Henven HJ-7 100 mL Light Oil Hydrogenation Pilot Plant

Overview

The Henven HJ-7 is a bench-scale, dual-reactor hydrogenation pilot plant engineered for controlled catalytic upgrading of light hydrocarbon fractions under elevated temperature and pressure. Designed around Couette-type fixed-bed and fluidized-bed reactor configurations, the system enables precise simulation of industrial hydrotreating conditions—including desulfurization (HDS), denitrogenation (HDN), and saturation of olefins and aromatics. Its core architecture integrates high-integrity stainless-steel process piping, ASME Section VIII-compliant pressure boundaries, and redundant thermal management zones to ensure operational fidelity across reaction kinetics studies, catalyst screening, and process parameter optimization. The unit operates on a closed-loop gas recirculation principle with integrated H₂ purity monitoring and automatic purge control, supporting both batch and continuous-flow modes with full traceability of mass and energy balances.

Key Features

• Dual-reactor configuration: Independent fixed-bed and fluidized-bed modules, each with segmented heating zones and real-time thermocouple arrays (Type K, Class I accuracy)
• Automated feed delivery: Dual-syringe high-pressure liquid metering pumps (light oil: 0–20 mL/min; heavy oil: 0–50 mL/min) with pulse-dampened flow paths and back-pressure regulation
• Integrated gas handling: Mass flow controllers (MFCs) for H₂, N₂, and H₂S (0–40 L/min total), equipped with inline moisture and sulfur traps, and optional online GC sampling interface
• Advanced thermal control: Three-zone programmable heating—reactor core (up to 500 °C), vaporization/preheat section (ambient to 200 °C), and gas–liquid mixer outlet (up to 520 °C)—with ramp rates adjustable from 0.1 to 40 °C/min and isothermal stability within ±0.1 °C over 24 h
• Intelligent process supervision: Renmai Fluidized-Bed Control System (RFCS) with embedded PID logic, auto-triggered safety interlocks, and dynamic setpoint adaptation based on real-time sensor feedback (pressure transducers: 0.1–20 MPa, ±0.05% FS; differential pressure sensors across catalyst beds)
• Robust mechanical construction: All-welded 316L stainless-steel frame with IP65-rated operator panel, explosion-proof junction boxes, and seismic anchoring provisions per IEC 60068-2-6

Sample Compatibility & Compliance

The HJ-7 accommodates a broad range of liquid feedstocks—including naphtha, kerosene-range fractions, bio-oils, and model compounds (e.g., thiophene, quinoline, tetralin)—as well as gaseous reagents (H₂, H₂/N₂ blends, syngas). Catalyst compatibility spans supported NiMo/Al₂O₃, CoMo/Al₂O₃, Pt/Al₂O₃, and novel transition-metal phosphides. The system meets structural and instrumentation requirements outlined in ASTM D2622 (XRF sulfur analysis integration), ISO 17025 calibration traceability for all primary sensors, and supports GLP-compliant audit trails per FDA 21 CFR Part 11 when paired with validated data acquisition software. Pressure relief devices conform to PED 2014/68/EU and are certified by TÜV Rheinland.

Software & Data Management

Control and data acquisition are managed via a Linux-based embedded HMI with 10.1″ capacitive touchscreen interface, running real-time deterministic firmware (RTOS). All process variables—including temperature gradients, differential pressures, feed rates, and gas composition—are logged at 10 Hz with timestamped binary archives (.bin) and CSV exports. The system supports OPC UA server integration for connection to enterprise-level SCADA or LIMS platforms. Audit trail functionality includes user login history, parameter change logs with electronic signatures, and immutable event records for critical alarms (e.g., overtemperature, overpressure, pump stall). Raw data files are SHA-256 hashed and stored with dual redundancy—on-board eMMC and external NAS via Gigabit Ethernet.

Applications

• Catalyst deactivation kinetics under realistic hydrotreating conditions
• Reaction mechanism validation using isotopic labeling (D₂, ¹³C-labeled feeds) and in situ FTIR coupling
• Optimization of H₂ partial pressure vs. residence time trade-offs for aromatic saturation selectivity
• Fluidization behavior mapping of fine-particle catalysts (dp < 50 µm) under high-velocity gas flow
• Development of surrogate fuel blends compliant with ASTM D7566 Annex A2 (hydroprocessed esters and fatty acids)
• Training platform for refinery process engineers in safe high-pressure hydrogen operations (per OSHA 1910.119 Process Safety Management)

FAQ

Is the HJ-7 suitable for corrosive feedstocks containing organic acids or chlorides?

Yes—the wetted parts include Hastelloy C-276 trim on critical valves and flow restrictors, and all internal surfaces undergo electropolished passivation per ASTM A967.
Can the system be operated remotely via Ethernet or Modbus TCP?

Yes—Modbus TCP slave functionality is enabled by default; remote start/stop, setpoint adjustment, and alarm acknowledgment are fully supported without additional licensing.
What calibration documentation is provided with delivery?

Each unit ships with NIST-traceable calibration certificates for all pressure transducers, RTDs, and MFCs, plus as-built P&IDs stamped by a registered professional engineer (PE).
Does the fluidized-bed module support Geldart Group B and D particle classifications?

Yes—the distributor plate design and gas velocity range (0.1–1.2 m/s superficial) accommodate particles from 20 µm (Group C) up to 500 µm (Group D), with optional tapered riser extensions for dilute-phase transport studies.
Is explosion-proof certification available for Zone 1 installation?

ATEX II 2G Ex db IIB T4 Gb and IECEx certification packages are available as optional factory-installed upgrades, including flameproof enclosures and intrinsically safe signal barriers.