Batch Reactors

Roben Mfg, Inc. specializes in batch reactors.

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Batch reactors are vessels used for carrying out chemical reactions, where the reactants are charged into the reactor, mixed, and allowed to react for a specific period of time under controlled conditions. Once the desired product is formed, the reaction mixture is discharged from the reactor for further processing or purification.

How Batch Reactors Work:

1. Charging: The reactants, along with any necessary catalysts or additives, are charged into the batch reactor. The charging process can be done manually or through automated systems, depending on the scale and complexity of the operation.
2. Mixing: Once the reactants are charged, they are mixed thoroughly to ensure uniform composition and temperature throughout the reactor. Mixing can be achieved through various methods, such as mechanical agitation using impellers or stirrers, recirculation of the reaction mixture using pumps, or sparging with inert gases.
3. Heating or Cooling: Depending on the specific reaction requirements, the batch reactor may need to be heated or cooled to maintain the desired temperature range. Heating can be achieved through the use of external jackets, internal coils, or electric heating elements. Cooling can be done using cooling jackets, internal coils, or by circulating cooling fluids.
4. Reaction: With the reactants mixed and the temperature controlled, the chemical reaction takes place inside the batch reactor. The reaction time can vary from a few minutes to several hours or even days, depending on the kinetics and nature of the reaction.
5. Monitoring and Control: Throughout the reaction, various parameters such as temperature, pressure, pH, and reagent concentrations are monitored and controlled to ensure optimal reaction conditions. This is typically done using sensors, instrumentation, and control systems that allow for real-time monitoring and adjustment of process variables.
6. Sampling and Analysis: During the reaction, samples may be taken from the batch reactor for analysis to monitor the progress of the reaction and to ensure that the desired product quality is being achieved. This information can be used to make necessary adjustments to the process conditions.
7. Discharging: Once the reaction is complete and the desired product has been formed, the reaction mixture is discharged from the batch reactor. This can be done through bottom outlets, drain valves, or by pumping the mixture out of the reactor.
8. Cleaning and Preparation for the Next Batch: After discharging the product, the batch reactor is cleaned thoroughly to remove any residual materials and to prepare it for the next batch. Cleaning can be done using various methods, such as solvent washing, steam cleaning, or chemical cleaning agents, depending on the nature of the residues and the reactor material.

Advantages of Batch Reactors:

1. Flexibility: Batch reactors offer high flexibility in terms of the types of reactions that can be carried out and the products that can be produced. The same reactor can be used for different reactions by simply changing the reactants and process conditions.
2. Quality Control: Batch reactors allow for better quality control, as each batch can be monitored closely and adjustments can be made as needed to ensure consistent product quality.
3. Small-Scale Production: Batch reactors are well-suited for small-scale production runs, as they do not require continuous operation and can be easily adapted to changing production needs.
4. Handling of Hazardous Materials: Batch reactors are often used for reactions involving hazardous materials, as they can be designed with special safety features and containment systems to minimize the risk of accidents and environmental releases.
5. Customization: Batch reactors can be customized to meet specific process requirements, such as high pressure, high temperature, or corrosive environments, by selecting appropriate materials of construction and incorporating necessary design features.

Batch reactors play a crucial role in various industrial processes, offering flexibility, quality control, and the ability to handle a wide range of reactions and products. Their versatility and adaptability make them essential tools for the production of high-value chemicals, pharmaceuticals, and specialty materials.

Roben, Mfg, Inc. is a leading state-of-the-art manufacturer of premium batch reactors designed to meet the demanding requirements of various industries. Our experienced team of engineers deliver reliable and efficient solutions for your critical processesto handle a wide range of applications, from hazardous environments to corrosive materials, ensuring optimal performance and safety.

Batch Reactors Industries Served:

1. Chemical and Petrochemical:
   • Batch reactors for chemical synthesis, polymerization, and catalytic reactions
   • Reactors for the production of specialty chemicals, fine chemicals, and intermediates
   • Vessels for petrochemical processing, including cracking, reforming, and alkylation
2. Pharmaceutical and Biotech:
   • Reactors for the production of active pharmaceutical ingredients (APIs) and intermediates
   • Bioreactors for cell culture, fermentation, and enzyme reactions
   • Vessels for vaccine production and sterile processing
3. Food and Beverage:
   • Reactors for the production of food additives, flavors, and fragrances
   • Vessels for brewing, fermentation, and pasteurization processes
   • Reactors for the production of edible oils and fats
4. Specialty Materials and Polymers:
   • Reactors for the production of adhesives, coatings, and sealants
   • Vessels for the synthesis of advanced materials, such as ceramics and composites
   • Reactors for the production of resins, elastomers, and thermoplastics
5. Environmental and Water Treatment:
   • Reactors for wastewater treatment processes, including chemical oxidation and reduction
   • Vessels for the production of water treatment chemicals and coagulants
   • Reactors for air pollution control and gas scrubbing applications
6. Agricultural and Agrochemical:
   • Reactors for the production of fertilizers, pesticides, and herbicides
   • Vessels for the synthesis of crop protection chemicals and growth regulators
   • Reactors for the production of animal feed additives and supplements
7. Energy and Power Generation:
   • Reactors for the production of alternative fuels, such as biodiesel and ethanol
   • Vessels for the processing of crude oil and natural gas
   • Reactors for the production of catalysts used in energy applications
8. Mining and Mineral Processing:
   • Reactors for the extraction and purification of metals and minerals
   • Vessels for the production of mining chemicals and reagents
   • Reactors for the processing of rare earth elements and precious metals
9. Pulp and Paper:
   • Reactors for the production of pulping chemicals and bleaching agents
   • Vessels for the processing of wood chips and cellulosic materials
   • Reactors for the production of specialty paper coatings and additives
10. Cosmetics and Personal Care:
    • Reactors for the production of cosmetic ingredients and active compounds
    • Vessels for the formulation of personal care products, such as lotions and creams
    • Reactors for the production of fragrances and essential oils

Additional Batch Reactors End Applications:

1. Chemical Synthesis:
   • Batch reactors for the production of organic and inorganic compounds
   • Vessels for the synthesis of intermediates and building blocks
   • Reactors for the production of specialty chemicals and fine chemicals
2. Polymerization:
   • Reactors for the production of polymers, such as polyethylene, polypropylene, and polyvinyl chloride (PVC)
   • Vessels for the synthesis of copolymers and terpolymers
   • Reactors for the production of engineered plastics and high-performance polymers
3. Catalytic Reactions:
   • Reactors for heterogeneous and homogeneous catalytic processes
   • Vessels for the production of catalysts and support materials
   • Reactors for the regeneration and reactivation of spent catalysts
4. Crystallization and Precipitation:
   • Reactors for the crystallization of organic and inorganic compounds
   • Vessels for the precipitation of fine particles and powders
   • Reactors for the production of nanoparticles and nanostructured materials
5. Fermentation and Biotechnology:
   • Bioreactors for the cultivation of microorganisms, such as bacteria, yeast, and fungi
   • Vessels for the production of enzymes, proteins, and antibodies
   • Reactors for the fermentation of sugars and starches into alcohols and acids
6. Hydrogenation and Hydrocracking:
   • Reactors for the hydrogenation of unsaturated compounds and aromatics
   • Vessels for the hydrocracking of heavy hydrocarbons into lighter fractions
   • Reactors for the production of specialty chemicals through hydrogenation reactions
7. Oxidation and Chlorination:
   • Reactors for the oxidation of organic compounds using oxygen or air
   • Vessels for the chlorination of hydrocarbons and the production of chlorinated derivatives
   • Reactors for the production of epoxides and peroxides through oxidation reactions
8. Esterification and Transesterification:
   • Reactors for the production of esters through the reaction of alcohols and acids
   • Vessels for the transesterification of oils and fats into biodiesel
   • Reactors for the production of plasticizers and lubricants through esterification reactions
9. Alkylation and Acylation:
   • Reactors for the alkylation of aromatic compounds and the production of alkylbenzenes
   • Vessels for the acylation of alcohols and amines to produce esters and amides
   • Reactors for the production of surfactants and detergents through alkylation reactions
10. Hydrolysis and Condensation:
    • Reactors for the hydrolysis of esters, amides, and nitriles
    • Vessels for the condensation of alcohols and acids to produce polymers and resins
    • Reactors for the production of specialty chemicals through hydrolysis and condensation reactions

Specifications and Characteristics: Our batch reactors are engineered to excel in the most challenging conditions. We offer a comprehensive range of specifications and characteristics to cater to your specific needs:

1. Atmospheric, Azeotropic, and Vacuum: Our reactors are designed to operate under atmospheric, azeotropic, and vacuum conditions, providing versatility for your processes.
2. Bead Blasted and Polished: We offer both bead-blasted and polished finishes to ensure a smooth and clean surface, minimizing the risk of contamination.
3. Corrosion Resistant: Our reactors are constructed using high-quality, corrosion-resistant materials to withstand harsh environments and extend equipment lifespan.
4. Critical Process and Hazardous Environment: We specialize in designing reactors for critical processes and hazardous environments, ensuring safe and reliable operation.
5. Heat Treated and Heavy Duty: Our reactors undergo rigorous heat treatment processes to enhance their durability and performance in heavy-duty applications.
6. High and Low Pressure: We offer both high-pressure and low-pressure reactor options to accommodate your process requirements.
7. Insulated and Packed: Our reactors can be insulated and packed to optimize heat transfer and improve efficiency.
8. Lethal Service and Toxic Substance: We have expertise in designing reactors for lethal service and handling toxic substances, prioritizing safety and containment.
9. Painted and Tray: We provide painted and tray reactor options to suit your specific application needs.
10. Seismic and Vibration Resistant: Our reactors are engineered to withstand seismic events and vibrations, ensuring stable operation in challenging environments.

Batch Reactors Accessory Options: We offer a wide range of accessory options to enhance the functionality and safety of your batch reactors:

• Ladders, Platforms, Handrails, Stairways, and Railings for safe access and maintenance
• Man-ways (Manways) for easy inspection and cleaning
• Legs and Lugs for stable support and mounting
• Sight-glasses (Sightglasses) for process monitoring
• Flanges for easy connection to other equipment
• Mixers and Agitators for efficient mixing and homogenization
• Trays and Baffles for improved mass transfer and separation
• Distribution Pipes for even distribution of fluids
• Skirt Brackets and Ring Supports for secure installation
• Internal Coils and External Coils for precise temperature control
• Spools and Tube-sheets (Tubesheets) for heat exchange
• Fixed Tubesheet and Expansion Joints for thermal expansion management
• Jackets (Dimple Jackets, Conventional Jackets, Half Pipe Jackets, 3″ Half Pipe Jackets, 4″ Half Pipe Jackets, 5″ Half Pipe Jackets, 6″ Half Pipe Jackets) for efficient heating or cooling

Certifications and Standards: At Roben, Mfg, Inc., we adhere to the highest industry standards and certifications to guarantee the quality and reliability of our batch reactors. Our reactors are compliant with:

• ASME Boiler and Pressure Vessel Code (BPVC)
• ASME Code Section VIII Div 1 and Div 2
• ASME Code Section IX
• National Board Inspection Code (NBIC)
• ISO 16528
• API 510, API 620, and API 650
• PED Compliant
• JIS B 8241
• Canadian Registration Number (CRN)
• TEMA Standards for Shell-and-Tube Heat Exchangers
• Heat Exchange Institute (HEI)
• Heat Transfer Research, Inc (HTRI)
• R Stamp and U Stamp

Design Software: We utilize industry-leading design software to ensure the optimal performance and safety of our batch reactors. Our design process incorporates the following software:

• Pressure Vessel Design Software: PV Elite, Compress, ASME CodeCalc, AVEVA Mechanical Equipment Interface (MEI), DB-JAC, Codeware COMPRESS, NozzlePRO, and Bentley AutoPIPE Vessel.
• Reactor Design Software: Aspen HYSYS, CHEMCAD, COMSOL Multiphysics, ANSYS Fluent, ProSimPlus, and AFT Fathom.
• Column Design Software: Aspen Plus, PRO/II, HTRI Xchanger Suite, CHEMCAD, Aspen HYSYS, ColumnBase, and ColumnGenius.
• General Analysis and Simulation Software: Ansys Mechanical and STAAD.Pro.
• Heat Exchanger Design Software: HTRI Xchanger Suite, PV Elite, Compress, and AVEVA Mechanical Equipment Interface (MEI).
• Finite Element Analysis (FEA) Software

Materials: We offer a wide selection of high-quality materials for our batch reactors to ensure optimal performance and durability. Our material options include:

• Stainless Steel: 188, 230, 303, 304/304H, 304/304L, 309, 310/310H/310S, 316/316L, 317L, 321/321H, 330, 347/347H, 405, 410, 410S, 416, 416R, 420, 430, 440C, 15-5, 15-5 PH, 17-4, 17-4 PH, PH Annealed
• Alloys: 6AI-4V, 718 (AMS 5663), 800H/AT, A-286, AL-6XN, AL6XN, Alloy 20, Alloy 625, Alloy 825, Alloy 904L, Alloy X, C-2000, C-22, C-276, C2000, C22, C276, D-979, Duplex 2205, Duplex 2507, Duplex Stainless Steel, Ferralium alloy 255, FM62, FM69, FM92, Hastelloy (C, C-2000, C-22, C-276, C2000, C22, C276, S, W, X), Haynes 230, Haynes 230W, Haynes alloy 25 (L605), HPA cobalt alloy 6B, Incoloy (020, 330, 800, 800H, 800HT, 801, 825, 901, 909, 925, 945, A-286, DS), Inconel (600, 601, 617, 625, 702, 718, 718SPF, 722, X, X750), Invar 36, L605, LDX 2101, Monel (400, K-500, K500, R-405, R405), N-50, N-60, N50, N60, Nichrome V, Nickel (200, 201, 205), Nimonic 263, Nimonic 90, Nitronic 30, Nitronic 50, Nitronic 60, Prodec (17-4, 303, 304/304L, 316/316L), RA 253 MA, RA 602 CA, RA333, Rene 41, Super Duplex 2507, Waspaloy, X750, ZERON 100
• Titanium: Grade 2, Grade 5 (Ti-6Al-4V)
• Aluminum: 5154, 5454
• Others: Carbon steel, Cladded steel, Cobalt, Low alloy steel, Nickel-chromium alloy, Austenitic Stainless Steels (300 Series), Ferritic Stainless Steels (400 Series), High-Nickel Austenitic Stainless Steel

Roben Mfg, Inc.’s Batch Reactors Frequently Asked Questions (FAQs)

Contact our knowledgeable batch reactors sales team to provide you with the best solutions, and best quote, for your process needs.