Chemical Reactor

Company Profile

PIONEER GROUP was founded in 2006, covered an area of 50,000㎡and has more than 200 employees. The headquarters of PIONEER GROUP which located in Zibo city, Shandong province - a famous manufacture base of chemical equipment in RR.China, also build two new manufacturing bases in Weifang city, Shandong province and Zhangye city, Gansu province.
Glass lined and stainless steel reactor, storage tank/receiver, distillation tank , film evaporator, vacuum dryer, filter, separator, heat exchanger, condenser, column systems and various accessories. Also can specializes in GMP standard products and customized operating unit of chemical process.

Why Choose Us

Our Factory
PIONEER GROUP is a professional design & manufacture in chemical equipment especially in glass lined equipment with advanced technology, completed production equipment, perfect quality control system and intimate sale and after-sale service.

Our Certificate
Certification of ISO 9001:2015, Design & manufacture License of pressure vessel, 10 Certificate of Patent

Production Equipment
CNC plasma cutting machine, CNC rolling machine, Automatic submerged arc welding machine, Swagging machine, Grinding machine, PLC control underground electric furnace, Coating room, Painting room, Spark tester, Thickness indicator, RT/MT tester, Hydraulic test machine and etc.

Our Service
The R&D department welcome customization with many years experience,we can design and order all kinds of glass lined and stainless steel products and non-standard products according to the requirements of customers.

Glass Lined RCVD From Pioneer

The glass-lined RCVD from Pioneer is a composite product made by attaching high silica-containing glass to the inner surface of a steel container and burning it at a high temperature to firmly adhere

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Open Type Glass Lined Reactor

Capacity of open type glass lined reactor is from 50 to 12500 Liters, it is a kind of two-piece vertical type pressure vessel equipment with top insert agitator, also named Flange type or Clamped

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K Type Glass Lined Reactor

Standard capacity：50 to 5000 Liters. Customized capacity ： 6300 to 12500 Lites. Design and manufacture standard: GB/T25025-2010, GB/T25027-2018. Divided structure design can be replace the top cover

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AE Type Glass Lined Reactor

Standard capacity: 63 to 6300 Liter. Design and manufacture standard: DIN28136. Separated structure design can be change the damaged top cover or vessel body conveniently.

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Closed Type Glass Lined Reactor

Capacity: 1000 to 40000 Liters (F series, GB/T25026-2017); 3000 to 40000 Liters (Q series, GB/T25026-2017); 1600 to 40000 Liters (CE series, DIN28136). it is a kind of is a kind of closed-welded

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F Type Glass Lined Reactor

Capacity: 1000 to 40000 Liters; 40000 to 50000 Liters (Customize). Design and manufacture standard: GB/T25025-2010, GB/T25026-2017. Closed-welded structure design can be allow for higher pressure

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Q Type Glass Lined Reactor

Capacity: 1000 to 40000 Liters; 40000 to 50000 Liters (Customize). Design and manufacture standard: GB/T25025-2010, GB/T25026-2017. Full closed-welded structure with no bigger opening on the head but

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CE Type Glass Lined Reactor

Capacity of CE type glass lined/enameled reactor: 1600 to 40000 Liters. Design and manufacture standard: DIN28136. Monoblock type structure without large opening on the top head.

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Electric Heating Glass Lined Reactor

Capacity: 50 to 5000 Liters(Flange Type); 1600 to 10000 Liters (Monoblock Type). Design and manufacture standard: GB/T25025-2010, GB/T25026-2017, GB/T25027-2018.

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Half Coil Jacketed Glass Lined Reactor

Capacity:1000 to 40000 Liters; 40000 to 50000 Liters (Customize). Half pipe coiled/Limpet/Semi-coil/Spiral jacket which welded on the outer wall of the glass lined reactor vessel for zone

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GMP Compliant Glass Lined Reactor

Capacity: 1000 to 40000 Liters; 40000 to 50000 Liters (Customize). GMP compliant glass lined reactor has a stainless steel shell in order to meet the requirements of pharmaceutical factory clean

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Stainless Steel Jacketed Reactor

Capacity: 50 to 50000 Liters. Jacketed stainless steel reactor has smooth inner surface and polished outer surface special apply in clean production.

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What is Chemical Reactor？

Batch reactors are used for most of the reactions carried out in a laboratory. The reactants are placed in a test-tube, flask or beaker. They are mixed together, often heated for the reaction to take place and are then cooled. The products are poured out and, if necessary, purified.
This procedure is also carried out in industry, the key difference being one of size of reactor and the quantities of reactants.
Following reaction, the reactor is cleaned ready for another batch of reactants to be added.

Benefits of Chemical Reactor

Efficiency
Chemical reactors maximize continuous processes to convert reactants into products quickly. Their efficient operation results in higher yields and throughput compared to batch reactors. Reactors can be designed for optimal temperature profiles, mixing, and flow patterns to improve kinetics and enhance reaction rates.

Quality Control
Careful control of temperature, pressure, residence time distribution, mixing intensity, and other critical parameters within the chemical reactor improves product quality consistency. Automated process controls with feedback loops allow tight regulation of conditions for high-purity output.

Consistent Quality
The continuous operation of chemical reactors with steady-state conditions enables very consistent product quality compared to batch reactors. Maintaining stable operating parameters like temperature and flow rates leads to uniform product specifications over long production runs.

Reduced Waste
Optimized reaction conditions inside chemical reactors minimize side reactions, by-products, and impurities, resulting in less waste. Continuous processing reduces downtime and the need for reactor cleaning between batches, lowering wastewater generation.

Energy Conservation
Heat integration within the chemical reactor system helps conserve energy by recycling waste heat through heat exchangers. Optimized reaction rates enabled by reactors also lower energy usage by minimizing heating/cooling needs.

Type of Chemical Reactor

Batch Reactor

A batch reactor is a non-continuous form of reactor consisting of a closed vessel wherein reactions occur. Initially, all of the reactants are added to the reactor simultaneously. Batch reactors usually have an agitator that mixes the reactants thoroughly to execute the reaction and synthesize the product effectively.

Continuous Stirred Tank Reactor

A continuous stirred tank reactor (CSTR) is also known as a mixed flow reactor. In this reactor, the reaction takes place in a closed tank. An agitator is also included in the tank to make sure that the reactants are well mixed.
The reactants enter the reactor at a constant flow rate, react within the vessel for a time indicated by the space-time of the reactor, and then produce products. All products flow out of the reactor at the same time. The time it takes to execute one reactor volume is equivalent to one space-time.

Semi-Batch Reactor

A semi-flow reactor is a batch reactor modification. It is a closed vessel with an agitator to mix the reactants. One reactant is completely charged in the reactor initially, while the other is charged after regular time intervals. So, one chemical reactant is filled into the reactor, and the other chemical is added slowly (e.g., to prevent side reactions), or a product formed by a phase transition is continuously separated, such as gas formation during the reaction, precipitation of solids, or formation of hydrophobic product.

Catalytic reactor

Catalytic reactors are frequently deployed as plug flow reactors; however, their calculations demand a more complicated technique. The amount of catalyst that the reagents come into contact with and the concentration of the reactants determine the catalytic reaction rate. A catalytic reaction pathway frequently happens with chemically bound intermediates in numerous phases. The kinetics may be affected by the chemical bonding to the catalyst, which is itself a chemical process. Catalytic processes commonly display so-called faked kinetics, in which the perceived kinetics vary from the true chemical kinetics due to physical transport factors.

Application of Chemical Reactor

Chemical reactors exist in such a wide range of forms and types that a complete sys-tematic classification is impossible. Two main categories that can be distinguished are homogeneous and heterogeneous reactors. In homogeneous reactors,only onephase, usually a gas or a liquid, is present. If more than one reactant is involved,provision must be made for mixing them together to form a homogeneous mixture.Another kind of classification, which cuts across the homogeneous–heterogeneous division, is the mode of operation,batchwise or continuous.

Homogeneous batch re-actions are carried out in vessels, tanks or autoclaves in which the reaction mixture isagitated and mixed in a suitable manner. This operation is familiar to anybody whohas carried out small-scale preparative reactions in the laboratory. Continuous flow reactors for homogeneous reaction systems already show a much greater va-riety. Predominant forms are thetubular reactorand themixed tank reactor,which have essentially different characteristics.In heterogeneous reactors, two or more phases are present.

The classification of reactors for heterogeneous systems shows a great number of possibilities. The dominant factor is the contact between the different phases. This leads to a classification of reac-tors as a contact apparatus. Common examples are gas–liquid, gas–solid, liquid–solid,liquid–liquid and gas–liquid–solid systems. In many cases, the solid phase is present as a catalyst.Gas–solid catalytic reactors comprise an important class of heteroge-neous chemical reaction systems. Generally, heterogeneous reactors exhibit a greater variety of configurations and contacting patterns than homogeneous reactors.
Associated with every chemical change, there is a heat of reaction that is only in a few cases small enough to be neglected. The magnitude of the heat of reaction has often a major influence on the design of a reactor.

Key Components of Chemical Reactors

Vessel

The chemical reaction occurs in the vessel. Depending on reactor temperature, pressure, reactant, and product corrosiveness, reactor vessels are made of stainless steel, carbon steel, glass-lined steel, nickel alloys, or titanium. Stalwart International, a prominent chemical reactor manufacturer in India, uses skilled engineers to custom-build reactor vessels to fulfill industrial process pressure, temperature, corrosion resistance, and material compatibility requirements.

Agitators

Mechanical mixing devices called agitators are positioned within reactor vessels to provide adequate mixing and equal temperature, concentration, viscosity, and catalyst contact. Paddle, propeller, turbine, anchor, helical ribbon, and magnetic drive are different types of agitators. These may be top-mounted on the reactor head plate, side-mounted on the reactor shell, or bottom-mounted, depending on vessel design and mixing demands.

Heat Transfer System

For exothermic and endothermic processes, the reactor vessel temperature must be controlled via an efficient and responsive heat transfer mechanism. Reactor jackets, cooling coils, heating coils, reboilers, condensers, heat exchangers, and other heat transfer equipment may provide or remove heat from reactor contents. Optimal thermal control improves reaction rates, yield percentage, and product selectivity.

Sensors

Reactor and pipeline sensors detect temperature, pressure, pH, liquid level, and reactant/product composition. The valuable data from these sensors enables precise automated control of feeds, heating/cooling utility flow, agitation speed, and other parameters to maintain safe, efficient reactor operation at optimal conditions.

Chemical Reactor Mixing Speed

Higher mixing speeds can result in faster mixing times: As a general rule, increasing the mixing speed will result in a shorter mixing time, as the reactants will be brought into contact with each other more quickly. This can be beneficial if the reaction rate is limited by the mixing process, but may also result in increased energy consumption and potentially higher shear forces on the fluid.

Higher mixing speeds can result in increased energy consumption: As the mixing speed increases, the energy required to mix the reactants will also generally increase. This can be a trade-off to consider when designing a reactor, as it is important to balance the need for fast mixing times with the desire to minimize energy consumption.

Higher mixing speeds can result in higher shear forces: As the mixing speed increases, the shear forces applied to the fluid may also increase. This can be beneficial in some cases, as it can help to break up any agglomerates or lumps in the fluid. However, it is important to consider the impact of shear forces on the reactants and the overall process, as excessive shear forces can cause degradation or unwanted side reactions.

Mixing speed should be optimized for the specific process: In general, it is important to carefully consider the mixing speed when designing a reactor, as it can affect the mixing efficiency, energy consumption, and shear forces on the fluid. The optimal mixing speed will depend on the specific process and the desired outcome and may require experimentation to determine the best balance.

For fluids with low viscosity, a higher mixing speed may be necessary to achieve efficient mixing. This is because low-viscosity fluids can be more difficult to mix due to their reduced resistance to flow. In general, a mixing speed in the range of 500 to 1000 rpm may be appropriate for low-viscosity fluids.

For fluids with high viscosity, a lower mixing speed may be necessary to avoid excessive shear forces and degradation of the reactants. In general, a mixing speed in the range of 50 to 200 rpm may be appropriate for high-viscosity fluids.

For fluids with high surface tension, a higher mixing speed may be necessary to break up any surface tension-driven structures or agglomerates in the fluid. In general, a mixing speed in the range of 1000 to 2000 rpm may be appropriate for high surface tension fluids.

Chemical Reactor Flow Patterns

Laminar flow patterns can result in slower mixing times

Laminar flow patterns are characterized by a smooth, orderly flow of the fluid, with little turbulence or mixing. This can result in slower mixing times, as the reactants may not be brought into contact with each other as quickly.

Turbulent flow patterns can result in faster mixing times

Turbulent flow patterns are characterized by high levels of turbulence and mixing, with the irregular and chaotic flow of the fluid. This can result in faster mixing times, as the reactants will be brought into contact with each other more quickly.

The shape and size of the reactor can affect the flow patterns

The shape and size of the reactor can influence the flow patterns within the reactor. For example, a larger reactor may have more space for the fluid to flow, leading to more laminar flow patterns. A smaller reactor may have less space for the fluid to flow, leading to more turbulent flow patterns.

The mixing device can affect the flow patterns

The type and design of the mixing device can also influence the flow patterns within the reactor. For example, an impeller with a high power number may generate more turbulent flow patterns, while an impeller with a low power number may generate more laminar flow patterns.

Chemical Reactor Temperature Control System

The control system maintains a constant temperature by measuring the temperature of the reactor vessel, and throttling steam from a boiler to the steam jacket to add more or less heat as needed.
We begin as usual with the temperature transmitter, located near the bottom of the vessel. Note the diﬀerent line type used to connect the temperature transmitter (TT) with the temperature indicating controller (TIC): hollow diamonds with lines in between. This signiﬁes a digital electronic instrument signal – sometimes referred to as a ﬁeldbus – rather than an analog type.

The transmitter in this system is actually a digital (fieldbus), and so is the controller. The transmitter reports the process variable (reactor temperature) to the controller using digital bits of information. Here there is no analog scale of 4 to 20 milliamps, but rather electric voltage/current pulses representing the 0 and 1 states of binary data.
Digital instrument signals are capable of transferring multiple data points rather than single data points as is the case with analog instrument signals. This means digital instrument signals may convey device status information (such as self-diagnostic test results) as well as the basic measurement value.

At the temperature control valve (TV) the 3 to 15 PSI pneumatic pressure signal applies a force on a diaphragm to move the valve mechanism against the restraining force of a large spring. The construction and operation of this valve is the same as for the feedwater valve in the pneumatic boiler water control system.
An eﬀective way to identify the proper direction of action for any process controller is to perform a “thought experiment ” whereby we imagine the process variable increasing over time, and then determine which way the controller’s output needs to change in order to bring the process variable value back to setpoint based on the ﬁnal control element’s inﬂuence within the process.

In this process, let us imagine the reactor temperature increasing for some reason, perhaps an increase in the temperature of the feed entering the reactor. With an increasing temperature, the controller must reduce the amount of steam applied to the heating jacket surrounding the reactor in order to correct for this temperature change.
With an air-to-open (ATO) steam valve, this requires a decreased air pressure signal to the valve in order to close it further and reduce heat input to the reactor.
Alternatively, if the steam valve were air-to-close (ATC) rather than air-to-open (ATO), an increasing reactor temperature (requiring less steam be sent to the reactor) would necessitate the controller outputting an increased signal to the valve, so that more air signal pressure pushed the valve further closed.

Our Certificate

Certification of ISO 9001:2015, Design & manufacture License of pressure vessel, 10 Certificate of Patent

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FAQ

Q: What does a chemical reactor do?

A: A chemical reactor is a closed container where a chemical reaction is carried out. Process designers have to make sure that the reaction progresses as efficiently as possible towards the intended product, resulting in the best yield while needing the least money to buy and operate.

Q: What are the advantages of a chemical reactor?

A: Chemical reactors maximize continuous processes to convert reactants into products quickly. Their efficient operation results in higher yields and throughput compared to batch reactors. Reactors can be designed for optimal temperature profiles, mixing, and flow patterns to improve kinetics and enhance reaction rates.

Q: How are chemical reactors heated?

A: As mentioned above, thermal boilers are used in the different chemical sectors mainly for the heating of reactors, which is carried out by means of “half-round” enclosures, double heating bottoms, jackets or coils ranged inside the reactor.

Q: What is the biggest chemical reactor?

A: Designed by Sinopec Engineering, the largest single-unit hydrogenation reactor in the world weighs 3,025 tons, which is the equivalent of 17 blue whales, the biggest animal on earth, and has a height of 72 meters (236.2 feet) that corresponds to a 26-story building.

Q: What materials are used in chemical reactors?

A: There are several broad classes of materials available for use in creating a chemical reactor. Some examples include metals, glasses, ceramics, polymers, carbon, and composites.

Q: What is the purpose of a chemical reactor?

A: A chemical reactor is an enclosed volume in which a chemical reaction takes place. In chemical engineering, it is generally understood to be a process vessel used to carry out a chemical reaction, which is one of the classic unit operations in chemical process analysis.

Q: What is the highest temperature in a reactor?

A: A high temperature gas-cooled reactor (HTGR) is a nuclear reactor that can supply high temperature heat energy of 750°C–950°C by using a spherical fuel coated with ceramics such as carbon and silicon carbide, inert helium gas as a coolant, and graphite as a moderator.

Q: What is the name of a chemical reactor?

A: The document describes different types of reactors used in chemical processes. It discusses batch reactors, continuous stirred tank reactors (CSTR), plug flow reactors, fixed bed reactors, and fluidized bed reactors.

Q: What is the difference between a bioreactor and a chemical reactor?

A: Chemical reactors involve non-living materials and chemicals, while bioreactors involve living microorganisms. This difference in the nature of reactions also leads to differences in the design and operation of these reactors.

Q: What are the advantages of a chemical reactor?

Q: What happens in a chemical reactor?

Q: What materials are used in chemical reactors?

A: There are several broad classes of materials available for use in creating a chemical reactor. Some examples include metals, glasses, ceramics, polymers, carbon, and composites.

Q: How does a chemical reactor work?

A: In a tubular reactor, fluids (gases and/or liquids) flow through it at high velocities. As the reactants flow, for example along a heated pipe, they are converted to products (Figure 4). At these high velocities, the products are unable to diffuse back and there is little or no back mixing.

Q: What is the biggest chemical reactor?

Q: What is the difference between a bioreactor and a chemical reactor?

Q: Why are chemical reactors important?

A: The most important unit operation in a chemical process is generally a chemical reactor. Chemical reactions are either exothermic (release energy) or endothermic (require energy input) and therefore require that energy either be removed or added to the reactor for a constant temperature to be maintained.

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