Reactions covered include: Homogeneous fluid-phase • Fluid-solid – catalytic and non-catalytic (solid undergoing conversion) • Mixed surface and fluid-phase reactions • Chain reactions • Non-stoichiometric reactions • Any complexity of kinetics
Reactors covered include: Batch • CSTR • Packed bed – both catalytic and non-catalytic (solid undergoing conversion) • Non-catalytic reactor-Regenerator dual bed • Multi-tubular • Double-walled (bayonet tube) • Bubbling/ turbulent fluid bed • Circulating fluid bed • Bubble-column • Slurry (2-phase/ 3-phase) • 3-phase fluid bed • Microchannel reactor
Operating modes include: Recycle • Quench • Multi-stage • Temperature-programmed • Adiabatic • Isothermal • Reactors-in-series
Past applications include: Various POX reactors • Bayonet tube (Double-walled fixed bed-DWFXB) methanol converter • Turbulent fluid bed (BFB) for Maleic anhydride (world’s first) production • Tubular fixed bed (FXB) and BFB for Acrylonitrile production • Fluid Catalytic Cracker (FCC) • Microchannel for diesel fuel production • Dual-packed bed (PKD) sulfur absorber • Bubbling fluid bed (BFB) Laterite ore pre-roaster/ incinerator • Packed carbon bed for Hg removal from refinery waste incinerator • Circulating Fluid Bed (CFB), BFB and Moving Bed (MVB) hot gas Desulfurization by zinc titanate • Coal pyrolysis/ Combustor/ gasifier • CFB catalyst regeneration • Oxidative coupling of methane in multiple reactor types • Trace oxygen removal in PKB • Hydrocracking in FXB and slurry reactors • Hydrocarbon Combustor/ burner • Solid acid Alkylation • BFB for fuels from tar sands • FXB, Quench and BFB reactors for chemicals from SG
Design/ experience in Auxiliary Systems include: NOx/ S/ Hg removal • Coolant/ solids/ slurry flow or circulation loop design • Internal cooling-coil-bank layout • Dip-leg and aeration system design • Filters/ cyclones • Fluid or solid distributor designs • Solids conveying-charge-discharge system designs • Reactor internals/ baffles, cones/ domes, nozzles/ bends, measurement/ control probes, entrance/ exit zones • Set points for operation & control
Addressing potential instability/ temperature runaway, foaming, fines build-up, depositions, plugging, agglomeration, soot formation, fouling/ coking, attrition, erosion
