Dynamic simulation is a powerful technique for the study of batch processes. It can be used in design development, design validation, process optimisation and problem analysis. The presentation link reviews the various configurations used to control stirred tank reactors. It also discusses the application of heat transfer oils for the heating and cooling of reactors.”

1. Dynamics Seminar
Section 7 Batch Reactor Summary
John Edwards, P&I Design Ltd
November, 2018
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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
HEAT & MASS BALANCES

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
VOLUME SCALE UP CHARACTERISTICS
1.00
10.00
10 100 1000 10000 100000
HTA/UnitVolume(1/m)
Reactor Volume (litres)

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
GLASS LINED VESSEL HEAT UP TIMES
0
20
40
60
80
100
120
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
TemperatureºC
6.3 m3 12.5 m3 25.0 m3
Time h

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
JACKET FLUID PHYSICAL PROPERTIES
Liquid Density
Liquid Heat Capacity
Liquid Viscosity
Liquid Thermal Conductivity

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BATCH REACTORS
HEAT TRANSFER FLUID SELECTION

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BATCH REACTOR
HEAT TRANSFER OIL SELECTION

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
HEAT TRANSFER OIL ADVANTAGES
SINGLE FLUID SYSTEM WITH NO PHASE CHANGE
SINGLE FLUID SIMPLIFIES CONTROL SYSTEM
MULTIPURPOSE PLANT WIDE TEMPERATURE RANGE
THERMAL SHOCK EFFECTS CONTROLLABLE
FLUID PROPERTIES STABLE OVER WIDE RANGE
NO CORROSION CLEAN HEAT TRANSFER SURFACES
JACKET SIDE EROSION MINIMISED
REDUCED MAINTENANCE COSTS

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
HEAT TRANSFER OIL DISADVANTAGES
HIGHER CAPITAL EQUIPMENT COST
HIGH COST OF INITIAL FLUID CHARGE
LOWER THERMAL EFFICIENCY THAN WATER SYSTEM
SPECIAL COMMISSIONING PROCEDURES
SPECIAL OPERATION & MAINTENANCE PROCEDURES
LONGER DOWNTIME ON EQUIPMENT FAILURE
FLAMMABILITY-TOXICITY-ODOUR-GMP ISSUES

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
DIRECT HEAT COOL
DIRECT HEAT - COOL
DIRECT HEAT – COOL INDIRECT CHILL

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT HEAT DIRECT COOL

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT HEAT DIRECT COOL

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT HEAT DIRECT COOL

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT HEAT DIRECT COOL - VALVES
Fail Open
C-12mA O-4mA
Fail Closed
C-12mA O-20mA
Fail Closed
C-4mA O-20mA

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT HEAT DIRECT COOL - RESULTS

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT HEATING INDIRECT COOLING

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT DIRECT COOLING CURVES

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTORS
INDIRECT HEATING INDIRECT COOLING

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT HEATING INDIRECT COOLING

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT HEATING INDIRECT COOLING
BATCH REACTOR TEMPERATURE RESPONSE - MIXING NOZZLES
0
20
40
60
80
100
120
140
160
180
0 50 100 150 200 250 300
Process Time (min)
Temperature(degC)
Contents T Wall T Jacket T Set Point T

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
INDIRECT HEATING INDIRECT COOLING
REACTOR JACKET FLOWS
0
2000
4000
6000
8000
10000
12000
14000
0 50 100 150 200 250 300
Process Time (min)
HTFFlowrate(kg/h)
Heating Loop Cooling Loop Bypass Loop

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
SHELL - PLATE HEAT EXCHANGER

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SIMULATION SUITECHEMCAD SOFTWARE
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SHELL - PLATE HEAT EXCHANGER
HTC CONTROL FROM EXCEL DATA TABLE

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
PARALLEL KINETIC REACTIONS
Section 7

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
PARALLEL KINETIC REACTIONS

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
PARALLEL KINETIC REACTIONS

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
ETHANOL FERMENTATION

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTOR
ETHANOL FERMENTATION

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTORS
HEAT REMOVAL CONSIDERATIONS
REDUCING REACTOR SIZE INCREASES HEAT REMOVAL
LIMIT REACTION HEAT RATE TO HEAT REMOVAL
USE LATENT HEAT TO ENHANCE HEAT REMOVAL
MAXIMISE dT SUBJECT TO THERMAL SHOCK
UTILITY PROPERTIES SUITABLE FOR OPERATION
ENSURE JACKET / COIL IN TURBULENT FLOW
MIXING SYSTEM PARAMETERS TO MATCH PROCESS
JACKET SERVICE MODULE DESIGN NOT LIMITING

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SIMULATION SUITECHEMCAD SOFTWARE
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BATCH REACTORS
DYNAMICS BENEFITS
EXTENSIVE DATABASE OF FLUID PROPERTIES
FLUID PROPERTIES AT ACTUAL CONDITIONS
DYNAMIC DESIGN PARAMETERS USED
DESIGN VERIFICATION
PERFORMANCE OPTIMISATION
CONTROL SYSTEM TUNING
COMMISSIONING & TROUBLESHOOTING TOOL
SCADA ENABLED OPTIMIZATION & TRAINING TOOL