Senior Reactor Design Engineer (SolidWorks + CFD/SYSFLUENT) for Chemical Reactor Revamp Project

Project Overview We are undertaking a detailed engineering revamp of an industrial polymerization reactor used for HPEG, TPEG, IPEG, and EPEG production. The project requires both mechanical design completion and CFD/thermal validation to finalize fabrication, procurement, and installation packages. We are looking for an experienced engineer or engineering team with expertise in: * SolidWorks mechanical design of process equipment * ANSYS Fluent / CFD simulation * Agitated vessel design * Heat transfer and cooling system analysis * Chemical reactor engineering * Fabrication drawing development The work may be awarded to one multidisciplinary consultant or split between two specialists. --- ## Scope 1: SolidWorks Mechanical Design Package ### Existing Design Data Available The reactor design basis is already established, including: * Reactor shell dimensions * ID = 2000 mm * T/T = 2952 mm * Dished heads * 10 mm shell thickness * Complete nozzle schedule (N1–N22) * Agitator shaft concept * 110 mm diameter * 3900 mm length * Impeller arrangement: * Bottom PBT impeller (700 mm) * Three hydrofoils (950 mm diameter) * Internal cooling coil * External limpet coil * Dip tubes (DT-201, DT-202, DT-203) * Mechanical seal specification (API Plan 53B) * Gearbox and motor selection (30 kW) * Existing support arrangement ### Required Deliverables The selected freelancer will develop: * Complete 3D SolidWorks reactor assembly * General Arrangement (GA) drawings * Nozzle orientation drawings * Agitator assembly drawings * Shaft manufacturing drawings * Impeller fabrication drawings * Internal coil fabrication drawings * Limpet coil fabrication drawings * Dip tube fabrication drawings * Mechanical seal assembly details * Structural support drawings * Complete Bill of Materials (BOM) * Weight report * Interference/clash detection report * Procurement-ready fabrication package ### Desired Experience * Pressure vessels * Mixing equipment * Agitated reactors * Chemical process equipment * ASME vessel design * Fabrication detailing --- ## Scope 2: ANSYS Fluent / CFD Thermal Validation Package ### Objective Validate reactor performance before fabrication through CFD and thermal analysis. ### Studies Required #### Mixing Performance * Mixing time prediction * 95% homogenization assessment * Velocity field analysis * Dead-zone identification * Turbulence intensity mapping * Vortex analysis #### Feed Dispersion Analysis Evaluate feed injection systems: * DT-201 * DT-202 * DT-203 Outputs required: * Feed plume trajectories * Dispersion quality * Concentration distribution * Feed interaction assessment #### Heat Transfer Validation Evaluate: * Internal cooling coil * Limpet cooling coil * Steam heating system Required outputs: * Heat-transfer coefficient prediction * Overall U-value validation * Temperature distribution * Hot-spot identification * Cooling capacity verification * Heating profile verification #### Process Safety Assessment Analyze: * Hydrogen peroxide concentration distribution * Acrylic acid concentration distribution * Exothermic reaction behavior * Thermal runaway risks * Gas entrainment potential * Foam generation potential #### Mechanical Verification Support Provide: * Impeller power draw prediction * Torque profile * Hydraulic shaft loading * Dynamic load assessment ### Expected Deliverables * CFD model setup documentation * Mesh report * Mixing study report * Species transport report * Heat transfer report * Cooling validation report * Mechanical load report * Executive summary with engineering recommendations --- ## Software Requirements ### Mechanical Design * SolidWorks (preferred) * AutoCAD (supporting documentation) ### Simulation * ANSYS Fluent * ANSYS Meshing * CFD Post Equivalent professional CFD software may be considered if justified. --- ## Proposal Requirements Please include: 1. Relevant reactor, mixing vessel, or chemical equipment projects. 2. Examples of fabrication drawings completed. 3. Examples of CFD studies involving: * Mixing * Heat transfer * Agitated vessels * Chemical reactors 4. Proposed timeline. 5. Estimated hours and rate. 6. Whether you can perform: * Mechanical design only * CFD only * Both disciplines --- ## Preferred Background We are particularly interested in engineers with experience in: * Polymer reactors * EO/PO derivative plants * PEG production systems * Specialty chemicals * Process scale-up * Industrial mixing systems * Heat transfer equipment The goal is to produce a complete fabrication-ready reactor package validated through CFD and thermal analysis before procurement and construction.