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Batch Reactors
The following link provides an introduction to the technology infrastructure : https :// www . youtube . com / watch ? v = PzRmtHKJwpo
degree of design adjustment and tuning even before the first materials were fully specified or cut . This fully integrated computer design modelling combination allowed PTSC to go from conceptual design to full scale detail design without passing through an intermediate scaled or prototype step . The TCU was specifically developed by PTSC sister company , Thermal Fluid Systems Ltd to integrate seamlessly with the new PI QFlux™ reactor as well as provide the opportunity to run the reactor as an electric only heat source which could operate on a zero-carbon basis with green electric supply . This has provided the PI QFlux™ with a 50 % reduction in energy requirements in conventional steam supplies , additionally the system has been designed to further reduce its energy demand by integrating within the TCU an electric heating module due to its higher source and transmission efficiency .
PI QFlux™ Innovations From the outset the integration of the PI QFlux™ system technology with existing chemical plant and infrastructure had been considered both in terms of process connections and integration but importantly services , safety , and maintenance requirements . Some examples of the unique features of the PI QFlux™ technology include increased vessel process openings for ease of flow and the number of utilities that can be connected , the “ cool to touch ” top head , primary and secondary balanced seals on main flange closures thus preventing fugitive emissions and same performance options utilizing both low and high shear mixers . One of the many patented features of PI QFlux™ and a core technology differentiator is its heated baffle design which in addition to providing ideal mixing , operates completely independently mechanically and thermally from the vessel heat transfer zones . This technology allows very rapid heat flux changes due to its lower thermal mass and high thermal conductivity .
A further unique feature of the many in the PI QFlux™ batch reactor is that the complete reactor is supported from the top head and not the vessel body , this has two important functions in that it alleviates expansion effects on the vessel overheads , but it also enables maintenance and vessel / mixer removal to take place without ever having to remove the overheads from the top head . The PI QFlux™ reactor system enables multiple options for production flexibility which include using 75 % smaller capacity vessels for the same overall output or similar vessel capacity for 300 % output increase , with the reactor in turn capable of operating at any percentage level or capacity fill . Scalability and thermal flux capability are given problems when moving from lab and pilot plant scale up to production scale and Q max
/ V ( kWm -3 ) [ 1 ] for various lab and plant with 1 m 3 reactor typically being 12 times lower than a 1ltr reactor . This requires a significant de-tuning of the lab scale performance to meet with the production scale requirements . The PI QFlux™ is designed to achieve
Q max
/ V in the range of 650 kW m -3 which is some 50 % of that performed at 1ltr scale , allowing higher kinetics and reagent addition improving yield quality by compressing the reagent addition period . It is also worth noting that some 75 % of all production time of a batch reactor involves heat transfer either through content heating , exothermic / endothermic reaction control , crystallization , cool down , evaporation / reflux and CIP . The following link provides an introduction to the technology infrastructure : https :// www . youtube . com / watch ? v = PzRmtHKJwpo
PI QFlux™ Test Centre The only true way to compare performance claims is to provide a benchmark with a back-to-back testing utilizing the same services and infrastructure between both technologies . To provide such a comparative test PTSC in col-
48 Heat Exchanger World October 2022 www . heat-exchanger-world . com