Reactor plant

The predictions checked in the pilot-plant reactor were reasonable. Later, when the production unit was improved and operators learned how to control the large-scale reactor, performance prediction was also very good. The highest recognition came from production personnel, who believed more in the model than in their instruments. When production performance did not agree with model predictions, they started to check their instruments, rather than questioning the model. 

Because there are advantages in maintaining geometric similarity between the pilot plant and the full-scale plant reactors, the larger unit often has the same aspect ratio as the small unit. That is, Rj = Rj. Equation 13-27 then becomes... 

Consider the scale-up of a batch reactor from a pilot plant reactor to a full-scale reactor. Rewriting Equation 13-82 to the full-scale reactor yields ... 

In specifying the number of jacket zones and the aspect ratio for a full-scale reactor, there is a limitation on the temperature adjustment time. This implies that it must be of the same duration as experienced in the pilot plant reactor. Combining Equations 13-89 and 13-97 yields... 

A reaction was believed to be thermally neutral, as no rise in temperature was observed in the laboratory. No cooling was provided on the pilot plant, and the first batch developed a runaway. Fortunately the relief valve was able to handle it. Subsequent research showed that the reaction developed 2 watts/kg/°C. Laboratory glassware has a heat loss of 3-6 watts/kg/°C, so no rise in temperature occurred. On the 2.5-m3 pilot plant reactor, the heat loss w as only 0.5 watt/kg/°C [21]. Reference 22 lists heat losses and cooling rates for vessels of various sizes. 

For nuclear plants reactor type BWR for Boiling Water reactor, PWR for pressurized water reactor... 

Nuclear Power Plant reactor building and cooling tower (left). (Field Mark Publications... 

To prompt remedial action when stainless-steel agitators in a phosphoric-acid-plant reactor show a potential shift towards a value associated with active corrosion due to an increase in corrosive impurities in the phosphate rock. 

Miscellaneous There are many interesting applications that arise from time to time that are outside the main stream of industry described above. Examples include desalination plant reactor cooling water circuits automobile body corrosion in situ) marine (vessels, piling, harbour installations) aircraft (in situ) packaging and cavitation monitoring. 

A 100-gal pilot-plant reactor is agitated with a six-blade pitched turbine of 6 in diameter that consumes 0.35 kW at 300 rpm. Experiments with acid-base titrations showed that the mixing time in the vessel is 2 min. Scale up to a 1000-gal vessel with the same mixing time is desired. 

Example 5.10 A liquid-phase, pilot-plant reactor uses a 12-ft tube with a 1.049-in i.d. The working fluid has a density of 860 kg/m, the residence time in the reactor is 10.2 s, and the Reynolds number is 8500. The pressure drop in the pilot plant has not been accurately measured, but is known to be less than 1 psi. The entering feed is preheated and premixed. The inlet temperature is 60°C and the outlet temperature is 64°C. Tempered water at 55°C is used for cooling. Management loves the product and wants you to design a plant that is a factor of 128 scaleup over the pilot plant. Propose scaleup alternatives and explore their thermal consequences. 

Figure 4. Measured and model predicted residual monomer for mini-plant reactor run with new finishing process.

Computer Data Logged Pilot-Plant Reactors... 

Pilot plant reactor system used in the temperature control... 

Scahng up will probably continue to be a problem since large reactors carmot be as efficient as small laboratory reactors. However, it may be possible to make laboratory or pilot-plant reactors that are more similar to large-scale reactors, allowing more rebable validation of the simulations and process optimization. The time from laboratory-scale to full-scale production should be shortened from years to months. 

A Pilot Plant Reactor-Surface Analysis System for Catalyst Studies... 

Furthermore, Identical surfaces were found In postmortem analysis of catalyst samples from the pilot plant reactor and the mlnlreactor. These observations provide assurances that the "working" catalyst surface can be examined with the system described here despite the necessary transfer from high pressure feed gas to ultrahlgh vacuum. 

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