Example: Design of multitubular reactor
[LG Chem, Ltd]

LG Chem, Ltd optimised the mechanical design of a terephthaldehyde multitubular reactor using hybrid modelling methods that coupled gPROMS models of the tube-side catalytic reaction with FLUENT® models of the shell-side cooling fluid hydrodynamics.

The result was a high-performance reactor with uniform temperature distribution through the radius, leading to longer catalyst life.

In addition LG Chem was also able to undertake the detailed engineering design of the unit.

Example: Optimisation of catalyst life for a methanol process [Süd-Chemie]

Süd-Chemie used advanced process models of catalyst and multitubular reactor to simultaneously advise their client on optimal processing conditions to maximise operating time before catalyst changeover and to optimise their catalyst formulation.

Example: Optimisation of PTA process impeller design and operating conditions [Korean terephthalic acid producer]

This PSE plan improvement project (one of many) determined optimal nozzle placing for terephthalic acid oxidation reactor, ranked agitator design alternatives and optimised process operating conditions for the chosen agitator configuration.

The result was to reduced raw material consumption by 0.5-1% and around 15% respectively of the key materials involved, leading to a significant increase in profitability.

Example: Scale-up of a pyrolising Internally Circulating Fluidised-bed Gasifier (ICFG) [Ebara Corporation]

Determined key design parameters for detailed design of this complex process such as sand hold-ups, sand circulation rate, size of the cooling coils and minimum temperature of feed streams.

The understanding of the effects of particle temperature distribution on the pyrolysis reaction is a key step in the process development.

Example: Optimisation of partial oxidation petrochemical reactor design [Korean chemical producer]

Determined optimal mechanical design for high-performance multitubular reactor for a series of highly-exothermic partial oxidation reactions.

This resulted in an enhanced process, the ability to perform detailed engineerig design locally and an estimated $5m saving on the reactor contract.

New process for production of methyl ethyl ketone via liquid-phase catalytic oxidation of butane

An integrated system for rapid catalyst evaluation in catalytic naphtha cracking

Product quality and scale-up in polyethylene co-polymerisation

Process development assistance for Fischer-Tropsch gas-to-liquid (GTL) reactors.

Polysilicon process design and development.

A novel reactor design for maleic anhydride production.

Design of Heat-Integrated Distillation Columns (HIDiC).