Continuous Reactions

Major savings in production can be achieved by operating the process continuously. The BCT Loop Reactor is being used increasingly as a continuous reactor system due to its great potential to intensify the reaction and to significantly shorten the reaction time.

Such advantages can be realized not only in new plants but also by modifying existing ones.

The BCT Loop Reactor ensures highest possible mass transfer and minimizes the reaction time. This makes the ideal reactor system for continuous operation. Continuous operation results in a reduction on utility and raw material consumption, on catalyst cost and can even improve the product quality. In comparison to batch reactors a continuously operated BCT Loop Reactor can cut energy consumption and operational costs up to 50%.

BCT engineers have developped other significant improvements to the BCT Loop Reactor to optimize continuous reactions even further.

Operation Principles

The raw material is dosed into the reactor system near the reaction mixer. In the reaction mixer gas is dispersed into fine gas bubbles and reacts extremely efficiently with the liquid raw material. The heat exchanger ensures stable operation conditions - final product can be discharged from the self cleaning in-line filter which keeps all catalyst in the reactor system.

Under the constant reaction conditions achieved by this design, catalyst lifetime increases and the consumption of catalyst is lower than that of batch reactors. Catalyst is replaced periodically using an automatic dosing and discharging system. An optimal catalyst load is maintained during the complete operation time.

Industrial Reference I

Continuous Hydrogenation of Nitrobenzene to Aniline:

		STIRRED REACTOR CASCADE	CONTINUOUS BCT LOOP REACTOR
	Pressure	10 barg	10 barg
	Temperature	95 °C	110 °C
	Vessel Volume	2 x 16 m3 Cascade	10 m3 Single Reactor
	Reaction Time	80 min.	45 min.
	Yield	95.7 %	97.0 %
	Capacity	950 MTPY	1'500 MTPY
	Catalyst Concentration	5 % Pd/C	2.5 % Pd/C
	Catalyst Consumption	0.88 kg/t	0.34 kg/t

Industrial Experience II

Hydrogenation of an Aliphatic Compound with a double bond:

Modification of a BCT Loop Reactor from batch to continuous

		BATCH MODE BLR	CONTINUOUS MODE BLR
	Pressure	30 barg	30 barg
	Temperature	180 °C	200 °C
	Vessel Volume	5 m3	5 m3
	Total Batch Time	135 min.	100 min. (residence time)
	Capacity	16'000 MTPY	25'000 MTPY
	Catalyst Consumption	ca. 0.15 kg/t	ca. 0.05 kg/t
	Energy Consumption	ca. 6 kW/t	ca. 2 kW/t

Conclusion

Many more processes than expected could be operated in a continuous mode. Continuously operated plants have significant economic advantages and as a consequence make your operation more efficient and increase your profitability.

Plant operators should consider reviewing their reactions and contact us for further information and support. Prior to any industrial investment, you can ask us to optimize your chemistry in our pilot plant. Learn what you can expect and what we guarantee before we plan and realize your industrial plant. - You are invited to contact us info(at)buss-ct.com .

Benefits of Continuous Operation using the BCT Loop Reactor Technology

One reactor, no cascade
High conversion
Less catalyst consumption
Reduced environmental impact

Reduced by-products
Lower operational costs
Attractive pay-back time