Stainless Steel Reactor Design and Manufacturing

Chemical reactors are the main reaction equipment of plants designed and built to provide the reaction conditions required for the chemicals to be produced. Once a suitable and correct stainless steel reactor design and manufacturing process has been completed, the other production equipment and systems required for the plant are connected around the reactor.

Components of a Reactor Unit

In the chemical industry, reactors used particularly for alkyd, polyester and esterification reactions are often equipped with a distillation/reflux system so that the water or solvent released during the reaction can be removed. Such a reactor unit typically consists of the following equipment:

• Main reactor: the reaction vessel with agitator and heating/cooling jacket or coil
• Packed column: separates the components in the vapour phase
• Vertical and horizontal condensers: condense the vapours
• Decanter: separates the water and solvent phases of the condensate by gravity and returns the solvent to the reactor

General Operating Requirements of Reactors

Depending on the process, reactors are expected to operate under pressure or vacuum, to mix with an agitator type and speed suited to the product, and to heat and cool the product to the required temperature. While many reactors run at atmospheric or moderate pressure, some processes require high pressure or high vacuum, and the design is made accordingly.

Information Required for Chemical Reactor Design

For a correct reactor design, the following data are gathered from the customer and the process:

• Operating and design pressure, operating vacuum
• Operating and design temperature
• Heating and cooling media (steam, thermal oil, cooling water, etc.) and their temperatures
• Heating and cooling times
• Working volume and filling ratio
• Product viscosity, density and mixing requirements
• Corrosion resistance and material selection for product-contact surfaces (AISI 304/316L, duplex stainless steel or nickel alloys such as Hastelloy)
• Condenser duty and quantity of distillate to be removed
• Hazardous area classification and cleaning requirements

Design Codes and Manufacturing

Reactors operating under pressure are designed under the Pressure Equipment Directive PED 2014/68/EU in accordance with EN 13445 or AD 2000-Merkblatt rules, or to ASME BPVC Section VIII. Makfen manufactures stainless steel reactors at its Dilovası facility under an EN ISO 3834-2 welding quality system and delivers them with a hydrostatic test, material certificates and technical documentation.