CFD modelling is a rapid, safe and economical approach to chemical reactor design, optimisation and scale up. Our specialist CFD consultants are experienced engineers who understand process problems and how to apply CFD as an engineering tool. And all of our modelling is backed up by our extensive laboratory facilities, enabling validation and calibration of models against project-specific data.

Benefits

• Faster time to market
• Improved product quality
• Increased yields and purity
• Rapid payback
• Reduced waste
• Lower operating costs
• Start up right first time
• Rapid and reliable scale up
• Reduced separation costs
• Higher profitability
• Safer cleaner process
• Reduced CAPEX

Equipment

• Stirred tank reactors (batch, semi-batch or continuous)
• Crystallisers
• In-line mixers
• Jet mixed systems
• Bubble columns
• Absorption towers
• Low shear mixers for the following products:
  • Fine chemicals
  • Speciality chemicals
  • Pharmaceuticals
  • Bulk chemicals
  • Polymers
  • Petrochemicals
  • Agrochemicals

Parameters

• Velocity and turbulence fields
• Concentrations of reactants, products and by-products
• Product distribution
• Temperature profiles
• Gas hold up
• Particle size/chain length distributions
• Solids distributions
• Batch time
• Residence time distribution
• Power draw Mix times
• Heat transfer coefficient

Simulation predictions include:

• Flow patterns
• Turbulence profiles
• Shear profiles
• Blending characteristics
• Solids distribution
• Multiphase distributions
• Crystal size distribution
• Reaction yields
• Particle tracking
• Heat transfer
• Pressure drop
• Power draw
• Free surface modeling

Applications

• Bespoke model development
• Process and equipment optimisation, e.g.. process yield, crystallisers, reactors
• Reactor design (STR, bubble column, static and rotor-stator mixers)
• Process and reactor scale up
• Parameter sensitivity studies
• Temperature control strategies
• Monomer/initiator dosing strategies
• Equipment rating
• Troubleshoot existing design problems
• Evaluate retrofit options

Flow patterns in a multi-impeller reactor

Processes

• Single liquid phase flow
• Solid/liquid mixing
• Multiphase flow
• Mixing and reaction
• Crystallisation
• Polymerisations
• Heat and mass transfer Integration of micro mixing and reaction kinetics into CFD
• Integration of population balance models
• Particle tracking
• Non-Newtonian rheology

Effect of feed time and arrangement on by-product formation in semi-batch micromixing-controlled reaction

BHR Group is an international centre of fluid mixing expertise and knowhow in the design, optimisation and scale-up of chemical reactors for single-phase, two-phase and multiphase processes. Expertise in CFD modelling, chemical engineering and chemistry is backed by unrivalled pilot and production-scale experimental facilities for model validation.

To discuss applying a similar approach to your case, please contact us or search our site for your specific interest.