Case Study
Case Study
Case Study
Case Study
Case Study

Multipurpose 16-Parallel Ultra-high pressure Trickle Flow Unit

A flexible, High-Throughput reactor
The task

We were approached by Evonik interested in having a flexible, High-Throughput reactor unit capable of operating up to 300Barg.

The reactors should be designed for speciality-chemicals production in trickle-flow mode with ability to dose liquid gases as well as viscous feedstocks.
The ILS solution

We first performed a large series of feasibility tests upfront using their unique feedstock liquids in order to demonstrate the ability to perform reliable single-stage, 2-phase backpressure control and still close the mass-balance.

This is often challenging as mist- or aerosol formation can result in significant liquid materials losses.

ILS was able to “tweak” the suggested design appropriately and clearly demonstrate to the client an ability to perform the 2-phase, 300-bar backpressure control in single step with neglegible materials losses. Only then did ILS move on to the final design and construction phases of the fully automated unit.

Liquid gases are dosed in the liquid phase and quantitatively measured using mini-coriolis mass-flow-control technology. Viscous feedstocks are stored in weighed, heated and pressurized feed barrels and dosed with high-temperature dosing pumps. The unit has a fully-integrated liquid-fraction collection robot, which can collect samples from all 16 reactors in parallel. The liquid-fraction collection vials are simultaneously the gas-liquid separators. An on-line GC provide analysis of the gaseous products formed.

The result

The unit is for more than 2 years in successful operation and provides Evonik with a powerful multipurpose tool being able to study a variety of trickle flow reactions.

The low amount of catalysts and feedstocks required combined with the online analytics, robotics and the ILS quick-loading system decrease the human effort needed and reduce the running costs. Increased number of reactors coupled with high data quality significantly improved the speed for Evonik to develop and improve their catalyst business.
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