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Home » Industry & Applications » Chemicals & Speciality Chemicals Manufacturing

Chemicals & Speciality Chemicals Manufacturing

CD Automation supplies SCR/thyristor power control for chemical and polymer processes including jacketed reactors, distillation reboilers, dryers, tray ovens and tank farms. Our REVO controllers help improve temperature stability, support batch repeatability and provide useful diagnostic and energy data to automation systems.

With REVO C for single zones, REVO-PN for compact multi-zone systems, and REVO-PC, or REVO-DPU zone control for larger units and multi-reactor systems, we integrate with PLC, DCS and SCADA platforms using common fieldbuses.

Industry Overview - Electric Heating in Chemicals & Polymers

Chemical and polymer plants use electric heating on reactors, distillation systems, dryers and utilities where accurate temperature control, fast response and integration with automation systems are important.
Electric heaters can offer precise power delivery and flexible control compared with simple on/off systems.
Intelligent SCR power control from CD Automation supports temperature stability, batch repeatability and energy monitoring as sites modernise and optimise their processes.

  • Jacketed reactors and vessels
  • Extruder barrel and die heaters
  • Distillation and evaporation systems
  • Dryers, tray ovens and small kilns
  • Tank farms, manifolds and heat trace
  • Autoclaves and curing presses

Process Machinery & Applications

Electrically heated systems in chemical and polymer plants commonly controlled with REVO SCR power controllers.
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Reactors & Jacketed Vessels

Electric heating for batch and semi-batch reactors used in synthesis, crystallisation or neutralisation.
Common pain points:
  • tight temperature bands
  • ramp/soak profiles
  • traceability
Recommended controllers:
REVO DPU
REVO C
Reactor and jacketed vessel

Extruder Barrel & Die Heaters

Multi-zone barrel and die heating on compounding and devolatilisation extruders.
Common pain points:
  • profile stability
  • vent zone control
  • energy usage
Recommended controllers:
REVO PC
REVO PN
REVO C
Extruder Barrel & Die Heaters

Compounding & Pelletising

Electrically heated compounders, side feeders and strand pelletising lines.
Common pain points:
  • throughput consistency
  • material changes
  • downtime
Recommended controllers:
REVO PC
REVO PN
Compounding & Pelletising

Polymerisation & Curing

Electric heating for polymerisation reactors, curing vessels and post-curing ovens.
Common pain points:
  • controlled ramps
  • exotherm management
  • product consistency
Recommended controllers:
REVO DPU
REVO PC
REVO C
Polymerisation & Curing

Distillation & Evaporation

Electric heating of reboilers and evaporators for solvent recovery and purification.
Common pain points:
  • boil-up control
  • solvent handling
  • energy demand
Recommended controllers:
REVO DPU
REVO C
Distillation and Evaporation system

Dryers & Tray Ovens

Electrically heated tray, cabinet and small continuous ovens for powders and intermediates.
Common pain points:
  • drying uniformity
  • overheat prevention
  • energy efficiency
Recommended controllers:
REVO PC
REVO PN
REVO C
Dryers & Tray Ovens

Tank Farms & Heat Trace

Tank heaters and heat tracing for storage tanks, lines and manifolds handling chemicals or polymers.
Common pain points:
  • freeze protection
  • temperature stratification
  • load diversity
Recommended controllers:
REVO PN
REVO C
REVO PC
REVO DPU
Tank Farms & Heat Trace

Autoclaves & Curing Presses

Electric heating for autoclaves, curing presses and vessels used for composites, rubbers and advanced materials.
Common pain points:
  • cycle repeatability
  • pressure/temperature interplay
  • safety interlocks
Recommended controllers:
REVO DPU
REVO C
Autoclaves & Curing Presses

Typical Pain Points & How We Solve Them

  • Temperature Accuracy & Product Quality
Many chemical and polymer processes rely on tight temperature control to achieve the desired conversion, molecular weight and product properties.
Solution: REVO C and REVO-PC-based architectures provide smooth power control to reactors, reboilers and ovens, helping to maintain narrow operating windows.
  • Energy Use in Heat-Intensive Operations
Reactors, distillation columns, dryers and heat-traced systems can account for a large portion of site energy use.
Solution: Demand limiting, appropriate firing modes and staggered starts with REVO-PN and REVO-PC help manage peaks and support energy-efficiency initiatives.
  • Maintenance, Fouling & Heater Failures
Heaters can experience fouling or degradation over time, leading to uneven performance and outages.
Solution: Current monitoring and open/partial-load alarms from REVO C and REVO-PC can help maintenance teams identify developing issues earlier.
  • Solvent Handling & Safety
Processes involving flammable solvents or volatile components require careful temperature control and integration with safety systems.
Solution: REVO controllers can be integrated into panels and systems that include appropriate safety instrumentation, providing alarms and status signals to DCS or SIS.
  • Batch Consistency & Repeatability
Batch and semi-batch processes need repeatable temperature profiles and reliable ramp/soak behaviour.
Solution: Using REVO C or REVO-PC with PLC or DCS recipe control supports consistent heating performance across multiple batches.
  • Modernisation & Sustainability
Sites are looking to modernise electric heating control while improving efficiency and supporting wider sustainability goals.
Solution: Replacing older contactor-based systems with REVO controllers improves controllability and provides data that can be used in energy and performance monitoring.

Snapshot: Reactor & Distillation Electric Heating Control Upgrade

Problem: a multi-product plant used contactor-based control on jacketed reactors and reboilers, leading to temperature overshoot, limited data for troubleshooting and little coordination between units.
Solution: jacket heaters on key reactors were migrated to REVO C, while reboilers and selected utilities were grouped under a REVO-PC master with REVO-C zone control. The site PLC/DCS now coordinates ramp/soak profiles and receives power, current and alarm data from the REVO architecture over a fieldbus connection.
Result: improved temperature stability, clearer visibility of heater performance, more consistent batch profiles and better support for energy and performance monitoring (typical benefits achievable on similar upgrade projects).
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Why CD Automation?

  • REVO solutions for reactors, reboilers, dryers and utilities
  • REVO-PC with Modbus, Profinet, EtherCAT into PLC/DCS/SCADA
  • Firing modes suited to resistive and transformer-fed loads
  • Support for OEMs, system integrators and site engineers
  • Suitable for brownfield upgrades and new-build projects

👉 Explore technical articles on electric heating control in our knowledge centre hub→

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One of our team will look at the information you've provided and review the application from an engineering point of view.

We may come back with a few questions, but we'll normally be looking at things such as:

  • The type of electrical load
  • Supply and current requirements
  • The most appropriate firing method
  • REVO-S, REVO-C or multi-loop architecture
  • Diagnostics and monitoring requirements
  • PLC and communications
  • Opportunities to simplify the design
  • Future machine standardisation

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Inside, you’ll discover the 5 common mistakes that can affect machine performance and how to avoid them to save time, reduce downtime, and improve product quality.

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This paper explores how integrated thyristor power and temperature
control improves heating consistency, energy efficiency, and reliability,
helping UK manufacturers reduce downtime, extend equipment lifespan,
and shift from reactive to predictive maintenance.