Stainless Steel Chemical Reactor
(1)2L/3L/5L/10L/20L/30L/50L/100L/150L/200L---Standard
(2)2L/3L/5L/10L/20L/30L/50L/100L/150L/200L---EX-proof
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2. Customization:
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Description
Technical Parameters
The design principle of Stainless Steel Chemical Reactor is based on the optimization of the heating and cooling system inside the reactor. The heating system generally uses electric heating or steam heating to allow the reactants to react within a specified temperature range. At the same time, the cooling system has been fully considered to achieve rapid cooling of the reaction process.
For some reactions that require pressure control, a pressure control system will be equipped. The application in organic synthesis also pays more attention to environmental protection and safety. It has good corrosion resistance and sealing properties, which can effectively prevent reactant leakage and environmental pollution. At the same time, it is also equipped with various safety accessories (such as pressure gauges, thermometers, rupture discs, etc.), which can automatically cut off the reaction and alarm in abnormal situations such as overpressure and overtemperature, ensuring production safety.
In addition, by optimizing reaction conditions and adopting green synthesis technologies (such as using environmentally friendly solvents, recyclable catalysts, etc.), environmental pollution and ecological risks in organic synthesis processes can be further reduced.
Product Introduction
It is an alloy steel, and elements such as chromium and nickel are added to make it have the characteristics of oxidation resistance, acid and alkali resistance and corrosion resistance. Therefore, the reaction kettle can withstand the corrosion of various chemicals and the reaction at high temperature.
Manufacturing Process
The manufacturing process of Stainless Steel Chemical Reactor is a complex and delicate process, involving multiple links from raw material selection to final product delivery. The following is a detailed introduction to the manufacturing process of stainless steel chemical reaction kettle, aiming to comprehensively and deeply explain its manufacturing process.
Raw material preparation
► Material selection
The manufacturing of stainless steel chemical reaction vessels first relies on high-quality stainless steel materials.
Commonly used stainless steel materials include 304, 316L, etc., which have good corrosion resistance and mechanical properties, and can meet the special requirements of chemical reactions on equipment materials.
When selecting materials, the manufacturer will comprehensively consider factors such as the usage environment, medium characteristics, and process conditions of the reaction vessel to ensure that the selected materials can meet the usage requirements.
► Material inspection
Before raw materials are stored, manufacturers will conduct strict inspections on them. The inspection content includes the chemical composition, mechanical properties, surface quality, and other aspects of the material.
Through inspection, it can be ensured that the raw materials used comply with relevant standards and specifications, providing a reliable foundation for subsequent processing and manufacturing.
Processing and Forming
► Cutting and pre-processing
In the processing and forming stage, the stainless steel plate needs to be cut first to obtain the required size and shape.
Cutting can be done through various methods such as mechanical cutting and laser cutting.
After cutting, it is necessary to polish and deburr the cutting edges to improve the quality of subsequent welding.
► Rolling and Forming
Next, it is fed into a plate rolling machine for rolling, forming the cylinder and head of the reaction vessel and other components.
During the rolling process, it is necessary to strictly control parameters such as temperature, speed, and pressure to ensure accurate dimensions and regular shapes of the rolled components.
For components such as heads, stamping or pressing forming processes are also required.
► Accessory production
In addition to the cylinder and head, stainless steel chemical reaction vessels also require the production of various accessories, such as agitators, transmission devices, shaft sealing devices, etc.
The production of these accessories also requires high-precision processing equipment and techniques to ensure that their quality and performance meet the design requirements.
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Welding and assembly
► Welding process
Welding is a crucial step in the manufacturing process of stainless steel chemical reaction vessels.
Common welding methods include TIG (tungsten inert gas welding), MIG/MAG (melting inert gas/active gas welding), etc.
Strict control of welding parameters, such as welding current, voltage, welding speed, etc., is required during the welding process to ensure the quality of the weld seam.
At the same time, it is necessary to use an appropriate protective atmosphere (such as argon) to prevent oxidation and contamination of the welding area.
► Weld seam inspection
After welding is completed, strict inspection of the weld seam is required. The testing content includes the appearance quality, internal quality, and mechanical properties of the weld seam.
Common testing methods include X-ray inspection, ultrasonic inspection, etc. Through inspection, defects in the weld seam can be detected and repaired in a timely manner, ensuring the quality and reliability of the weld seam.
► Assembly and debugging
After welding and testing are completed, assemble each component according to the design requirements.
During the assembly process, attention should be paid to whether the connections between each component are firm and whether the sealing is good.
After assembly, it is necessary to debug the reaction vessel, including airtightness testing, pressure testing, etc., to ensure that its performance meets the design requirements.
Surface treatment
► Polishing treatment
In order to improve the aesthetics and corrosion resistance of stainless steel chemical reaction vessels, it is necessary to polish the inner and outer surfaces.
Polishing can be done through various methods such as mechanical polishing and chemical polishing. By polishing, the surface of the reaction vessel can be made smoother and smoother, improving its corrosion resistance and service life in chemical reactions.
► Sandblasting treatment
For some reaction vessels that require higher surface quality, sandblasting treatment can also be used.
Sandblasting can remove surface oxide and impurities, and improve the adhesion of coatings.
At the same time, sandblasting can also increase the surface roughness, improve the wear resistance and corrosion resistance of the coating.
► Coating treatment
In order to further improve the corrosion resistance and aesthetics of stainless steel chemical reaction vessels, coating treatment can also be applied to their surfaces. Coatings that are resistant to acid, alkali, and high temperatures can be chosen for coating to increase the service life and stability of the reaction vessel.
During the painting process, attention should be paid to factors such as the type of coating, coating thickness, and painting process to ensure that the painting effect meets the requirements.
Innovations and Future Trends
Advancements in materials science and manufacturing technology continue to drive innovations in stainless steel chemical reactors. New alloys with enhanced corrosion resistance and mechanical properties are being developed to meet the demands of increasingly complex and demanding chemical processes.
Moreover, the integration of automation and digitization in reactor design and operation is transforming the industry. Real-time monitoring, predictive maintenance, and advanced process control systems are improving safety, efficiency, and productivity.
Mixing form
The stirring form of the reactor is one of its core components, which has an important influence on the mixing effect of the reactants, the reaction rate and the quality of the final product.
Overview of mixing forms
Stainless steel chemical reactors have a variety of stirring forms designed to meet different reaction needs and reactant properties. Common mixing forms include anchor type, paddle type, turbine type, push type, frame type, screw type, scraper type and combined type. Each stirring form has its unique characteristics and scope of application, and the selection needs to be comprehensively considered according to the viscosity, reaction characteristics and process requirements of the material.
Common mixing forms and characteristics
Features: The outer edge of the blade is closely fitted with the inner wall of the mixing tank, and the gap is very small, which can effectively remove the viscous reaction products attached to the wall of the tank and the solid matter at the bottom of the tank, and ensure excellent heat transfer effect.
Application scenario: Especially suitable for high viscosity liquid or clay mixture, can effectively push the material.
Classification: Divided into flat paddle type and oblique paddle type two. The flat paddle type consists of two straight blades, and the two blades of the oblique paddle type are reversed by 45° or 60°.
Features: Simple structure, often used for the mixing of low viscosity liquids and the dissolution and suspension of solid particles.
Application scenario: The flat paddle type is suitable for the mixing of low viscosity liquids, and the oblique paddle type improves the mixing efficiency by producing an axial flow.
Features: It is composed of 2~4 flat or curved blades installed on the horizontal disc, which is suitable for the dispersion and liquid-liquid reaction process of gases and immiscible liquids.
Application scenario: It is especially suitable for reaction systems requiring high turbulence and radial flow.
Features: The blade of the agitator is helical, which can produce strong axial flow, and is suitable for reaction systems requiring large flow cycles.
Application scenario: Commonly used in liquid-liquid mixing, solid suspension and gas-liquid dispersion processes.
Features: The blade of the agitator is shaped like a frame, which can ensure that the material is evenly blended in a short time.
Application scenario: It is often used in material systems with high viscosity or requiring uniform mixing.
Features: The blade of the screw type agitator is spiral, which can scratch the inner wall of the container to prevent the material from sticking to the wall; The scraper mixer uses a specially designed scraper to remove the material from the inside of the container.
Application scenario: It is especially suitable for reaction systems requiring high mixing efficiency and preventing the material from sticking to the wall.
Features: Two or more mixing forms are combined to improve mixing efficiency and adaptability.
Application scenario: It is often used in complex reaction systems or reaction processes requiring a variety of stirring effects.
The principle of mixing form selection
When choosing the stirring form of the reactor, the following principles need to be followed:
Selection according to the properties of the material
The viscosity, density, particle size and other properties of the material have an important impact on the selection of mixing forms. For example, high viscosity materials are suitable for anchor or frame agitators; Low viscosity materials are suitable for paddle or turbine agitators.
Select according to reaction characteristics
Factors such as reaction type (such as homogeneous reaction, heterogeneous reaction), reaction rate, and whether heating or cooling is required also affect the choice of stirring form. For example, a reaction system that requires strong mixing and heat transfer is suitable for choosing a turbine or propulsion agitator.
Selection according to process requirements
Process requirements include reaction time, yield, product quality and so on. When choosing the mixing form, these factors need to be considered comprehensively to ensure the efficiency and stability of the reaction process.
Conclusion
Stainless steel chemical reactors play a vital role in many industries, facilitating a wide range of chemical reactions and processes. Their construction makes corrosion resistance of stainless steel possible, ensuring their durability, safety and versatility. While there are challenges such as cost and manufacturing complexity, the benefits of using it far outweigh these considerations.
As the industry continues to evolve and new chemical processes become available, the importance of this reactor will only increase. With their ability to withstand extreme conditions and meet specific process requirements, these reactors will continue to be cornerstones of the chemical, pharmaceutical, food processing and coatings industries for years to come.
In summary, the reactor is an indispensable equipment for achieving efficient and safe chemical reactions in all walks of life. Their structure, material selection and advantages make them the first choice for many industrial applications. As technology advances, the design and functionality of these reactors will continue to evolve, further enhancing their role in the global industrial landscape.
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