Keep track of the spent catalyst packaging during unloading and note the reactor and bed number on each drum together with the sequential drum number. Establish a sampling strategy: take samples during unloading and submit them for analysis. If the question is solely whether or not a batch is suitable for regeneration, then a simple visual check may already be sufficient to determine whether the catalyst is a candidate for regeneration or not, thereby avoiding further analysis costs. Conduct a sieving test to determine screening losses and measure the particle length distribution. If losses are low (below 10 wt%) and particle length is acceptable, proceed with careful lab regeneration, to determine loss on ignition, and prepare samples for contaminant investigation. If contaminant levels are acceptable (ask catalyst supplier for guidelines), then the catalyst may be regenerated by qualified vendors. Compiling a specific sampling and analysis plan can minimise the costs of determining regenerability.
