Chemical Reactor Process Trainer with PLC
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.
Topics:
- 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)
Utilities:
- Electrical power single phase (all world voltages)
- Instrument Air
- Cooling water
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