improve batch reactor temperature control
TRANSCRIPT
UFLEX LIMITED
Practice School 1
IMROVE BATCH REACTOR OF TEMPERATURE CONTROL
Submitted to: Submitted By:Dr. NEHA SHARMA SANA PERWEEN
UFLEX LIMITED
• UFLEX Limited is India’s largest and fastest-growing flexible packaging company.
• Headquartered in NOIDA, the Company has manufacturing facilities in India and Dubai. It has offices in UAE, Europe & North America as well, and has significant market presence in more than 85 countries.
Batch Reactor Temperature Control
Fast heat up or cooldown to a new set point withoutoscillation and with minimum over-shoot.
hold temperature within a certain band around the set point,preferably without oscillation.
Proper mixing of temperature during reaction.
BATCH REACTOR
FORMATION OF POLYOL
When excess diol react with acid in the presence of specific catalyst form the polyester polyol.
FLOW DIAGRAM OF POLYOL REACTOR
P-COD 1152SP
CHARGING TIME 2hr
REFLEX TIME 1hr
THERMOPAK SETTING 250-280
REACTOR TEMP FROM CHARGING TO REFLEX 180-154
REACTOR TEMP FROM REFLEX TO 1ST SAMPLE OF ACID VALUE 154-195
COLUMN TEMP FROM REFLEX TO 1ST SAMPLE OF ACID VALUE 75-148
QC PARAMETER OF ACID VALUE >1
WATER VACCUM TIME 0.3hr
MAX WATER VACCUM ACHIEVED 0-620mmhg
OIL AND BOOSTER PUMP TIME 0.1hr
MAX VACCUM ACHIEVED 700
FINAL QC PARAMETER av-0.97,oh-36.76
R-42 ADD AT TEMP 72
REACTOR RPM @37TEMP MAINTAINED AT 82-87 82-87@37 RPM
REFLEX CONTINUOUS/BREAK continuous
1ST PART NCO FREE 5.3hr
QC PARAMETER VISCOSITY 3270
2ND PART NCO FREE 4.45hr
QC PARAMETER VISCOSITY 4460
FINAL RESULT 4780
ACTUAL DATA OF1152SP PRODUCT
DATE 23-May-16 28-May-16 7-Jun-16 8-Jun-16
POLYOL CODE 1152SP-23 1152SP-28 1152SP-16 1152SP-8
TOTAL POLYOL RM 4668.12 4668.12 4668.12 4668.12
1ST DRT 174.1 185.1 177 188
2ND DRT 494 483 491.1 470
TOTAL DRT 668.1 668.1 668.1 658.12
POLYOL PRODUCTION 4000 4000 4000 4010
%YIELD OF POLYOL 85.68% 85.68% 0.8568 85.90%
TOTAL TIME TAKEN BY POLYOL 19:00 19:30 19:30 18:30
POLYOL VISCOSITY 690cps 846cps 740cps 660cps
POLYOL ACID VALUE >1 0.89 0.93 0.88
POLYOL OH VALUE 36.97 33.67 34.9 37.4
TOTAL PU RM 6304.46 6264.902 6262.632 6495.608
PU PRODUCTION 6298 6237 6231.6 6469
%YIELD OF PU 99.89% 99.55% 99.82% 99.59%
TOTAL TIME TAKEN BY PU 17:30 20:00 17:00 22:00
PU SOLID CONTENT 65.98% 65.95% 66.12% 65.17%
PU VISCOSITY 4740 5090 4390 4320
PRODUCTION DATA OF 1152SP PRODUCT
TIME
REACTOR TEMP 23-
MAY
REACTOR TEMP 28-
MAY
REACTOR TEMP 7-
JUNE
REACTOR TEMP 8-
JUNE
00:00 124 179 140 186
00:30 70 77 74 74
01:00 92 68 84 96
01:30 110 150 117 130
02:00 145 142 158 161
02:30 158 160 167 176
03:00 173 173 184 190
03:30 187 187 193 198
04:00 193 198 199 200
04:30 200 201 203 201
05:00 202 201 205 205
05:30 203 205 176 179
06:00 196 192 196 193
06:30 199 196 199 200
07:00 196 197 199 201
07:30 199 196 199 202
08:00 199 197 198 201
08:30 199 197 198 201
09:00 199 196 198 201
POLYOL REACTOR TEMPERATURE
09:30 199 196 198 201
10:00 199 196 198 201
10:30 198 195 198 201
11:00 199 196 198 201
11:30 198 196 198 201
12:00 199 197 198 202
12:30 199 197 198 202
13:00 199 197 199 202
13:30 199 197 199 202
14:00 199 197 198 202
14:30 199 198 199 202
15:00 199 198 199 203
15:30 199 198 200 203
16:00 200 198 200 203
16:30 200 199 200 203
17:00 200 198 200 201
17:30 200 198 200 198
18:00 188 198 196 197
18:30 186 199 195 195
19:00 172 197
19:30 188
20:00 188
TIME
REACTOR TEMP 23-
MAY
REACTOR TEMP 28-
MAY REACTOR TEMP 7-JUNE REACTOR TEMP 8-JUNE
0
50
100
150
200
2500
:00
0:3
0
1:0
0
1:30
2:0
0
2:3
0
3:0
0
3:30
4:0
0
4:3
0
5:0
0
5:30
6:0
0
6:3
0
7:0
0
7:30
8:0
0
8:3
0
9:0
0
9:3
0
10:0
0
10:3
0
11:0
0
11:3
0
12:0
0
12:3
0
13:0
0
13:3
0
14:0
0
14:3
0
15:0
0
15:3
0
16:0
0
16:3
0
17:0
0
17:3
0
18:0
0
18:3
0
19:0
0
19:3
0
20
:00
TE
MP
ER
AT
UR
E(D
eg
ree
Ce
lciu
s)
Time(min)
POLYOL REACTOR TEMPERATURE
REACTOR TEMP 23-MAY REACTOR TEMP 28-MAY REACTOR TEMP 7-JUNE REACTOR TEMP 8-JUNE
POLYURETHANE REACTOR
polyurethanes are made from the reaction between an isocyanate and a polyol.
The first step of this reaction results in the chemical linking of the two molecules leaving a reactive alcohol (OH) on one side and a reactive isocyanate (NCO) on the other These groups react further with other monomers to form a larger, longer molecule.
FLOW DIAGRAM OF POLYURETHANE REACTOR
POLYUREATHANE REACTOR TEMPERATURE
TIME PU TEMP 23-MAY PU TEMP 28-MAY PU TEMP 7-JUNE PU TEMP 8-JUNE
00:00 37 20 40 30
00:30 139 130 137 145
01:00 124 120 120 120
01:30 106 106 106 105
02:00 92 190 90 96
02:30 78 86 80 89
03:00 59 70 57 77
03:30 72 55 65 78
04:00 78 65 80 81
04:30 84 80 85 82
05:00 86 82 85 84
05:30 87 83 86 85
06:00 86 83 87 85
06:30 86 83 90 84
07:00 86 84 89 85
07:30 87 86 89 86
08:00 85 87 88 85
08:30 86 87 88 85
09:00 86 88 89 85
09:30 85 88 87 85
10:00 85 88 87 85
11:00 86 88 89 84
11:30 86 87 91 84
12:00 86 87 88 84
12:30 86 86 58 85
13:00 59 86 57 85
13:30 55 72 58 85
14:00 50 63 57 85
14:30 50 59 57 85
15:00 50 57 52 85
15:30 50 56 52 85
16:00 50 56 52 85
16:30 49 54 52 85
17:00 49 54 51 58
17:30 49 55 63
18:00 56 53
18:30 56 51
19:00 56 52
19:30 55 53
20:00 52 52
20:30 53
21:00 53
21:30 52
22:00 51
10:30 86 87 87 85
TIME PU TEMP 23-MAY PU TEMP 28-MAY PU TEMP 7-JUNE PU TEMP 8-JUNE
0
20
40
60
80
100
120
140
160
180
200
TE
MP
ER
AT
UR
E(D
eg
ree
ce
lciu
s)
Time(min)
POLYURETHANE REACTOR TEMPERATURE
PU TEMP 23-MAY PU TEMP 28-MAY PU TEMP 7-JUNE PU TEMP 8-JUNE
PROBLEM IDENTIFIED
Oscillatory tuning of the reactor temperature controller. Oscillatory tuning of the jacket temperature controller. Excessive dead zone in the jacket split range logic; and
Control valve setup problems. Power cut off is main problem. Excess amount of acid input .
THANK YOU