Mansim was commissioned by Ingevity Ltd to investigate operational issues within their caprolactone monomer reactor system, where non-uniform temperatures, poor mixing and localised hot spots were affecting process stability and yield.

Using advanced CFD, Mansim developed a transient multiphase model of the reactor to analyse flow behaviour, heat transfer and mixing performance under realistic operating conditions. A series of design options was assessed, focusing on the position and configuration of the mixing tee and internal components.

The study identified an improved reactor configuration that enhanced circulation, reduced stagnant regions and delivered a more uniform temperature distribution throughout the vessel. The proposed design improved mixing efficiency, thermal consistency and overall process reliability, providing Ingevity with a robust, data-driven solution for long-term operation.