Batch Reactor Performance | Chemical

Control and Instrumentation Enables Plants to Achieve the Highest Yield for All Batch Processes

Many companies constantly tweak processes to achieve a “golden batch,” without fully understanding how it happens. Resulting process errors negatively impact goals for batch optimization, efficient equipment utilization, and new product development. Emerson’s analytics for batch solutions reduces process variability, minimizes cycle time, reduces waste and energy, and enables consistently maximized yields.

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Click to continue reading Control and Instrumentation Enables Plants to Achieve the Highest Yield for All Batch Processes

Solutions in Action: Golden Batch is About Repeatable Cycle Time and Improved Product Quality

Managing Material/Feed Additions

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Optimizing a batch requires precise recipe control, the right measurement and batch analytics. It starts with precise material addition measurement compositional analysis and control. Emerson’s field devices and control systems help you avoid errors that cause reduced reaction rates, off-spec product, and costly reprocessing.

Field Device Management

Predictive diagnostics from field devices enable you to keep these devices configured, calibrated, and operating effectively, protecting the reliability of your production equipment.

Micro Motion Coriolis Flow and Density Meters

Our Coriolis meters deliver unmatched reliability for mass flow, volume flow & density measurement in your chemical operation.

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Fisher Control Valves

Fisher control valves manipulate a flowing fluid (such as gas, steam, water), or chemical compounds to compensate for the load disturbance, and keep the regulated process variable as close as possible to the desired set point.

Micro Motion Density and Viscosity Meters

Unbeatable accuracy and performance for applications requiring density, concentration, or viscosity measurement.

AMS Optics Software Platform

Expertly manage your assets with a uniform software solution for condition monitoring, workflow integration and more.

Rosemount 3408 Non-Contacting Radar Level Transmitter

Dependable non-contacting level measurement with simple top-down installation and easy commissioning.

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Click to continue reading Managing Material/Feed Additions

Accurate Heating and Cooling

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Temperature control is critical for repeatable on-spec production in both batch and continuous reactors. Emerson has a wide variety of temperature measurement solutions covering all manner of reactions. Accurate control is also a safety concern given the energy exchange in chemical reactions. For exothermic reactions, temperature spikes can lead to thermal runaway. For endothermic reactions, insufficient heat addition can cause the reaction to stall. 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.

Temperature Sensors and Transmitters

Our temperature instrumentation provides reliable, accurate measurements in the toughest applications, helping you maintain ideal temperature levels and keep your operations running smoothly.

Fisher Control Valves

AMS Optics Software Platform

Expertly manage your assets with a uniform software solution for condition monitoring, workflow integration and more.

Field Device Management

Predictive diagnostics from field devices enable you to keep these devices configured, calibrated, and operating effectively, protecting the reliability of your production equipment.

Rosemount 8800 Series Vortex Flow Meters

Rosemount 8800 Series Vortex Flow Meters offer world-class reliability with a gasket-free, non-clog meter body that eliminates potential leak points, resulting in maximum process availability and fewer unscheduled shutdowns.

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Outdoor tanks at a water treatment plant

Bettis Electric Actuators

Smart, reliable electric actuators that safely automate multi-turn, quarter-turn, linear valves.

Click to continue reading Accurate Heating and Cooling

Optimize Reactor Control

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In a batch when reaction rates are unstable, operators typically run at less-than-optimal conditions to maintain safety and product quality. This limits them from operating at the optimal upper limit for high production levels. 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 by operating closer to constraints.

Micro Motion Density and Viscosity Meters

Unbeatable accuracy and performance for applications requiring density, concentration, or viscosity measurement.

Fisher Control Valves

Field Device Management

Predictive diagnostics from field devices enable you to keep these devices configured, calibrated, and operating effectively, protecting the reliability of your production equipment.

Level Measurement Solutions for Reactors & Mixing Tanks

Optimize level control and quality assurance with accurate and reliable level measurement in challenging conditions.

AMS Optics Software Platform

Expertly manage your assets with a uniform software solution for condition monitoring, workflow integration and more.

Rosemount 3051 Coplanar Pressure Transmitters

The Rosemount 3051 Coplanar Pressure Transmitter family offers an all-in-one solution for pressure, level and flow measurement. This transmitter is easy to install and designed with direct process mounting capability for cost-effective installation and efficiency.

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ASCO Series 641/2/3 aluminum filter regulators

ASCO™ Filter Regulator Series 641/642/643 and 342A

Durable regulators provide high flow rates and precise pressure regulation and prevent contamination in harsh process enviornments.

Click to continue reading Optimize Reactor Control

Health, Safety and Environmental (HSE)

Process upsets and excess feedstock variability can lead to environmental and safety hazards that put property and personnel at risk. Considerations include minimizing overfill, manual sampling and corrosion risks. Automated procedural control ensures proper operations during startups, shutdowns, product changes, and other abnormal conditions. The correct process measurements, with conditional interlocking strategies, help operators with early detection of abnormal situations.

Rosemount Incus Ultrasonic Gas Leak Detector

Instantaneously detects gas leaks using ultrasonic leak detection technology to trigger an early warning system.

Rosemount Flame Detectors

Find the right flame detection product to help keep your people and facilities safe.

TopWorx™ ESD Valve Controllers

TopWorx™ ESD Valve Controllers provide a complete Partial Stroke Test Solution with unique features and functionality that enable partial stroke testing of emergency shutdown valves without disrupting or shutting down the process.

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Fisher Digital Isolation Solutions

Take the guesswork out of your safety instrumented system valve assemblies with our proven solutions and expertise.

Field Device Management

Predictive diagnostics from field devices enable you to keep these devices configured, calibrated, and operating effectively, protecting the reliability of your production equipment.

Rosemount 3408 Non-Contacting Radar Level Transmitter

Dependable non-contacting level measurement with simple top-down installation and easy commissioning.

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Fisher FIELDVUE DVC6200 SIS High Cv Construction

Fisher FIELDVUE DVC6200 SIS Digital Valve Controller

Minimize risk for your plant and personnel by controlling valve safety shutdown and using partial stroke testing, while concurrently monitoring the health of the entire valve assembly.

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Rosemount Vibrating Fork Liquid Level Detectors

Learn about our broad portfolio of vibrating fork switches and detectors and discover the perfect match for your specific needs.

AMS Optics Software Platform

Expertly manage your assets with a uniform software solution for condition monitoring, workflow integration and more.

Click to continue reading Health, Safety and Environmental (HSE)

Frequently Asked Questions About Batch Reactors

What are common challenges for improving batch reactor processes?

Controlling batch reactors in chemical processes presents challenges due to variable reaction rates, heat transfer variations, mixing and mass transfer complexities, safety concerns, measurement limitations, and the need for process flexibility. Achieving consistent product quality and reaction completion time can be difficult due to the dynamic nature of batch reactions. Batch reactors often require frequent process changes and adjustments for different products or recipes. Optimizing the process parameters and cycle times to maximize production efficiency and yield can be complex. Managing heat transfer, ensuring proper mixing and mass transfer, and maintaining safe operating conditions are crucial. Addressing these challenges typically involves the use of advanced control strategies, such as model-based control, adaptive control, and optimization techniques. Continuous monitoring, automation, and the integration of sensors and actuators can also help improve control and overall performance in batch reactors.

What safety considerations are associated with batch reactors?

Things to consider when ensuring the safety of a reactor include: pressure management, temperature control, handling of corrosive, explosive, and flammable products, vessel containment and ventilation. All of this requires the proper monitoring and control that is typically done in a safety system.

What are the different types of reactors?

In chemical engineering, various reactor types are employed depending on the reaction specifics and operational requirements. These include Batch Reactors, operating as a closed system where the reaction happens over time with no inflow or outflow of substances. Continuous Stirred-Tank Reactors (CSTR) and Plug Flow Reactors (PFR) are open systems where reactants and products flow continuously, with the former involving immediate mixing of inputs and the latter having a “plug” flow mechanism. Semi-Batch Reactors combine features of both batch and continuous systems, allowing either continuous inflow of reactants or outflow of products. Packed Bed Reactors (PBR) and Fluidized Bed Reactors involve solid catalyst particles to enhance reaction rates, with PBRs having reactants flow over packed catalysts and Fluidized Bed Reactors suspending catalysts in a fluid. Membrane Reactors allow simultaneous reaction and separation of products, while Photochemical Reactors enable reactions using light energy.

Click to continue reading Frequently Asked Questions About Batch Reactors

Batch Reactor Control and Performance

Control and Instrumentation Enables Plants to Achieve the Highest Yield for All Batch Processes

Solutions in Action: Golden Batch is About Repeatable Cycle Time and Improved Product Quality

Managing Material/Feed Additions

Accurate Heating and Cooling

Optimize Reactor Control

Health, Safety and Environmental (HSE)

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Catalytic Reactors

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