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EKATO Hydrogenation Reactor
The heart of our hydrogenation plants is the EKATO hydrogenation reactor, which is equipped with an unique agitator, the EKATO Combined Gassing System. Until the late 1990s, almost all hydrogenation reactions on an industrial scale were carried out under mass transfer limited conditions. That was the reason why EKATO further developed early concepts of self-aspirating agitation systems to the EKATO Combined Gassing System, thereby overcoming the limitations of traditional reactor systems.
EKATO Combined Gassing is now used worldwide in more than 500 gas-liquid reactors and is an important basis for our success in numerous industrial hydrogenation applications.
High Performance Hydrogenation
The EKATO Combined Gassing System guarantees an extremely high mass transfer of the gaseous hydrogen into the liquid phase. In the bottom of the hydrogenation reactor, the fresh gas is fed directly into the EKATO Phasejet. This high-performance impeller disperses the fed hydrogen into very fine gas bubbles and thus creates an extremely large interface area between gas and liquid. The EKATO Gasjet, a self-aspirating turbine permanently re-disperses non-converted gas from the head space of the reactor back into the liquid through a hollow shaft. This ensures that sufficient amounts of dissolved hydrogen are always available to the chemical reaction and that the hydrogenation can always take place under ideal conditions.
Stirred hydrogenation reactors are often applied in the laboratory for the development of hydrogenation processes and are therefore always the first choice in production, too. There is almost no technological risk in the transfer of scale from agitated lab reactors to agitated production reactors. This is especially true for the EKATO Combined Gassing system , which always reaches the mass transfer values of a laboratory autoclave regardless of the reactor size – even up to 150 m3.
Our innovative hydrogenation reactors allow a maximum space-time yield and thus secure the long-term success of our clients.
Hydrogenation reactors from EKATO – reliable and robust
Because of the high volume-specific power inputs and the resulting high hydraulic load on vessel internals, the design of a hydrogenation reactor is particularly demanding.
EKATO determines hydraulic-based parameters, such as the hydraulic loads on heat exchangers in the reactor through numerical flow simulations (CFD). These offer the advantage that the simulation is carried out virtually in the full production scale of the foreseen hydrogenation reactor. The information obtained in this way is indispensable for the static and dynamic dimensioning as well as for the resonance-proof design of the hydrogenation reactor. EKATO also designs the reactor in house using numerical methods such as FEA and CAE.
At EKATO, the mechanical design of critical plant components is fast and robust through state-of-the-art design methods and numerical simulations on an operational scale and before actual production of the equipment.
EKATO combines the knowledge and experience for the integrated process engineering and mechanical design of critical plant components. We thus offer top performance in the planning and construction of hydrogenation plants.