Process Units

Training process units for a variety of industrial processes.
DTU-2 Portable Glass Distillation Training Unit
DTU-1 Glass Distillation Training Unit
FDST Flash Drum Separator
FCCU Glass Model Fluid Catalytic Cracking Unit
HTDU Heat Transfer Demonstration Unit

Fluid Bed Catalytic Cracking Unit

FCCU Glass Model Fluidized Bed Catalytic Cracking Unit

The model consists of a reactor, regenerator, standpipes, risers and air blower which forms the catalyst circulation system. The catalyst flow is controlled by the valves on the reactor standpipe and regenerator standpipe. Circulation fluidizing of the catalyst is achieved by injecting air into the air inlet of the regenerator, steam inlet of the stripper and the feed inlet to the reactor riser, and is controlled by three individual needle valves. (read more...)

Fluid Bed Catalytic Cracking Unit

The model consists of a reactor, regenerator, standpipes, risers and air blower which forms the catalyst circulation system. The catalyst flow is controlled by the valves on the reactor standpipe and regenerator standpipe. Circulation fluidizing of the catalyst is achieved by injecting air into the air inlet of the regenerator, steam inlet of the stripper and the feed inlet to the reactor riser, and is controlled by three individual needle valves.

A cracking process uses high temperature to convert heavy hydrocarbon into more valuable lighter products like gasoline and cracked gas oil while yielding less of the undesirable heavy residual product. The FCCU is a catalytic process employing a catalyst in the form of very small spherical particles which behave as a fluid when aerated with a vapor. The fluidized catalyst is continuously circulated from the reaction zone to the regeneration zone. The unit consists of two sections, Fractionation and Catalyst. The catalyst circulates up the riser to the reactor, down through the stripper to the regenerator, across to the regenerator standpipe and back to the riser. Fresh feed and recycle streams known as combined feed enter the unit at the base of the riser where they are vaporized and raised to the reactor temperature by the hot catalyst. This mixture of oil vapor and catalyst travels up the riser into the reactor. The gas oil commences to crack immediately when it contacts the hot catalyst in the riser and the cracking continues until the hot vapors are disengaged from the catalyst in the reactor. The cracked products in the vapor phase continue through the reactor vapor line to the fractionator.

In the fractionation section the reactor vapors are fractionated into recycle gas oils which are returned to the riser for further cracking and into products which include heavy cycle oil, cracked light cycle oil, unstabilized gasoline and wet gas. Coke is deposited on the circulating catalyst in the reaction zone. The now spent catalyst flows from the reactor to the regenerator where the coke is burned off. The heat of combustion raises the catalyst temperature to the 1100 - 1275° F range and most of this heat is transferred to the charge in the riser.

The dimensions of this model are as follows:
  • Base enclosure 25” X 18” X 12 ¼ ”
  • Overall unit height 44 ¼”

Heat Transfer Demonstrator (HTDU)

Controlling heat levels of fluids through industrial process operations is a very common requirement which has resulted in various heat exchanger configurations unique to specific applications. Bayport Technical has designed the Heat Transfer Demonstrator with a view to showing differences in efficiency depending on exchanger design, material of construction, flow direction or pattern, and flow velocities. The HDTU is a self contained unit complete with flow and temperature indicators and controllers.

Equipment Specifications

Equipment Specifications:

  • Entire unit mounted on metal structure with casters
  • Two pumps for hot and cold fluid
  • Manifolded with valving to accommodate reverse flows
  • Water heater with storage tank
  • Refrigerant type water chiller with storage tank
  • Flow meters and controllers on both phases
  • Digital thermometers on inlet and discharge of flows
  • Four various heat exchangers
  • Brazed plate exchanger
  • Single pass tube and shell – brass
  • Single pass tube and shell – stainless steel
  • Four pass tube and shell
  • All non-moving parts will be powder coated for durability and corrosion prevention
  • Approximate overall dimensions: 34” wide X 72” long X 72” high
  • Unit operates on 240 volt single phase power

Flash Drum Separator Trainer (FDST)

Many industrial processes deal with separation of volatile gasses dissolved in a liquid. Separation and recovery of the components is normally achieved using a flash drum. Bayport Technical has designed our FDST to allow visual observance and physical control of the 'flash drum' process during the separation of water saturated with carbon dioxide. The dedicated control panel operates flow, pressure, and temperature measurement devices required to achieve the separation process within operating parameters.

Equipment Specifications

Equipment Specifications:

  • Entire unit mounted on a metal structure with casters
  • Pump for water phase
  • Acrylic Flash Drum (separator tank)
  • Electric heater (in flash drum)
  • Pre-carbonator
  • Carbon dioxide bottle
  • Electronic analyzers
  • Flow meters
  • Pressure controllers
  • Operates on 240 volt single phase power
  • All static metal surfaces powder coated for durability and corrosion prevention
  • Approximate overall dimensions: 34” wide X 48” X 60” high

DTU-1 Working Glass Distillation Training Unit

This actual working glass distillation unit is our full size model. The DTU-1 is state of the art in teaching process distillation, incorporating a stripper column as well as the main column and includes a custom chilled water unit.

The pressure system, temperature readouts and controls, pump switch panel and flow controls are centrally located for ease of operation and safety.

DTU-2 Portable Glass Distillation Training Unit

The Process Operator Training Unit (DTU-2) was conceived and designed to give the operator of fractionation and distillation equipment a visual concept of what goes on inside those metal towers or columns that dominate the landscape in a petroleum refinery or petrochemical plant.

There are no automatic controls so that whatever happens on this unit is dependent on what the operator does, or does not do. The glass fractionating column allows the operator to see the results of his actions very quickly. Consists of the following equipment; Main Column, Pumps (4),Overhead Condensers, Heat Exchangers, Cooling System, Reboiler, Temperature Gauges and piping to actually perform distillation on a small scale model. This unit comes with carrying case which acts as a stand for the unit.

This unit has been a staple in the process training industry worldwide for many years and is currently our most widely used production item. With it’s hands on learning experience it is hugely popular in basic process classes in industry and education.

Chiller Unit

This unit has been developed to be used in conjunction with the Distillation Training Unit or DTU-2.

As a replacement for the current cooling system for the glass tabletop distillation process this unit adds stability in process control and doubles as a training unit itself, with an acrylic case allowing component identification and a visual demonstration of the chiller process.

Other Process Training Units

  • EPTU Ethanol Process Training Unit
  • CIT Chemical Injection Trainer
  • F&L Flow and Level Unit
  • CODTM Crude Oil Desalter Training Model
  • GLPT Gas Lift Process Trainer
  • PFDU Plate and Frame Demonstration Unit

More Information

Bayport

Bayport Training & Technical is dedicated to providing specialized services and educational or industrial tools aimed at promoting a true “hands-on” teaching concept. The variety of cutaways, demonstrators and models are conceived and orchestrated through a client driven needs analysis program.

Mission Statement: To continuously work to achieve and repeatedly prove Bayport’s focus on existing and new technologies, quality and value in our products and services, through never ending diligence and dedication in providing unique tools, experienced personnel and contribution to our field of endeavor.

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