Personal tools
You are here: Home SIMULATIONS Simulations: Ethylene Acetylene Reactor

Acetylene Reactor

Acetylene Converter Tutorial

Acetylene Converter Simulation

Envision Systems Acetylene Converter Tutorial


Copyright © 2009 by EnVision Systems Inc. All rights reserved worldwide.

Acetylene Converter Tutorial

The Acetylene Converter Reactor tutorial provides an overview, fundamental principles, control principles and operating principles for an acetylene converter reactor in an ethylene plant, using voice, video, animation and graphics. The topics covered are:


  • Importance of Ethylene
  • Ethylene Process
  • Thermal Cracking
  • Cooling    
  • Compression
  • Chilling
  • Product Separation

Importance of Ethylene Purity   

  • Introduction
  • Acetylene Breakthrough    

Acetylene Removal Methods

  • Introduction    
  • Front-End Unit
  • Tail-End Unit
  • Front-End with Tail-End-Guard Unit
  • Number of Reactors    

Difficulties with Reactor Operations

  • Operational Objectives    
  • Operating Difficulties
  • Green-Oil Formation
  • Catalyst Aging    
  • Reactor Temperature
  • Analyzers

Carbon Monoxide Moderation

  • Effect of Activity and Selectivity   
  • Effect of Carbon Monoxide on Selectivity
  • Effect of Carbon Monoxide on Operational Band
  • Sensitivity of the Reaction to Carbon Monoxide
  • Sources of Carbon Monoxide


Potential Hazards

  • Introduction
  • Runaway Reactions
  • Presence of Oxygen

Reaction Control

  • Introduction    
  • Acetylene Analysis
  • Hydrogen Analysis
  • Carbon Monoxide Analysis
  • Ethane/Ethylene Analysis
  • Reactor Temperature

Basic Control Strategy

  • Inlet Temperature    
  • Hydrogen to Acetylene Ratio
  • Carbon Monoxide Addition

Safety Devices

  • Runaway Reactions
  • High Temperature Shutdown
  • Water Deluge

Catalyst Regeneration

  • Introduction    
  • Regeneration Procedure


  • Introduction
  • Hydrogen Supply Pressure
  • Hydrogen Purity
  • Methanation
  • PSA Unit
  • Liquid in Feed
  • Feed Gas Disturbances
  • Freezing of Steam Heater
Envision Systems Acetylene Converter Simulation
Copyright © 2009 by EnVision Systems Inc. All rights reserved worldwide.


Acetylene Converter Simulation

The Acetylene Converter Reactor simulation is a rigorous and high-fidelity mathematical process model that provides a realistic dynamic response for an acetylene convertor reactor in an ethylene plant.

Process Overview:

Acetylene is produced as an impurity in the ethylene cracking heaters. The concentration of acetylene must be reduced to a few PPM (< 1 PPM) to produce a polymer-grade ethylene product. The simulated acetylene converter unit consists of a fixed bed catalytic reactor with three beds that performs selective hydrogenation of acetylene to ethylene.

Major Operations for Trainee Practice:

  • Startup and Shutdown Operations
  • Normal Operations
  • Emergency Shutdown Operations
  • Troubleshooting Equipment, Instrument and Control Valve Malfunctions
  • Malfunction Recovery Actions


Simulation Features:

  • Detailed Reaction Kinetics
  • Effect of CO Moderation
  • Acetylene Breakthrough and Loss of Ethylene
  • Green Oil Formation
  • Catalyst SOR and EOR Conditions
  • Plant Alert with Sound
    • Acetylene Breakthrough
    • High Bed Temperature
    • Flaring Condition
    • Safety Valve
  • Interlock/Safeguard System
  • Dynamic Composition, Temperature and Pressure Profile along the Bed
  • User Changeable Feed and Rich Hydrogen Flow Composition Including CO, Acetylene, Ethylene and Ethane
  • Customizable for Your Reactor Configuration and Kinetics
Document Actions
Top of page