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Dynamics Seminar Section 7 Batch Reactors John Edwards, P&I Design Ltd
August, 2014 1
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BATCH REACTORS SESSION OBJECTIVES
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS SESSION OBJECTIVES Process Simulation Dynamic Modelling & Control Section 7 Session Objectives are to study Dynamic simulation mass balance constraints Batch reactor process design considerations Batch reactor UnitOp configuration Jacket temperature control module configurations Develop multiple reaction case
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BATCH REACTORS HEAT & MASS BALANCES
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS HEAT & MASS BALANCES Section 7 page 153
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BATCH REACTORS VOLUME SCALE UP CHARACTERISTICS
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS VOLUME SCALE UP CHARACTERISTICS HTA/Unit Volume (1/m) Reactor Volume (litres)
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BATCH REACTOR GLASS LINED CONSTRUCTION HEAT UP TIMES
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTOR GLASS LINED CONSTRUCTION HEAT UP TIMES 1 TIME CONSTANT Temperature ºC 6.3 m m m m m m Time h
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BATCH REACTORS JACKET FLUIDS PHYSICAL PROPERTIES
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS JACKET FLUIDS PHYSICAL PROPERTIES Liquid Density Liquid Heat Capacity Liquid Viscosity Liquid Thermal Conductivity
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BATCH REACTORS HEAT TRANSFER FLUID SELECTION
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS HEAT TRANSFER FLUID SELECTION Section 7 page 158
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BATCH REACTORS HEAT TRANSFER OIL SELECTION
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS HEAT TRANSFER OIL SELECTION Section 7 page 158
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BATCH REACTORS HEAT TRANSFER OIL ADVANTAGES
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS HEAT TRANSFER OIL ADVANTAGES Section 7 page 157 MULTIPURPOSE PLANT WIDE TEMPERATURE RANGE SINGLE FLUID SYSTEM WITH NO PHASE CHANGE FLUID PROPERTIES STABLE OVER WIDE RANGE SINGLE FLUID SIMPLIFIES CONTROL SYSTEM THERMAL SHOCK EFFECTS CONTROLLABLE NO CORROSION CLEAN HEAT TRANSFER SURFACES JACKET SIDE EROSION MINIMISED REDUCED MAINTENANCE COSTS
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BATCH REACTORS HEAT TRANSFER OIL DISADVANTAGES
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS HEAT TRANSFER OIL DISADVANTAGES Section 7 page 157 LOWER THERMAL EFFICIENCY THAN WATER SYSTEM HIGHER CAPITAL EQUIPMENT COST HIGH COST OF INITIAL FLUID CHARGE SPECIAL COMMISSIONING PROCEDURES LONGER DOWNTIME ON EQUIPMENT FAILURE SPECIAL OPERATION & MAINTENANCE PROCEDURES FLAMMABILITY-TOXICITY-ODOUR-GMP ISSUES
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BATCH REACTORS UNITOPS RETENTION TIMES
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS UNITOPS RETENTION TIMES Kinetic Reactor Batch Reactor SCDS Tower Tower + Dynamic Vessels
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BATCH REACTORS DIRECT HEAT COOL
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS DIRECT HEAT COOL Section 7 page DIRECT HEAT - COOL DIRECT HEAT – COOL INDIRECT CHILL
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BATCH REACTORS INDIRECT HEAT DIRECT COOL
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL Section 7 page 168
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BATCH REACTORS INDIRECT HEAT DIRECT COOL
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL Section 7 page 167
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BATCH REACTORS INDIRECT HEAT DIRECT COOL
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL D7.01 page 170
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BATCH REACTOR CONTROL VALVE CALIBRATION
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTOR CONTROL VALVE CALIBRATION SINGLE CONTROL VALVE OPERATIONS ACTION CONTROL OUTPUT POSITION STATE LOGIC EQUATION COEFFICIENTS mA % Av Bv FAIL CLOSED 4 Closed 0 = 4Av+Bv 0.0625 -0.25 20 100 Open 1 1 = 20Av+Bv OPEN 1 = 4Av+Bv 1.25 0 = 20Av+Bv Controller Output (mA) 4 20 V a l v e Open Closed Fail Open Signal to Close Av = Bv = 1.25 Cooling Valve Av = Bv = -0.25 Fail Closed Signal to Open 20 Controller Output (mA) 4 V a l v e Open Closed Heating Valve Av and Bv are CHEMCAD scaling constants
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BATCH REACTORS CONTROL VALVE CALIBRATION
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS CONTROL VALVE CALIBRATION DUAL CONTROL VALVE OPERATIONS IN SPLIT RANGE ACTION CONTROL OUTPUT POSITION STATE LOGIC EQUATION COEFFICIENTS mA % Av Bv FAIL CLOSED 12 50 Closed 0 = 12Av+Bv 0.125 -1.5 20 100 Open 1 1 = 20Av+Bv FAIL OPEN 4 1 = 4Av+Bv -0.125 1.5 4 Controller Output (mA) 12 20 V a l v e Open Closed Av = Bv = -0.25 Av = Bv = 1.25 3 Way Valve 4 Controller Output (mA) 12 20 V a l v e Open Closed Av = 0.125 Bv = -1.5 Av = Bv = 1.5 Split Range Valves Av and Bv are CHEMCAD scaling constants
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BATCH REACTORS CONTROL VALVE CHARACTERISTIC
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS CONTROL VALVE CHARACTERISTIC LINEAR EQUAL PERCENTAGE QUICK OPENING BUTTERFLY VALVE CHARACTERISTIC ANY POSITIONER 10 20 30 40 50 60 70 80 90 100 FLOW % VALVE STROKE (%) VALVE COEFFICIENT (Cv) Equal % for flow control Linear for level and pressure control
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BATCH REACTORS INDIRECT HEAT DIRECT COOL - VALVES
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL - VALVES D7.01 page 170 Fail Closed C-4mA O-20mA Fail Closed C-12mA O-20mA Fail Open C-12mA O-4mA
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BATCH REACTORS INDIRECT HEAT DIRECT COOL - REACTOR
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL - REACTOR D7.01 page 170 For boil up only No reaction spec Distillation is mixed phase No boil up without draw spec
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BATCH REACTORS INDIRECT HEAT DIRECT COOL - REACTOR
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL - REACTOR D7.01 page 170 For user specified select nearest Pfaudler To change spec Must reset to Initial State
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BATCH REACTORS INDIRECT HEAT DIRECT COOL - PLOTS
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL - PLOTS Set plot time units to reasonable value based on step size, in this case minutes For general plots de-select composition
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BATCH REACTORS INDIRECT HEAT DIRECT COOL – RUN TIME
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL – RUN TIME D7.01 page 170 Switch to dynamic mode under convergence Set Run Time to 360 minutes with 1 minute step size Record desired streams 3, 8, 9 & 12 Record desired UnitOps 3 & 6 Select Run Time plot options Run from Initial State Plot results Set plot time units to reasonable value based on step size, in this case minutes
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BATCH REACTORS INDIRECT HEAT DIRECT COOL - RESULTS
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL - RESULTS
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BATCH REACTORS INDIRECT HEAT DIRECT COOL
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEAT DIRECT COOL D7.01 page 170
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BATCH REACTORS INDIRECT HEATING INDIRECT COOLING
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEATING INDIRECT COOLING Section 7 page 169
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BATCH REACTORS INDIRECT DIRECT COOLING CURVES
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT DIRECT COOLING CURVES Section 7 page 169
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BATCH REACTORS INDIRECT HEATING INDIRECT COOLING
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
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BATCH REACTORS INDIRECT HEATING INDIRECT COOLING
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
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BATCH REACTORS INDIRECT HEATING INDIRECT COOLING
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
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BATCH REACTORS INDIRECT HEATING INDIRECT COOLING
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
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BATCH REACTORS INDIRECT HEATING INDIRECT COOLING
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
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BATCH REACTORS SHELL - PLATE HEAT EXCHANGER
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS SHELL - PLATE HEAT EXCHANGER D4.03 page 88
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BATCH REACTORS SHELL - PLATE HEAT EXCHANGER
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTORS SHELL - PLATE HEAT EXCHANGER
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BATCH REACTOR PARALLEL KINETIC REACTIONS
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTOR PARALLEL KINETIC REACTIONS Section 7 D7.05 page 177
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BATCH REACTOR PARALLEL KINETIC REACTIONS
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTOR PARALLEL KINETIC REACTIONS
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BATCH REACTOR PARALLEL KINETIC REACTIONS
SIMULATION SUITE CHEMCAD SOFTWARE BATCH REACTOR PARALLEL KINETIC REACTIONS
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BATCH REACTORS HEAT REMOVAL CONSIDERATIONS
SIMULATION SUITE CHEMCAD SOFTWARE 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 ENSURE JACKET / COIL IN TURBULENT FLOW UTILITY PROPERTIES SUITABLE FOR OPERATION JACKET SERVICE MODULE DESIGN NOT LIMITING MIXING SYSTEM PARAMETERS TO MATCH PROCESS
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BATCH REACTORS DYNAMICS BENEFITS
SIMULATION SUITE CHEMCAD SOFTWARE 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
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