

Do you need more information, don‘t hesitate to contact us:

Herr Peter Richter ([email protected])

UNIDENSE TM

Technology GmbH
 2. OUR SERVICES

Licencees

UNIDENSE™ is a patented loading technology, which is available through UNIDENSE™

Technology GmbH as the owner of the technology, and the following selective licensed
companies:

Anabeeb Intustrial Services Co.Ltd. (Saudi Arabia),

Buchen ICS GmbH (Germany),

Catalyst Loading and Services (Norway),

Contract Resources (S9 PTE Ltd. (Thailand),

Contract Resources (Australia),

Johnson Matthey Plc. (UK),

Mourik Caribbean N.V. (Aruba),

Mourik General Contractors Venezuela C.A. (Venezuela),

Mourik International B.V. (The Netherlands),

Mourik LP (USA),

Petroval S.A. (France).

Clients which intend to use the method have access to the technology through UNIDENSE™
Technology or any of the above mentioned companies. Equipment, loading funnels and load-
ing ropes, which is tailor made to fit each reformer, is only availabe together with supervision.
When UNIDENSE™ Technology GmbH is supervising a loading; the loading is either made by
a contractor hired by the client or by the plant personnel.

UNIDENSE TM

Technology GmbH
 3. CATALYST HANDLING

Our services include catalyst handling in all type

reactors including mechanical work under inert
(N2) or air atmospheres in a „blinds to blinds“
approach.

The range of equipment includes specially manu-

factured machinery for services requiring con-
tinuous discharge of catalyst/support media,vacu-
uming, screening, abd cooling/recycling of nitro-
gen.

Our equipment is designed to minimize catalyst

attrition and exposure to unwanted dust particles
typically expelled during loading/unloading ope-
rations. To complement these services we also
offer closed circuit video inspection, removal
and cleaning of vessel internals, blinding and
bolt tensioning and welding.

We offer pre-engineering services including

planning, scheduling, coordination and above
all, the right solutions for your problems. These
services complement and support the specialty
loading process, notably for assuring better den-
sity and/ or uniformity of beds.

All these skills are acquired though stringent

training programs with own facilities for life sup-
port and rescue training confined spaces.

UNIDENSE TM

Technology GmbH
 3. CATALYST HANDLING

Main services include:

Inert Entry (N2) - for catalyst unloading/ reloading as well as other

applications

Dense Loading - DENSICAT technology under license from Petroval

(total-Fina-Elf)

Dense Loading - technology under license from UOP (USA)

UNIDENSE™ - loading technology for reformer tubes under license

UNIDENSE™ - Technology GmbH

Catalyst Screening - under inert and normal atmospheric conditions

Reactor Internals - removal of reinstatements, video inspection, repairs,

modifications, upgrades, passivation

Reformers (Furnace) - total service including tube changing/ welding

and uniform loading

Reformers/ Platformers - catalyst change outs, mechanical works and

installation

Ammonia Converters - total service including upgrading and specialty

welding

CCR - total service including center pipe and scallop removal, repair,
welding and replacement

HCU - total service including repair, soda ash washing, welding and
dense loading

EO-Tabular Reactors - catalyst change outs

FCC - catalyst vacuuming and coke removal

UNIDENSE TM

Technology GmbH
 4. SAFETY

Pro-active participation in trade & industry platforms

UNIDENSE™ Technology GmbH pro-active attitude has led to a leading position in the field of
KAM management. This is reflected among other things in the participation in various trade &
industry platforms in the fields of safety and quality, such as:

the Central Board of Experts for VCA (Safety Checklist Contractors);

the Safety Steering Committee of the VOMI (Association of Employers in the

Metallurgical Industry);

various SIR working groups on training courses (SIR= Industrial Cleaning Council);

the Central Board of Experts for the development of Evaluation Guideline BRL 007
for industrial cleaning;

the chairmanship of the working group Training Courses of the DICA (Dutch Industrial
Cleaning Association)

Internal safety courses

The KAM Department also develops and organizes various specialist safety courses. The or-
ganizing of internal safety courses produces fruitful dialogue with employees and enables
flexible anticipation of particular situations. Both the KAM consultants organizing the courses
and the employees attending them benefit from these courses. Meanwhile a lot of experience
has been acquired with internal courses and a lot of teaching material has been procured.
Today the safety courses enjoy great renown and are attended (inter)nationally by personnel
of many fellow subsidiaries and third parties. An essential feature of the courses is their ex-
cellent practical orientation. Many courses can be followed in a number of different languages.

It goes without saying that all our operational personnel hold the Basic Safety VCA Certificate
(Safety for Contractors). All senior operational staff from the level of foreman and above also
holds the Safety for Operational Supervisors SCC certificate.

In compliance with the requirements of health, safety and environment we have received the
following certificates:

UNIDENSE TM

Technology GmbH
 5. CONTACTS

UNIDENSE™ Technology GmbH

Alexander - von - Humboldt - Strasse 2

D - 01987 Schwarzheide

Germany

Telephone: +49 - 35752 94 78 14

Fax: +49 - 35752 94 78 29

Website: www.unidense.com

E-mail: [email protected]

Geschäftsführer: Bernd Richter, Jelle Kramers Amtsgericht: Cottbus HRB 7271 CB

UNIDENSE TM

Technology GmbH