CATALYST RECHARGE (HDPE)

INTRODUCTION

A catalyst allows us to activate a chemical reaction and influences the rate of this reaction. These catalysts are generally very expensive and are usually specific for each individual reaction. When the level of catalyst falls below a certain level, the efficiency of the reaction decreases and eventually that chemical reaction shuts down. It is these parameters that make catalyst concentration levels very important to monitor in any chemical reaction process.

APPLICATION

Our main concern in this type of application is to monitor for low levels of catalyst. In normal processing, the catalyst mix in the isobutane carrier can reach as high as 20%. The Monitek unit however, is intended to monitor for low levels of catalyst of approximately 1000 ppm in the isobutane as it leaves the mixing chamber (better known as the “mud pot”). The mud pot needs to be recharged with catalyst in order to keep the reaction going. To let the catalyst drop too low would cause the reaction to shut down and cost the customer large sums of money in lost production time. The catalyst-Isobutane mix flows from the mud pot to the reactor where it is shocked into reaction to make high-density polyethylene (HDPE). This HDPE is the final product and is used as feedstock to other plants in the form of plastic pelletizing beads.

SOLUTION

The Monitek acoustic suspended solids monitor will continuously check the process and will immediately detect if the level of catalyst falls below 1000 ppm (or some predetermined low limit). The Monitek unit warns the operator of low-level conditions before they reach the reactor. This enables him/her to take immediate action.

ADDITIONAL COMMENTS

The acoustic sensor fits into a modified flange at the outlet of the mud pot to accommodate pressure of up to 800 psi.

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