PC-based automation of Rotoberty® reactor system Tibor Chovan, Aba Boros, Lajos Nagy, Charles Hasseman* EUROKIN Workshop on Laboratory Hardware and related experience for kinetics studies in gas-solid and gas-liquid-solid systems San Donato Milanese, Italy September University of Veszprem, Dept. of Process Engineering *Pressure Products Industries, Inc.
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Outline Objectives ROTOBERTY® reactor 1, 2 Reactor system for gas-solid experiments Data acquisition and control system Application of the apparatus (example) Conclusions 1 ROTOBERTY® is registered trademark of Berty Reaction Engineers Ltd., USA 2 It is manufactured under exclusive license by Pressure Product Inc, USA
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Objectives Apparatus for –studying of gas-solid catalytic systems –getting kinetic information for process design –conducting activity test of catalyst Automate experiments to –get reliable data –simplify analysis of experimental data –reduce the need for supervision Allow modifications and extensions of the experimental systems and procedures
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep ROTOBERTY® reactor Internal recycle reactor –magnetic drive with high RPM –high performance two-stage centrifugal blower –low gradients from atmospheric to high pressure –well defined flow conditions (calibration) Parameters –standard construction: SS-316 –pressure: 138 bar (13.9 MPa) –temperature 450 °C –blower RPM: /min –catalyst basket volume: 60 cm 3 –electric heating: 2 kW
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Picture and scheme of the ROTOBERTY® reactor
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Reactor system Fields of application –development and tests of catalysts –kinetic measurements –study of gas-solid systems Modules –Feed module (saturator) –Rotoberty reactor (precise kinetic data) –Tubular reactor (characterization of catalysts) –Analysis (gas-chromatograph, etc.) –Data acquisition and control system
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Scheme of the reactor system
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Data acquisition and control system Requirements: –monitoring and collecting of all measured, controlled parameters –simple extraction of experimental data –possibility for modifying control strategy Hardware options for PC based systems –data acquisition modules (simple extension) –data acquisition boards (smaller systems) –independent data acquisition unit (for many signals) –independent control unit - for critical applications Software options –development of special programs –standard SCADA software
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Hardware Advantech Labcard interface cards –universal input card (PCL-818; 16 AI, 32 DI/O) 2 mass flow rates reactor pressure multiplexer –analog output card (PCL-726; 6 AO) 2 setpoints for mass flow controllers reactor heating control –amplifier and multiplexer board (PCLD-789D) 6 thermocouples –SSR digital output board (PCLD-786D) GC sampling Rotoberty reactor cooling valve PC (well equipped Pentium, network)
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Software SCADA (Fix, InTouch, Genie, etc.) Simple configuration and programming Advantech Genie: –Task builder: control strategies (Visual Basic) –Display builder: comfortable operator screens
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Software functions Temperature control of the reactor Monitoring of the reactor temperatures (below and above the catalyst bed). Monitoring of the reactor pressure. Supervision of flow controllers. Start signal for analytical instrumentation (e.g. GC) with adjustable cycle time. Acquisition of all the measured and controlled signals into file. Four operator screens –temperature control –feed flow control –temperature monitoring –sampling control
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Feed control screen
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Temperature control screen
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Data collection simple text files groups of variables with different timing date and time stamp on every record Excel, Matlab, etc. Text file
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Application example: Oxitox® 1 Destruction of halogenated hydrocarbons Solid phase reacts with halogens Advantages –high conversion and removal efficiency –halogenated by-products are not formed –scrubber and stainless steel unnecessary (HCl, Cl 2 etc. not formed) Test components –Trichloro-ethylene (TCE), Toluene,... 1 Oxitox® is registered trademark of Berty Reaction Engineers Ltd., USA Catalytic oxidation of toxic components on activated solid reagent (Na 2 CO 3 ).
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Experimental methods Ignition curves (conversion-temperature relationship) –constant feed conditions –increasing and decreasing temperature stepwise Effect of the composition of solid reagent –constant feed composition and reactor pressure, reactor temperature –constant conversion (composition in the reactor) is kept by decreasing feed flow rate Deactivation studies –constant feed conditions and reactor pressure –reactor temperature is kept constant or increased to keep constant conversion
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Ignition experiment
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Ignition curve
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Study of the effect of solid composition
T.Chovan, A.Boros, L.Nagy, C.Hasseman - EUROKIN Workshop - San Donato Milanese - Sep Conclusions tight control of experimental conditions less manpower required replacing of standalone control units easy way to extend the experimental system simple programming for new experimental procedures Univ. of Veszprem, Dept. of Process Engineering acknowledges the cooperation and support of Pressure Product Industries Inc. and Berty Reaction Engineers Ltd. PC-based data acquisition and control systems improves the applicability of laboratory reactors in several way: