DESIGN AND FABRICATION OF AN AUTOMATED CONTINUOUS STIRRED TANK REACTOR FOR THE PRODUCTION OF ALKOXYLATED RESIN BASED DEMULSIFIERS

Crude oil emulsions pose major challenges in petroleum production, and although alkoxylated resin-based demulsifiers are effective, Nigeria still relies on imported products due to limited availability of specialized reactors for local production. This researches focuses on the design and fabrication of an automated 4 L Continuous Stirred Tank Reactor (CSTR) for the production of alkoxylated resin - a feedstock for the production of demulsifiers to reduce Nigeria’s dependence on imports. The reactor (SS316L, ID 162 mm, H/D = 1.5, wall 4 mm) was specified for 250 °C and 20 bar, fitted with dual pitched-blade impellers (8.1 cm, 45°) driven by a 0.25 hp variable-speed motor, two 8 L feed tanks, PLC automation, and safety interlocks. Design calculations and Aspen Plus simulation yielded a residence time of 2.0 h (simulation 1.78 h), material balance closure 99.98%, and conversions > 99.9% for ethylene oxide, phenol, and formaldehyde. The reaction is highly Exothermic with a net cooling requirement of 2.91 kW, and and generated heat of 335 W. Product analysis from the Aspen Plus simulation results showed Molecular weight of 175 g/mol, degree of ethoxylation of 3 – 4 EO units, HLB 15 - 20, and residual EO < 150 ppm. Mechanical checks confirmed ASME Section VIII compliance with conservative safety factors, impeller and pump sizing include safety margins. The CSTR was fabricated per ASME guidelines and demonstrated stable automated operation, accurate temperature control (±2 °C), effective mixing, and functioning safety systems. The work demonstrates feasible local manufacture of demulsifiers and broader alkoxylated products.