The various embodiments of the present invention relate to a polymerization reactor where the agitator mixing performance is optimized for use with a high activity catalyst and methods for developing the same.

The invention relates to a thermal conversion vessel (200) used during amidification step of acetone cyanohydrin (ACH), in the industrial process for production of a methyl methacrylate (MMA) or methacrylic acid (MAA). The thermal conversion vessel (200) is used for converting an hydrolysis mixture of α-hydroxyisobutyramide (HIBAM), α-sulfatoisobutyramide (SIBAM), 2-methacrylamide (MACRYDE) and methacrylique acid (MAA), into a mixture of 2-methacrylamide (MACRYDE). It comprises:—at least one compartment (C1, C2, C3, . . . Ci) comprising an inner wall (206a, 206b, . . . 206i) separating said compartment into two communicating parts (C1a, C1b) by a passage provided between the bottom of said vessel and said inner wall,—said compartment having a space above said inner wall, for separating gas phase from liquid phase during thermal conversion,—said compartment being connected to an outlet valve (204a, 204b, . . . 204i). Such vessel allows obtaining a high yield thermal conversion in very safe conditions.

The invention is directed to a chemical reactor (100) having (a) two or more gas reactor elements (12) with each gas reactor element (12) having (i) a first reaction chamber (38), and (ii) a feed assembly unit (36), (b) a second reaction chamber (20) coupled with each of the two or more gas reactor elements (12) and configured to independently receive two or more product streams from the two or more gas reactor elements (12); and optionally, (c) a gas converging section (40) located downstream to the second reaction chamber (20). The invention is further directed to a method of producing chemical products using the chemical reactor (100) of the present invention.

An equilibrium approach reactor with the ability to receive a highly variable gas and normalise it to a useful quality, and further to utilise the energy from the gas itself to robustly elevate the operating temperature, to ensure good mixing and high conversion while having the ability to handle solids in multiple states.

Methods of controlling olefin polymerization reactor systems may include a) selecting n input variables, each input variable corresponding to a process condition for an olefin polymerization process; b) identifying m response variables corresponding to a measurable polymer property; c) adjusting one of more of the n input variables using the olefin polymerization reactor system and measuring each of the m response variables as a function of the input variables for olefin polymers; d) analyzing the change in each of the response variables as a function of the input variables to determine coefficients; e) calculating a Response Surface Model (RSM) for each response variable determined in step d); f) applying n selected input variables to the calculated RSM to predict one or more of m target response variables; and g) using the n selected input variables to operate the olefin polymerization reactor system and provide a polyolefin product.

A method is disclosed for controlling retention time in a reactor, such as an autoclave, having a plurality of compartments separated by dividers with underflow openings. A retention time of the reaction mixture is calculated and compared with an optimal retention time, and the volumes of the reaction mixture in the compartments are adjusted while maintaining the flow rate of the reaction mixture, so as to change the retention time to a value which is closer to the optimal retention time. The reactor may include a level sensor in the last compartment for generating volume data; a control valve for controlling the liquid level in the last compartment; and a controller which receives volume data from the level sensor and controls operation of the control valve.

An embodiment of a reaction chamber is described that comprises a block of a material comprising a heat source positioned in a central location and a continuous channel comprising an inlet positioned at a first peripheral area of the block and an outlet positioned at a second peripheral area of the block, wherein the channel comprises a serpentine path from the inlet past the centrally located heat source to the outlet.

Flow control mechanisms control the direction and flow rate of synthesis reagent through one or more synthesis reaction vessels for automated solid phase synthesis. Selectable, known, and reproducible positive or negative pressure differentials (−5 to +10 psi) accomplish controlled, bidirectional (forward and reverse) flow of synthesis reagents through synthesis media contained within the reaction vessels. Venturi-based vacuum apparatus, valves, electronic pressure regulators and compound digital pressure gauge, can be added to automated solid phase synthesis instruments to provide, control, and monitor known, selectable, reproducible negative and positive pressures to one or both valve sealable and un-sealable ends (inlets and outlets) of the reaction vessel as needed to generate and reverse said pressure differentials between the opposite ends of said synthesis reaction vessels, yielding controlled forward and backward flows of synthesis reagents through the synthesis media.

A system and method is provided for upgrading a continuously flowing process stream including heavy crude oil (HCO). A reactor receives the process stream in combination with water, at an inlet temperature within a range of about 60° C. to about 200° C. The reactor includes one or more process flow tubes having a combined length of about 30 times their aggregated transverse cross-sectional dimension, and progressively heats the process stream to an outlet temperature T(max)1 within a range of between about 260° C. to about 400° C. The reactor maintains the process stream at a pressure sufficient to ensure that it remains a single phase at T(max)1. A controller selectively adjusts the rate of flow of the process stream through the reactor to maintain a total residence time of greater than about 1 minute and less than about 25 minutes.

A method and system for continuous production of contaminant free and size specific biochar using downdraft gasification of variable quality feedstock. The system and process of the present invention includes the transfer of biochar from a gasifier after gasification to a temperature-controlled cooling screw conveyor, into a drum magnet for ferrous metal removal into multiple diverters to separate and remove ungasified materials and non-ferrous metal contaminants, then transferred into a granulator for grinding and screening the biochar to a pre-selected size. By directly attaching a novel and continuous product treatment process to the biochar stream as it exits the gasifier, the particle size, moisture content, carbon content and yield of a contaminant free biochar product can be narrowly controlled and improved to meet strict product quality specifications required by specialty applications.