| Parameter | Typical Range |
|---|---|
| Pressure | 1–350 barg |
| Temperature | Ambient to 950°C |
| Hydrogen Flow | 1 mL/min to several thousand Nm³/h |
| Reactor Volume | mL scale to commercial plants |
| Residence Time | Seconds to several hours |
| Catalyst | Pd, Pt, Ru, Rh, Ni, Cu, Co, Raney Ni, Raney Co, Noble Metals, Custom Catalysts |
| PARAMETER | BATCH HYDROGENATION | CONTINUOUS HYDROGENATION |
|---|---|---|
| Operation | One batch at a time | Continuous feed and product withdrawal |
| Impurities | Higher | Lower |
| Production | Intermittent | Steady, uninterrupted |
| Product Quality | Can vary batch to batch | Highly consistent |
| Hydrogen Utilization | Lower efficiency | Higher efficiency, better contact |
| Heat Transfer | Difficult, highly exothermic | Excellent removal & control |
| Safety | Larger reactant inventory | Smaller volume, reduced risk |
| Pressure & Temp Control | Can fluctuate | Maintained at setpoints |
| Catalyst Use | Slurry, needs separation | Fixed-bed / continuous system |
| Scale-up | Increase reactor size | Number-up or run longer |
| Automation | Limited | High level of automation |
| Downtime | Charge / Heat / Cool / Clean Cycle | Minimal downtime |
| Operating Cost | Higher labor & utility cost | Lower cost over time |
| Capital Cost | Lower initial investment | Higher initial investment |
| Best For | Small volumes, R&D | Large-volume, consistent production |
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