Catalyst handling and reactor services


Specialised catalyst handling, dense loading and inert-entry-free reactor services for refineries, petrochemical and LNG sites.
about

About

Specialist catalyst handling
and reactor services for complex turnarounds

Cleanaway’s Industrial Services (Contract Resources) delivers world-class catalyst handling and reactor services for refineries, petrochemical plants and LNG operations across Australia and offshore energy environments. Our teams specialise in safe, efficient and fully compliant catalyst change-outs, inert-entry work and reactor maintenance, using advanced automation to remove people from high-risk conditions and deliver faster, more predictable turnaround outcomes.

Contract Resources full colour logo

These capabilities form part of Cleanaway’s integrated Industrial Services offering, strengthened through our integration with Contract Resources.

Driving certainty in high-value turnarounds 

By combining specialist crews, proven methodologies and automation, we help deliver faster, more predictable outcomes for refineries, petrochemical and LNG operations. 

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CW_Web_Asset_CATALYST HANDLING

Removing people from harm’s way

Through inert-entry techniques and automated systems, we help customers manage catalyst change-outs safely, compliantly and with greater control. 

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Service

Who we work with

Refineries and petrochemical plants   

Supporting catalyst change-outs, dense loading and reactor maintenance for major refining and processing facilities.   

LNG and gas processing facilities

Delivering inert-atmosphere catalyst handling, reactor cleaning and hazardous material management for LNG trains and gas plants. 

Energy and industrial operators

Providing automated catalyst handling, screening and reloading across high-risk industrial environments. 

Engineering, shutdown and turnaround teams 

Working closely with EPCs and plant shutdown managers to deliver safe, compliant and efficient change-outs. 

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Process

Our process

Planning and inert entry preparation
We develop detailed project plans, hazard assessments and nitrogen-purge strategies to ensure reactors are brought offline safely and prepared for entry-free or controlled-access handling.
Automated unloading and dense loading
Using CatSpider™ and other remote systems, we unload and reload catalyst at high speed with zero inert-entry exposure, improving accuracy, safety and throughput.
Screening, treatment and containment
Catalyst is screened, conditioned, contained and managed under strict environmental and safety controls, with compliant handling of mercury-impacted, NORM or hazardous catalyst media.
Quality control, testing and recommissioning support
We complete inspection-ready cleaning, vessel integrity checks, documentation and final verification to support safe recommissioning and optimal performance.
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Details

Technology specialist capability

CatSpider™ robotic unloading

Fully remote catalyst removal that eliminates inert-entry exposure, doubles unload rates and reduces overall turnaround duration.

Dense loading and automated packing

Precision dense-loading technology ensures uniform catalyst distribution for maximum reactor performance and improved run length.

Nitrogen recirculation and inert atmosphere control

Specialised systems maintain safe oxygen levels and controlled atmospheres during catalyst handling, screening and reloading.

Hazardous and Mercury/NORM handling

Integrated solutions for mercury-bearing catalyst, contaminated fines and NORM materials, with direct pathways to the Gap Ridge Processing Facility for high-temperature treatment. 

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Details

Outcomes for your operation

Cleanaway delivers catalyst handling services that set new benchmarks for safety, speed and technical performance across refinery, petrochemical and LNG operations. By removing personnel from inert vessels and confined spaces, we significantly reduce risk while improving project predictability and asset uptime.

Our advanced technologies, including CatSpider™ robotics, dense-loading equipment and nitrogen recirculation systems, deliver cleaner reactors, faster cycle times and greater consistency across multi-bed units. These methods have been adopted by major operators including BP, Santos, Chevron and Woodside, who seek safer and more efficient alternatives to traditional catalyst handling approaches.

Through our Industrial Services (Contract Resources) integration, we offer a complete reactor lifecycle solution—from unloading and screening to mechanical support, vessel cleaning, hazardous waste treatment and final recommissioning. Whether delivering a standalone catalyst change-out or supporting a full refinery turnaround, we ensure every project meets strict safety requirements, environmental standards and operational goals.

 

Output

What happens to the waste

Catalyst media, fines, mercury-bearing residues and NORM-impacted materials are safely contained, transported and processed through Cleanaway’s licensed treatment network. Hazardous catalyst waste streams are directed to our Gap Ridge Processing Facility for high-temperature treatment, metal recovery and compliant disposal, ensuring full traceability and environmental protection across every project.
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Our promise

Why choose Cleanaway

  • A one-stop solution

    We offer an expansive range of services, custom waste solutions and expert support to meet the waste management and resource recovery needs of Australian businesses, councils and industries of any size. 

  • Optimised waste management solutions

    Our team of resource recovery professionals work closely with you to find the best waste management solution for your business, helping you achieve cost savings while meeting your sustainability goals.

  • Market-leading infrastructure

    Our EPA-licensed, state-of-the-art facilities enable safe, efficient waste processing and resource recovery at scale.

  • Making a sustainable future possible together

    We’re leading the way in sustainable waste management and resource recovery, helping Australia to transition to a circular economy and investing in lasting solutions for the benefit of all Australians – now and into the future.