Activity Report: Automatic Control 2002

The project is aiming at improving process control of chemical reactors, especially the new Alfa Laval Plate Reactor. Innovative process design leads to vastly improved control capabilities, allowing increased productivity, efficiency and safety. Background and process description In the chemical industry of today, the batch reactor is the most common reactor type. However is it unsuitable for highly exothermic reactions due to its limited heat transfer capacity. The reactant solutions have to be diluted with water to reduce the amount of energy released during the reaction. After the reaction, separation is necessary to remove the excess water of the product solution. Alfa Laval AB is currently developing a new kind of reactor technology, a plate heat exchanger of new design, where one side is used as a chemical continuous reactor and the other side is filled with a cooling/heating medium. See Figure 5.8 A typical reaction can be stated as: A + B -> C + D. The primary reactant A enters the main inlet of the reactor. The secondary reactant B is then added in multiple inlet ports along the reactor, to distribute the heat from the exothermic reaction. See Figure 5.9. The process has a much higher heat transfer capacity, so solutions of higher concentrations can be used leading to less separation need. The process will also have higher productivity, more efficient reaction and a safer process.

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