Polymerization Granulation and Pellet Processing Educational Unit Operations Pilot Plant

Introduction

The Polymerization, Granulation, and Pellet Processing Educational Unit Operations Pilot Plant is an integrated, multi-stage process platform designed for academic laboratories and hands-on engineering instruction. Featuring a 30L capacity polymerization reactor, this pilot-scale system bridges the gap between pure laboratory chemistry and industrial polymer manufacturing. The plant provides students with a physical demonstration of consecutive chemical and mechanical unit operations—ranging from initial material batching and polymerization to hydrolysis, extrusion-granulation, drying, crushing, and sieving. Constructed from corrosion-resistant stainless steel and engineered for atmospheric pressure operation, it offers university students a safe yet realistic environment to study polymer synthesis, mass and heat transfer, and solids-handling dynamics.

Customizable System Design

To accommodate the varying curricula, laboratory layouts, and research focuses of different universities, this pilot plant is highly adaptable. We offer comprehensive customization options across both hardware and software configurations to meet your specific instructional needs:

• Hardware Customization: Reactor volume scales, alternative agitator designs (such as anchor or paddle impellers), customized material feeding systems, and specialized sensor ports can be integrated to match specific process requirements.
• Software Customization: The control interface, data acquisition systems, automation sequences, and software logging capabilities can be tailored to align with your department's preferred computer-aided engineering tools and teaching protocols.

Key Teaching Functions and Engineering Advantages

This educational pilot plant is designed to optimize classroom instruction and simplify laboratory management while delivering significant engineering value:

• Complete Process Visualization: Students can follow the transition of raw materials from monomers to finished, sized polymer pellets within a single, continuous workflow.
• Industrial-Grade Material Handling: Featuring a robust ribbon agitator and a dedicated vibration conveying system, the unit replicates the mixing mechanics and transport dynamics found in actual polymer manufacturing plants.
• Integrated Unit Operations: It consolidates liquid-liquid mixing, chemical reaction, liquid-solid phase change, heat exchange, solids drying, and mechanical classification into a cohesive footprint.
• Safe and Controlled Learning Environment: Designed to operate under atmospheric pressure, the system reduces the safety risks typically associated with polymer synthesis. Precise temperature control is achieved via an electric heating system and constant temperature bath, preventing overheating or rapid temperature drops.
• Multidisciplinary Teaching Utility: A single platform serves multiple departments, including Chemical Engineering, Materials Science, Polymer Engineering, Environmental Engineering, and Food Technology.

Detail & Parts

Alignment with Core Chemical Engineering Curriculum

To help educators easily integrate this equipment into existing coursework, the pilot plant’s components and functions are directly mapped to fundamental concepts in standard engineering textbooks, such as Unit Operations of Chemical Engineering, Transport Processes and Unit Operations, and Chemical Engineering Design.

The table below illustrates how the physical modules of the pilot plant correspond to core academic topics and practical learning outcomes.

Technical Specifications

The system is constructed with materials and control interfaces designed to withstand typical laboratory usage while providing accurate process data.

• Reaction Volume: 30 Liters
• Primary Structural Material: High-grade corrosion-resistant stainless steel
• Agitation System: Stainless steel ribbon agitator with adjustable speed drive
• Heating System: Integrated electric heating paired with a constant temperature bath for stable thermal control
• System Pressure: Atmospheric pressure operation for enhanced laboratory safety
• Solids Processing Train: Integrated pelletizer, vibratory conveyor, dry-air vibration dryer, mechanical crusher, and multi-deck sieve

Tailored Educational Solutions

Every institution has unique spatial constraints and laboratory standards. Whether you need to integrate specific digital sensors for real-time data logging, modify the physical layout of the platform to fit a specific lab space, or configure customized software dashboards for student access, the hardware and software of this pilot plant can be adapted to match your exact pedagogical objectives.

About LABPARK

LABPARK has spent more than 20 years serving the global higher education sector, providing high-quality engineering training equipment and pilot-scale systems. We specialize in developing educational solutions across six key academic disciplines: Chemistry, Chemical Engineering, Bioprocess Engineering, Food Engineering, Pharmaceutical Technology, and Environmental Engineering.

Driven by continuous innovation, LABPARK holds 209 technical patents and has established collaborative partnerships with more than 289 universities and colleges worldwide. Our operations are anchored by a state-of-the-art, 49,000-square-meter production and research & development base, ensuring that every piece of equipment we deliver meets rigorous quality, safety, and educational standards.

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