Apollo screens

Scaled Traps

PRODUCT OVERVIEW

Protect Catalyst. Control Fouling. Extend Run Length

Apollo Screens’ Scale Trap Wedge Wire Screens are precision-engineered reactor internals designed for hydroprocessing units, including hydrotreaters and hydrocrackers. Installed above the catalyst bed or integrated with distributor trays, Apollo scale traps effectively capture metallic scale, rust, coke fines, and particulate debris before they reach the catalyst — significantly reducing pressure-drop rise and extending catalyst life.

Industry Challenge

Hydroprocessing feeds often contain contaminants generated from:

  • upstream corrosion (iron oxide scale),
  • coke fines from delayed coking or FCC units,
  • silica and pipe debris.

These solids accumulate at the top of the catalyst bed, leading to:

  • rapid pressure-drop increase,
  • flow maldistribution and channeling,
  • premature catalyst deactivation,
  • unplanned shutdowns and higher operating costs.

Global licensors and refiners recognize mechanical scale trapping as a critical first line of defence in fouling-prone reactors.

Apollo Solution: Wedge Wire Scale Trap

Apollo Screens delivers robust, high-open-area wedge wire scale traps that mechanically intercept and disperse solid contaminants before they plug the catalyst bed.

Why Wedge Wire?

  • Continuous V-wire profile creates a self-cleaning effect
  • High open area with precise slot control
  • Superior mechanical strength under catalyst dump conditions
  • Proven performance in high-temperature, high-pressure environments

Key Benefits

  • Slows pressure-drop rise and stabilizes reactor performance
  • Protects high-value catalyst from abrasive contaminants
  • Extends run length and improves on-stream factor
  • Minimizes top-bed crusting and localized fouling
  • Retrofit-friendly designs for existing reactors
  • Low maintenance, designed to survive catalyst handling and dumping

Typical Applications

  • Naphtha & Diesel Hydrotreating Units
  • Residue Hydrotreaters (RHT)
  • Hydrocrackers (HCU)
  • Units processing FCC, coker, or opportunity crudes

Performance Expectations

While results vary by feed contamination level and trap sizing, properly designed Apollo scale traps have demonstrated:

  • significantly reduced pressure-drop ramp rates,
  • improved catalyst utilization,
  • longer cycles between turnarounds,
  • reduced need for excessive guard bed volumes.

Inspection & Maintenance

  • Designed for easy visual inspection during shutdowns
  • Capable of mechanical cleaning (wire brushing or washing)
  • Structurally robust to withstand catalyst dumping and reloading
  • Replaceable modules available if required

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How It Works

  1. Feed enters the reactor and flows through the distributor tray.
  2. Solid contaminants are intercepted by the Apollo wedge wire scale trap.
  3. The increased surface area spreads collected debris evenly instead of allowing localized accumulation.
  4. Clean, evenly distributed flow reaches the catalyst bed, maintaining performance and pressure drop stability.
  5. Trapped debris is removed during scheduled turnarounds or remains mechanically stable during catalyst replacement.

Design & Construction Options

Apollo Screens custom-engineers each scale trap based on reactor duty and feed characteristics.

Available Configurations

  • Flat or curved wedge-wire baskets
  • Annular or segmented trap assemblies
  • Tray-integrated scale traps
  • Modular, removable cassette designs

Slot Openings

  • Engineered slot sizes typically from 0.05 mm to 3.0 mm, optimized for feed particle size distribution

Materials of Construction

  • SS304 / SS316 / SS316L
  • Duplex & Super Duplex stainless steels
  • High-alloy materials for corrosive or high-TAN feeds

Why Apollo Screens

  • Decades of wedge wire manufacturing expertise
  • Proven designs trusted by global OEMs and process licensors
  • Precision slot accuracy and high structural integrity
  • Custom engineering for demanding hydroprocessing environments
  • End-to-end support: design, manufacturing, testing, and site fitment

Get the Right Scale Trap for Your Reactor

Provide Apollo Screens with:

  • feed contamination data (iron, silica, fines),
  • reactor dimensions and operating conditions,
  • turnaround or retrofit schedule.

Our engineering team will recommend the optimal wedge wire scale trap design, complete with drawings and technical justification.

Sustainable Solutions for Industry

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Power & Energy

Comprehensive internal components optimized for maximum separation efficiency, operational safety, and reduced maintenance cycles.

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