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Chemical Reactor Process Trainer with PLC

Direct and Catalytic Combustion Heads

Description and Specifications are preliminary and subject to revision

Description: Continuous flow reactors are common unit operations in chemical processing plants. They are found throughout the petroleum, petrochemical and numerous other industries. The Chemical Reactor Trainer is a reduced scale plant that demonstrates continuous flow, exothermic chemical reaction.
  • Reactants are hydrocarbon fuel and atmospheric oxygen; products are combustion flue gasses (CO2, CO, H2O and perhaps traces of NOx).
  • The process has instrumentation to provide for reactant flow rate control, product gas analysis, temperature and pressure indication and an interlocking safety system.
  • The entire trainer is controlled from a DCS or PLC computer interface with custom designed software and control configuration. •
  • This gives the student the opportunity to gain real operating experience focusing on both the process of exothermic chemical reactions and on control strategy.
  • Chemical Reaction Kinetics
  • Process Control
Sub Topic:
  • Exothermic Chemical Reactions
  • Continuous flow reactor operation
  • Material Balances
  • Industrial stoichiometry
Key Learning Objectives:
  • Continuous flow reactor operation and measurement
  • Equipment start-up and operating procedures
  • Process control concepts for manual and automatic operation
  • Material balances
  • Impact of varying operating conditions of reactant flow, excess or limiting reactants and residence time
  • Control experience on a Programmable Logic Controller(PLC)

Equipment Specification Highlights:
  • Continuous up-flow reactor with interchangeable direct combustion and catalytic combustion tips
  • Stainless steel reactor vessel with refractory blanket lining – 300mm (12”) OD X 600mm (24”) high
  • Integral viewing ports
  • Flow measurement of reactant streams (fuel, primary air and secondary air)
  • Analysis of product stream
  • Thermocouple temperature measurement
  • Electronic process measurement,
  • Control cabinet with:
    • Power supply, switching, transformer and controls
    • PLC or DCS with I/O cards
  • Pneumatic control valves
  • Dedicated computer control station with PID control
  • Custom programmed software configuration and computer/operator interface
  • Interlocking safety system to stop fuel flow in the event of a flame failure
  • Electronic ignition system
  • Integrally mounted fuel canister (propane, butane or LPG mixture)Time to reach steady state after a reasonable step change – less than 10 minutes
  • Complete unit mounted on a stainless steel frame
  • Personnel protection shields on hot surfaces
  • Approximate overall dimensions – 1500x90x1500 cm high (60” wide x 30” deep x 60” high)
  • Also included is a manual containing Instructor notes, Student Exercises modules and service manuals for all components
  • Optional self-contained with dedicated air compressor, receiver and pressure control
  • Available in all world voltages / frequencies (customer to specify electrical power available on-site)
  • Electrical power single phase (all world voltages)
  • Instrument Air
  • Cooling water
Process Schematic
Chemical Reaction

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