Contents

Introduction to Industrial Chemical Reactors ......................................................................................................... 2

Introduction ........................................................................................................................................................ 3
Types of Reactors ................................................................................................................................................ 3
Continuous stirred-tank reactor (CSTR): ............................................................................................................. 3
Introduction: ................................................................................................................................................... 3
Diagram: .......................................................................................................................................................... 3
Working principle: ........................................................................................................................................... 4
Start-up Procedures: ....................................................................................................................................... 4
Shut-down Procedures: ................................................................................................................................... 4
Applications: .................................................................................................................................................... 4
Advantages: ..................................................................................................................................................... 5
Disadvantages: ................................................................................................................................................ 5
Rotary kiln reactor:.............................................................................................................................................. 5
Introduction: ....................................................................................................................................................... 5
Diagram: .......................................................................................................................................................... 5
Working principle: ........................................................................................................................................... 6
Start-up Procedures: ....................................................................................................................................... 6
Shut-down Procedures: ................................................................................................................................... 6
Advantages: ..................................................................................................................................................... 6
Disadvantage: .................................................................................................................................................. 7
Introduction to Aspen Plus...................................................................................................................................... 8
Introduction of Aspen ......................................................................................................................................... 8
Introduction of simulation .................................................................................................................................. 8
Definition ......................................................................................................................................................... 8
Process of simulation ...................................................................................................................................... 8
Application of simulation ................................................................................................................................ 8
List of Figure
Figure 1- CSTR ....................................................................................................................................................... 3
Figure 2-KLin reactor ............................................................................................................................................. 5
 Introduction to Industrial Chemical Reactors
Introduction
Reactor is the heart of chemical process. Any closed volume body or (closed vessel) in
which chemical transformations (reactions) take place. An industrial reactor is a complex chemical
device in which heat transfer, mass transfer, diffusion and friction may occur along with chemicals
with the provision of safety and control.

Types of Reactors
There are two types of reactors are:

o Continuous stirred-tank reactor (CSTR)

o Rotary kiln reactor

Continuous stirred-tank reactor (CSTR):

Introduction:
The continuous stirred-tank reactor (CSTR), also known as vat- or back mix reactor, or a
continuous-flow stirred-tank reactor (CFSTR). The mathematical model works for all fluids:
liquids, gases, and slurries. If the residence time is 5-10 times the mixing time, this approximation
is valid for engineering purposes. The CISTR model is often used to simplify engineering
calculations and can be used to describe research reactors. In practice it can only be approached, in
particular in industrial size reactors.

Diagram:

Figure 1- CSTR
Working principle:
Continuous stirred-tank reactors (CSTRs) are open systems, where material is free to enter or exit
the system, that operate on a steady-state basis, where the conditions in the reactor don't change
with time. Reactants are continuously introduced into the reactor, while products are continuously
removed.

CSTRs are very well mixed, so the contents have relatively uniform properties such as temperature,
density, etc. throughout. Also, conditions in the reactor's exit stream are the same as those inside
the tank.

Start-up Procedures:
General start-up Procedures:

o The solutions like catalytic solution.

o All valves were initially closed.
o The feed vessels were charged .
o The power for control panel was turned on.
o Sufficient water in thermostat was checked. Refill as necessary.
o The overflow tube was adjusted to give a working volume in the reactor .
o Valves were opened.
o The unit was ready for reaction.

Shut-down Procedures:
o Keep the cooling water valve open to allow the cooling water to continue flowing.
o Switch off both pumps feed and product. Switch off stirrer M1.
o Switch off the thermostat . Let the liquid in the reaction vessel cool down to room temperature.
o Close cooling water valve .
o Open valves to drain any liquid from the unit.
o Turn off the power for the control panel.

Applications:
o Continuous stirred-tank reactors are most commonly used in industrial processing, primarily in
homogeneous liquid-phase flow reactions, where constant agitation is required. They may be
used by themselves, in series, or in a battery.

o CSTRs are also used in the pharmaceutical industry as a loop reactor. As mentioned earlier,
CSTRs are often used in biological processes The CSTR can be used for high-density animal
cell culture in research or production. The vessels used are for single use.

o Fermenters are another application of CSTR s that involve the use of a biological catalyst to
generate products.
Advantages:
o Good temperature control is easily maintained
o Cheap to construct
o Reactor has large heat capacity
o Interior of reactor is easily accessed

Disadvantages:
o Conversion of reactant to product per volume of reactor is small compared to other flow
reactors
o Dead zones, where no mixing occurs, can develop
o Reactants can bypass if outlet placed improperly

Rotary kiln reactor:

Introduction:
A rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a
continuous process. Materials produced using rotary kilns include:

o Cement
o Lime
o Refractories
o Metakaolin
o Titanium dioxide
o Alumina
o Vermiculite
o Iron ore pellets

Diagram:

Figure 2-KLin reactor

Working principle:
The kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated slowly about its
longitudinal axis. The process feedstock is fed into the upper end of the cylinder. As the kiln rotates,
material gradually moves down toward the lower end, and may undergo a certain amount of stirring
and mixing. Hot gases pass along the kiln, sometimes in the same direction as the process material (co-
current), but usually in the opposite direction (counter-current). The hot gases may be generated in an
external furnace, or may be generated by a flame inside the kiln. Such a flame is projected from a
burner-pipe (or "firing pipe") which acts like a large Bunsen burner. The fuel for this may be gas, oil,
pulverized petroleum coke or pulverized coal.

Start-up Procedures:
Recommended Checks Prior to Kiln Start-Up (Feed On)

o Kiln Feed systems:

o Cooler and Clinker Handling:
o D. Fan:
o Coal Conveying system
o Preheat System (These items to be done well before needed)
o Material Flow Check for Pre-heater Plant:
o Burner Pipe Alignment:
o Common Pre-checks:
o Ensure the proper direction or rotation of all fans, screws, conveyors, clinker breaker etc.

Shut-down Procedures:
o Reducing of the kiln feed and empty kiln can be easier heated-up and re-started.
o Stop of PC-Burner and kiln feed.
o Tertiary air flap to be closed.
o Stop of the main burner, primary fans to be kept in operation (cooling!!!).
o Fresh air flaps to be opened.
o Stop Pre-heater-fan and adjust the main Bag house-fan damper so that the pressure after the Pre
heater-fan is -1.5 mbar.
o Cooler fans: minimum speed or dampers to be closed.
o Cooler exhaust air fan: set to minimum to maintain kiln hood draugh.t
o Start the kiln on the barring drive.
o Cooler track units: to be operated in intervals.

Advantages:
o Can be use for a wide variety of both liquids and solid
o Good mixing and air for solids
o Continuous ash removal does not interfere with burning
o No moving parts in kiln
o Rotational speed of kiln can be varied to control residence time in burning
 o At very high temperature of 1400’ C to ensure destruction of toxic chemicals
o Able to handle a broad range of liquid
o Can handle small amounts of liquids
o Responds fast to waste temperature changes
o Low maintenance

Disadvantage:
o High capital cost for installation especially when using low feed rates.
o Careful operation in order not to damage refectory.
o Airborne gases or practices mat exit prior to complete oxidation.
o Spherical or cylindrical solids may pass through faster and avoid complete burning.
o Excess air required due to leaks, which lower fuel efficiency.
o If drying grates are used prior to kiln they may become plugged with heat.
o High particulate loadings.
o Relatively low thermal efficiency.
o Liquid must be able to be atomized.
o Liquid must be hated sufficiently or supplement fuel added.
o Must be capable of complete combustion without flames hitting refectory.
o Liquid waste may clog burner nozzles.
o Require sophisticated instrumentation.
 Introduction to Aspen Plus

Introduction of Aspen
ASPEN is a process simulation software package widely used in industry today.
Given a process design and an appropriate selection of thermodynamic models, ASPEN uses
mathematical models to predict the performance of the process.

Introduction of simulation
A simulation model is a mathematical model that calculates the impact of
uncertain inputs and decisions we make on outcomes that we care about, such as profit and loss,
investment returns. Simulation is imitation of some real thing, or a process. The act of simulating
something generally involves representation of certain key characteristics or behaviors of a selected
physical or abstract system. Simulation involves the use of models to represent real life situation

Definition
Simulation is the process of designing a model of a real system and conducting experiments with this
model for the purpose of understanding the behavior for the operation of the system. Example all video
game, aspen simulator and CFD simulator.

Process of simulation
It provides a chance to apply principles and theories student have learned and to see how and when the
principles work
To develop human interaction abilities in a controlled and safes setting
To helps students practice decision making and problem solving skills
Through an active involvement in a simulation exercise a game or a role playing situation, the student
achieves cognitive, affective and psychomotor outcomes

Application of simulation
Waiting line/service
Inventory management
Production and manufacturing systems
Supply chain systems
Service operations
Environmental and resources analysis