Fixed-Bed Chemical Reaction and Gas Dust Tar Removal Unit Operations Pilot Plant

Introduction

The Fixed-Bed Chemical Reaction and Gas Dust and Tar Removal Educational Unit Operations Pilot Plant is an integrated laboratory training system designed for higher education. This unit combines gas-solid catalytic reaction engineering with downstream gas purification processes, allowing students to study the generation, cooling, condensation, and filtration of post-reaction process gases. Equipped with a dual fixed-bed tubular reactor system, multi-stage electric heating, and dedicated separation modules, the pilot plant provides engineering students with hands-on experience in managing complex, multi-step process operations.

To accommodate different academic curricula, research focuses, and laboratory space constraints, this educational pilot plant offers comprehensive customization. Both the hardware components—such as reactor capacities, material ratings, and sensor types—and the software control interfaces can be customized to align with specific departmental requirements and pedagogical goals.

Key Teaching Functions and Advantages

• Process Unit Integration: Combines high-temperature catalytic reactions, heat exchange (cooling/condensation), and physical separation (dust filtration and tar extraction) into a single, continuous educational process line.
• Industrial-Grade Construction: Built with corrosion-resistant and high-temperature-tolerant alloys (such as 310S and 316L stainless steel) to simulate authentic industrial processing environments.
• Advanced Thermal Management: Features a three-stage independent heating furnace that provides uniform temperature distribution within the reactor zone, demonstrating real-world thermal control principles.
• Modern Process Control & Data Acquisition: Utilizes an integrated 15.6-inch touchscreen interface with PLC connectivity, enabling real-time monitoring of temperatures and pressures alongside cloud data-logging capabilities for student laboratory reports.
• Comprehensive Student Safety: Engineered with integrated pressure gauges, overpressure relief protocols, and quick-disconnect ferrule connections to maintain a secure learning environment during high-temperature operations.

Detail & Parts

Technical Specifications and Educational Modules

Curriculum Integration and Professional Fields

This educational pilot plant is designed for academic programs in Chemical Engineering, Environmental Engineering, Energy Technology, and Process Equipment & Control Engineering. It serves as a physical bridge between theoretical calculations and physical process operations, aligning with core curricula found in major engineering departments.

By working with this unit, students can apply and validate core engineering principles detailed in standard academic textbooks:

• Unit Operations of Chemical Engineering: Students can investigate the physical separation techniques of gas-solid and gas-liquid systems, analyzing the mechanics of filtration, particle collection, and condensation processes under varying flow rates.
• Transport Processes and Unit Operations: The equipment allows for the practical study of heat transfer mechanisms within packed beds, fluid flow dynamics through packed columns, and mass transfer operations during gas purification stages.
• Chemical Engineering Design: The pilot-scale configuration offers an excellent case study for teaching process piping layouts, instrumentation symbology, system safety interlocks, and reactor sizing calculations.

Both the hardware configuration and the control software of this pilot plant can be customized to match the terminology, units of measurement, and specific experimental protocols prescribed in your institution's course syllabi.

About LABPARK

LABPARK has spent over 20 years serving the global higher education sector, specializing in the design and manufacture of professional-grade laboratory teaching equipment. We focus on delivering robust, curriculum-aligned systems across six primary academic fields: Chemistry, Chemical Engineering, Biotechnology, Food Engineering, Pharmaceutical Engineering, and Environmental Engineering.

Operating from a modern 49,000-square-meter R&D and manufacturing base, LABPARK maintains strict quality standards backed by 209 technical patents. To date, we have partnered with over 289 universities and colleges worldwide, helping educators provide safe, practical, and highly educational engineering laboratory experiences for their students.

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