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Extend catalyst health, reduce risk, and improve the efficiency of your chemical reactor systems.

Take your reactors’ performance to the next level

Maintaining reactor performance is a formidable challenge. Catalyst health is difficult to measure and maintain, equipment issues can cause shutdowns, and process upsets can affect product quality and increase risk. Emerson’s solutions give you the power to operate at optimal setpoints that can extend catalyst life. By having accurate, real-time process data, and by reducing variability with the right process control strategy, you’ll be able to maximize productivity and improve safety.

Media & Case Studies

Learn how multipoint sensing can solve temperature profiling challenges in catalyst reactors

Solution In Action

High-accuracy addition of raw material is critical to meeting quality standards and delivering on-spec, high-value chemicals. Untrustworthy instrumentation and manual operations can cause errors that affect the product, requiring costly reprocessing. Having the right measurement and control strategy to measure material addition or feed flow and detect composition changes enables you to optimize conversion efficiency and free operators to perform more value-added work.

Temperature control is critical for repeatable on-spec production in both batch and continuous reactors. It is also a safety concern given the energy exchange in chemical reactions. For some reactors, sudden temperature spikes could lead to thermal runaway. Precise automated control ensures safe, productive, and efficient operations, whether it is switching from heating to cooling on a batch reactor, measuring heat input/takeaway, or controlling valves to run closer to temperature constraints.

Inability to operate closer to constraints is costly, and reactors involve highly complex, multi-variable processes that make them difficult to operate at optimum conditions. Emerson’s measurement, data analysis, advanced control, and final control technologies enable you to accurately measure key reactor process variables, predict the best setpoint trajectory, and manipulate the process to maximize conversion efficiency and improve profitability.

Temperature and pressure excursions or sudden feedstock changes can disrupt the reaction equilibrium and damage the catalyst. This increases pressure-drop, which affects flow through the reactor and reduces the amount of feed converted into product. By accurately measuring and analyzing reaction conditions with advanced process control, you’ll be able to detect process upsets early and take timely actions to maximize conversion efficiency and extend catalyst life.

Conditions within the reactor system can cause accelerated wear and tear of valves, instruments, and rotating equipment. Unreliable equipment can slow production or require shutdowns to make repairs, or even create environmental and safety hazards. Improved process insight from advanced diagnostics, such as agitation loss, allows you to conduct preventive maintenance rather than wait until a failure requires a shutdown. Durable sensors and valves help to reduce maintenance costs and maximize uptime.

Process upsets and excess variability can lead to environmental and safety hazards that put property and personnel at risk. Automated procedural control ensures proper operations during startups and shutdowns, which are the riskiest events of all. Having the correct process measurements with conditional interlocking strategies can help to detect abnormal situations early, and with partial stroke testing, you’ll be able to verify emergency shutdown valves without disrupting your process.

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