COURSE OVERVIEW:

Chemical reactor design is the cornerstone of chemical engineering, where the theoretical principles of kinetics and thermodynamics are translated into industrial-scale production hardware. This course provides a rigorous framework for selecting and sizing reactors, focusing on the mathematical modeling of ideal and non-ideal systems. Participants will explore the fundamental design equations for Batch, Plug Flow (PFR), and Continuous Stirred-Tank Reactors (CSTR) to determine the volume required to achieve specific conversion and selectivity targets.

The scope of this training bridges the gap between laboratory-scale experimentation and commercial-scale implementation. Attendees will learn the complexities of scale-up, including the management of heat transfer limitations, mixing dynamics, and mass transfer constraints that often emerge when moving to larger volumes. The course emphasizes the importance of residence time distribution (RTD) and non-ideal flow patterns, teaching engineers how to use "tanks-in-series" or "dispersion" models to account for real-world deviations from theoretical behavior.

Coverage includes specialized reactor types such as fixed-bed catalytic reactors, fluidized beds, and multiphase systems. Participants will analyze the impact of catalyst geometry and pore diffusion on overall reaction rates, incorporating the Thiele Modulus and Effectiveness Factor into their design calculations. By focusing on the integration of thermal safety and stability analysis, this course equips process engineers with the technical depth to design efficient, safe, and profitable reaction systems for a wide variety of industrial applications.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Formulate mole balances and design equations for Batch, CSTR, and PFR systems.

2.  Determine the optimal reactor volume for single and multiple reaction pathways.

3.  Analyze reaction rate data to derive kinetic rate laws and activation energies.

4.  Scale-up reactors from lab to pilot and commercial sizes while maintaining performance.

5.  Manage heat transfer and thermal stability in exothermic reaction systems.

6.  Calculate residence time distribution (RTD) from tracer experiment data.

7.  Implement non-ideal flow models to account for dead zones and bypassing.

8.  Design multi-stage CSTR configurations for improved conversion efficiency.

9.  Evaluate the impact of mass transfer resistance in gas-liquid and gas-solid reactors.

10.  Utilize the Thiele Modulus to assess internal diffusion limitations in catalysts.

11.  Design fixed-bed reactors considering pressure drop and catalyst life.

12.  Perform stability analysis to identify potential runaway reaction scenarios.

13.  Formulate a comprehensive reactor specification sheet for procurement and construction.

TARGET AUDIENCE:

Process Engineers, R and D Engineers, Chemical Engineers, and Project Managers involved in the design and scale-up of chemical production units.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.