Dynamics Seminar Section 7 Batch Reactors John Edwards PampI Design Ltd August 2014 wwwchemstationscom wwwchemcadcouk SIMULATION SUITE CHEMCAD SOFTWARE wwwchemstationscom ID: 767002
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Dynamics Seminar Section 7 Batch Reactors John Edwards, P&I Design Ltd August, 2014 www.chemstations.com
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS SESSION OBJECTIVES Session Objectives are to study Dynamic simulation mass balance constraints Batch reactor process design considerations Batch reactor UnitOp configuration J acket temperature control module configurations Develop multiple reaction case Process Simulation Dynamic Modelling & Control Section 7
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS HEAT & MASS BALANCES Section 7 page 153
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS VOLUME SCALE UP CHARACTERISTICS HTA/Unit Volume (1/m) Reactor Volume (litres)
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTOR GLASS LINED CONSTRUCTION HEAT UP TIMES Temperature ºC 6.3 m 3 16 m 12.5 m 3 21 m 25.0 m 3 33 m 1 TIME CONSTANT Time h
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS JACKET FLUIDS PHYSICAL PROPERTIES Liquid Density Liquid Heat Capacity Liquid Viscosity Liquid Thermal Conductivity
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS HEAT TRANSFER FLUID SELECTION Section 7 page 158
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS HEAT TRANSFER OIL SELECTION Section 7 page 158
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS 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 Section 7 page 157
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS 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 Section 7 page 157
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS UNITOPS RETENTION TIMES Dynamic Vessels SCDS Tower Tower + Batch Reactor Kinetic Reactor
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS DIRECT HEAT COOL DIRECT HEAT - COOL DIRECT HEAT – COOL INDIRECT CHILL Section 7 page 166-167
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL Section 7 page 168
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL Section 7 page 167
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL D7.01 page 170
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTOR CONTROL VALVE CALIBRATION SINGLE CONTROL VALVE OPERATIONS ACTION CONTROL OUTPUT POSITION STATE LOGIC EQUATION COEFFICIENTS mA % A v B v FAIL CLOSED 4 0 Closed 0 0 = 4A v +B v 0.0625 -0.25 20 100 Open 1 1 = 20A v +B v FAIL OPEN 4 0 Open 1 1 = 4A v +B v -0.0625 1.25 20 100 Closed 0 0 = 20A v +B v Controller Output (mA) 4 20 V a l v e Open Closed Fail Open Signal to Close A v = -0.0625 B v = 1.25 Cooling Valve A v = 0.0625 B v = -0.25 Fail Closed Signal to Open 20 Controller Output (mA) 4 V a l v e Open Closed Heating Valve A v and B v are CHEMCAD scaling constants
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS CONTROL VALVE CALIBRATION DUAL CONTROL VALVE OPERATIONS IN SPLIT RANGE ACTION CONTROL OUTPUT POSITION STATE LOGIC EQUATION COEFFICIENTS mA % A v B v FAIL CLOSED 12 50 Closed 0 0 = 12A v +B v 0.125 -1.5 20 100 Open 1 1 = 20A v +B v FAIL OPEN 4 0 Open 1 1 = 4A v +B v -0.125 1.5 12 50 Closed 0 0 = 12A v +B v 4 Controller Output (mA) 12 20 V a l v e Open Closed A v = 0.125 B v = -1.5 A v = -0.125 B v = 1.5 Split Range Valves 4 Controller Output (mA) 12 20 V a l v e Open Closed A v = 0.0625 B v = -0.25 A v = -0.0625 B v = 1.25 3 Way Valve A v and B v are CHEMCAD scaling constants
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS CONTROL VALVE CHARACTERISTIC Equal % for flow control Linear for level and pressure control LINEAR EQUAL PERCENTAGE QUICK OPENING BUTTERFLY VALVE QUICK OPENING CHARACTERISTIC ANY CHARACTERISTIC VALVE POSITIONER 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100 FLOW % VALVE STROKE (%) VALVE COEFFICIENT (C v )
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL - VALVES Fail Open C-12mA O-4mA Fail Closed C-12mA O-20mA Fail Closed C-4mA O-20mA D7.01 page 170
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL - REACTOR No boil up without draw spec Distillation is mixed phase For boil up only No reaction spec D7.01 page 170
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL - REACTOR For user specified select nearest Pfaudler To change spec Must reset to Initial State D7.01 page 170
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL - PLOTS For general plots de-select composition Set plot time units to reasonable value based on step size, in this case minutes
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL – RUN TIME 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 D7.01 page 170
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL - RESULTS
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEAT DIRECT COOL D7.01 page 170
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEATING INDIRECT COOLING Section 7 page 169
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT DIRECT COOLING CURVES Section 7 page 169
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS INDIRECT HEATING INDIRECT COOLING D7.02 page 171
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS SHELL - PLATE HEAT EXCHANGER D4.03 page 88
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTORS SHELL - PLATE HEAT EXCHANGER
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTOR PARALLEL KINETIC REACTIONS Section 7 D7.05 page 177
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTOR PARALLEL KINETIC REACTIONS
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com BATCH REACTOR PARALLEL KINETIC REACTIONS
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com 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
www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com 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