Double Layer Glass Reactor
(1)1L/2L/3L/5L---Standard
(2)10L/20L/30L/50L/100L---Standard/EX-proof/Lifting Kettle
(3)150L/200L---Standard/EX-proof
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Description
Technical Parameters
Double Layer Glass Reactor is an advanced experimental equipment with a double-layer glass design. Used for experiments and production in fields such as chemistry, biology, pharmaceuticals, and materials under high temperature and pressure conditions. The inner layer is filled with a reaction solvent, which can be used for stirring reactions. The interlayer can be connected to different cold and heat sources for cyclic heating or cooling reactions. The double-layer glass reactor, under constant temperature conditions and in a closed glass reactor, can be stirred and reacted under normal or negative pressure conditions according to usage requirements, and can perform reflux and distillation of reaction solutions. It is a conceptual pilot and production equipment for modern fine chemical plants, biopharmaceuticals, and new material synthesis. It has good thermal isolation performance, chemical stability, and reaction control ability, which not only protects experimental materials but also improves the safety of operators.
Production Process
The manufacturing process of a double layer glass reactor is a delicate and multi-step process, mainly involving material selection, structural design, welding assembly, annealing treatment, and final assembly and testing. The following is a detailed breakdown of this manufacturing process:
Material selection and preparation
Material selection
The core components of a product are the inner and outer tubes, which are usually made of high borosilicate glass material. High borosilicate glass is an ideal choice for manufacturing double-layer glass reactors due to its excellent corrosion resistance, high temperature resistance, and low thermal expansion coefficient. This glass material ensures that the reaction vessel remains stable in various chemical environments and can withstand working conditions of high temperature and high pressure.
Material preparation
According to the required volume of the product to be manufactured, two 3.3 borosilicate glass cylinders with appropriate volume and different diameters are selected as the inner and outer cylinders. The shape of these glass tubes is usually a round bottom at one end and a flat cut at the other end, with an average thickness between 5-8mm. In addition, other auxiliary materials need to be prepared, such as asbestos tape, glass transfer film scale lines, discharge tubes, thermal conductive medium inlet and outlet, etc.
Structural Design
Inner and outer cylinder design
The design of the inner and outer cylinders needs to be accurately calculated based on parameters such as the volume, working pressure, and working temperature of the reaction vessel. The inner cylinder is used to load reaction materials, while the outer cylinder is used to load coolant or heating medium, and precise temperature control is achieved through insulation materials in the interlayer. A certain gap needs to be maintained between the inner and outer cylinders to facilitate the filling of insulation materials and prevent rapid heat conduction.
Auxiliary component design
In addition to the inner and outer cylinders, auxiliary components such as discharge pipes and inlet and outlet of thermal conductive media also need to be designed. The discharge pipe is usually welded to the bottom of the inner cylinder to discharge the reacted material. The inlet and outlet of the thermal conductive medium are respectively set at the bottom and top of the outer cylinder to facilitate the introduction and discharge of coolant or heating medium.
Welding assembly
Welding is one of the key steps in the manufacturing process of double-layer glass reaction vessels. Firstly, weld a discharge pipe with a sealed step at the bottom of the inner cylinder. Then, fit the inner and outer cylinders together and fix them at multiple points in the gap between the inner and outer cylinders using asbestos tape. Next, start the glass welding lathe and rotate the chuck structure between the inner and outer jacket glass cylinders. Preheat the bottom of the inner and outer jacket glass tubes using a single headed porous gas welding gun to raise the temperature of the inner and outer jacket glass tubes to 500-600 ℃. Subsequently, using steel cylinder oxygen or pipeline oxygen as a single head porous gas welding gun to assist combustion, the flame temperature is rapidly raised to above 1000 ℃ to melt the bottom of the inner and outer jacket glass tubes. The discharge tube at the bottom of the inner tube is welded to the bottom of the outer tube. At the same time, a hole is opened in the middle of the bottom of the outer cylinder to connect with the discharge pipe at the bottom of the inner cylinder, and the pipe mouth of the bottom discharge pipe is welded to the through hole of the outer cylinder. In addition, it is necessary to weld the inlet of the thermal conductive medium at the bottom of the outer cylinder near the discharge port.
After welding is completed, the welding area needs to be annealed to eliminate internal stress. Adjust the flame to increase the gas flow rate and reduce the oxygen flow rate. Use a flame at 600-700 ℃ to anneal around the welded surface at the bottom of the outer cylinder for 5-6 minutes. After the bottom glass surface of the inner and outer jacket glass tubes turns dark red or black smoke fades away, stop the machine and release the chuck structure to remove the semi-finished product of the double-layer glass reaction kettle. At this point, the bottom welding is completed. Then, while it was hot, the bottom and mouth of the semi-finished double-layer glass reaction vessel were swapped and re clamped onto the chuck structure of the glass welding machine to remove the asbestos tape. Start the glass welding lathe and open the single headed porous gas welding gun to preheat the mouth of the inner and outer jacket glass tubes, raising the temperature of the inner and outer jacket glass tubes to 500-600 ℃. Then use a multi headed large flame welding gun with oxygen to assist combustion, rapidly raising the flame temperature to above 1000 ℃ and melting the mouth. Use graphite plates to flip the inside and outside of the mouth to melt and weld the two layers of glass at the mouth of the inner and outer jacket glass cylinder together. Then, a formed large-diameter glass flange is clamped onto the movable chuck on the right side and welded to the mouth of the inner and outer jacket glass cylinder, which is the top position of the jacket. Finally, adjust the flame to increase the gas flow and adjust the oxygen flow. Anneal the welded surface at the mouth of the outer cylinder with a flame of 600-700 ℃. After annealing for 5-8 minutes, when the glass surface at the mouth of the inner and outer jacket glass tubes turns dark red or black smoke fades away, the welding of the kettle mouth is completed.
After annealing treatment, quickly place the welded double layer glass reactor reaction kettle finished product into a preheated high-temperature oven and heat it up to 550-560 ℃ for overall annealing treatment and insulation for more than 8 hours. After the temperature of the oven drops below 180 ℃, open the box and take it out. Cool it to room temperature before taking it out. Next, polish the flange end face of the double-layer glass reaction kettle with a grinding wheel, and clean the glass residue in the flange end face and threaded hole. Then, attach a PTFE gasket to the flange end face and prepare for subsequent assembly.
- During the assembly process, the stirring device needs to be installed in the inner cylinder of the product first. This includes assembling the mixing blades, mixing shafts, and other components according to design requirements, and ensuring that they can rotate freely in the inner cylinder. Next, place the assembled mixing device into the inner cylinder and secure it through the flange opening.
- Subsequently, install the cooling coil. The cooling coil is an important component in a product, used to cool or heat the reactants. Bend the cooling coil into a suitable shape according to the design requirements and insert it into the inner cylinder through the through-hole of the outer cylinder. Then, use fixtures to fix the two ends of the cooling coil on the outer cylinder and ensure that it maintains a certain gap with the bottom and side walls of the inner cylinder.
- Next, install the inlet and outlet pipelines for the thermal conductive medium. Weld the inlet pipe of the thermal conductive medium onto the through-hole at the bottom of the outer cylinder, and weld the outlet pipe of the thermal conductive medium onto the through-hole at the top of the outer cylinder. In this way, coolant or heating medium can be introduced or discharged into the interlayer of the product through the inlet and outlet pipelines of the thermal conductive medium, achieving temperature control of the reactants.
- Finally, conduct an overall inspection and testing of the product. Check whether each component is securely installed, whether the sealing is good, and whether the mixing device can rotate normally. At the same time, it is necessary to conduct pressure and temperature tests on the reaction vessel to ensure that it can withstand the requirements of working pressure and working temperature.
Annealing treatment and final inspection
After completing all assembly work, it still needs to undergo annealing treatment. The purpose of annealing treatment is to eliminate internal stresses generated during welding and assembly processes, and improve the stability and service life of the reaction vessel. Place the reaction kettle in a high-temperature oven for annealing treatment, hold for a certain period of time, and then remove and cool to room temperature.
After annealing treatment, conduct final inspection and testing on the double-layer glass reaction kettle. Check if its appearance is intact, if all components are installed correctly, and if the sealing performance is good. At the same time, it is necessary to conduct actual reaction tests on the reaction kettle to verify its performance and stability under actual working conditions.
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