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A stirred tank reactor comes in various designs.
Conical stirred reactor
The outcome of a conical stirred reactor has a conical bottom form. Conical bottom stirred reactors are popular in solid-liquid separation. The cone shape helps gather suspended solids within the liquid at the cone's bottom point. Additionally, the exit bottom facilitates the removal of sediments or deposits. The geometry of conical stirred reactors Enable effective mixing and boosting the solid-liquid contact area. This speed up reaction or separation.
Cylindrical stirred reactor
A typical form for stirred reactors is a cylinder. In the chemical sector, cylindrical stirred reactors are frequently utilized. Based on the requirements of the reactions, different features can be equipped. For instance, the in-cylinder heating/cooling jacket can be used to realize endothermic/exothermic reactions. Moreover, cylindrical stirred reactors are appropriate for a variety of chemical processes, including synthesis, fermentation, and polymerization.
Horizontal stirred tank reactor
The outcome of a horizontal stirred tank reactor has a horizontal cylindrical shape. Horizontal stirred tank reactors are adequate for volume reactors. They are often located sideways to the ground in chemical production and processing. Horizontal stirred tank reactors have simple structures and capacities. They can deal with big quantities of materials at once. Moreover, horizontal stirred tank reactors are appropriate for batch production and continuous production.
Special stirred reactors
Furthermore, some reactors with specific purposes and characteristics can be referred to as special stirred reactors. For instance, vacuum stirred tank reactors include vacuum systems that can conduct reactions under vacuum conditions. The benefit is that the reactor can lower the boiling point of the solution, increase reaction rates, and reduce the danger of explosion. Additionally, pressure stirred tank reactors can generate reactions under pressurized conditions, which enhances the reaction's yield and density.
The specifications of an industrial stirred reactor tank vary based on the application requirements. Some specifications are as follows:
Size and Volume
The size and volume of the stirred tank reactor affect the mixing capacity of the reactor. Volume capacity ranges from 5L to 50 million liters. The small-scale stirred tank volume, like 500L, to 5 million liters, is ideal for the food, beverage, and biopharmaceutical industries. A large-scale capacity of more than 10 million liters suits chemical production.
Material of Construction
The material used to make the stirring tank affects the quality, durability, and resistance to chemicals. Materials like stainless steel 316 allow unhindered mixing of corrosive chemicals and high-temperature liquids in the industrial stirred tank. Sometimes polypropylene is good enough to make reactors that carry out non-hazardous and non-volatile chemical reactions.
Mixing System
The type of mixing system determines the effectiveness of the stirred tank reactor. Some stirred tanks have propeller stirrers, paddle stirrers, or disc stirrers. The choice of the stirring method depends on the viscosity level of the material. For example, stirs like propeller stirrers are ideal for materials with low to medium viscosity.
Temperature and Pressure Control
The stirred tank reactors can control temperature and pressure. Hence, the reactor can maintain chemical stability and promote reaction. Some reactors will have pressure valves and temperature gauges that allow manufacturers to regulate the tank's atmosphere and temperature.
Functional Features
Many stirred tank reactors have additional features. Some stirred tanks have baffles that reduce the turbulence of the liquid and increase mixing efficiency. Other stirred tanks have insulation to keep the temperature constant. Valves, pipes, and drainage ports allow for easy exit and entry of liquids and gasses in the stirred tank.
The performance of the stirred tank relies heavily on routine maintenance. Regular cleaning stops the build-up of residues and prevents cross-contamination of products. Clients may choose to automate the cleaning process through Clean-In-Place systems.
Start by draining the tank. Dispose of the residuals in line with standard regulation practices. Next, rinse the tank with water followed by a cleaning solution. Use the appropriate cleaning products for the kind of residue in the stirred tank. For hard-to-reach areas, use a pressure washer to apply the cleaning solution. Rinse with water until the pH level is neutral.
Always perform a thorough inspection of the tank before and after use. Look for leaks, cracks, or any mixing obstructions in the stirred reactor tank. Check the integrity of the lining and coatings. If baffles are present, make sure they are not loose.
Inspect the stirrer components to see if there are any signs of damage. If any, repair or replace the affected part promptly. Lubricate the moving parts of the stirrer as required to reduce wear and tear. Calibrate the pressure and temperature control devices regularly. The more the stirred reactor tank is used the more frequent required routines are.
Food and beverage industry: fermentation vessels of stirred reactor tanks
In the food and beverage industry, stirred tank reactors serve numerous purposes. The reactors make yogurt by stirring and mixing yogurts in a specific temperature range. Stirred tank reactors also ferment alcoholic beverages. The stirring tank constantly mixes alcohol to ensure equal distribution. It also allows the development of distinct flavors. Additionally, stirred tank reactors extract essential oils from plant materials through diffusion extraction methods.
Stirred tank reactors in chemical industry
Stirred tank reactors are commonly used in the chemical industry. The reactors synthesize different kinds of chemicals and utilize stirred tank reactors with appropriate stirring speeds and frequencies. The stirred tank reactors also facilitate chemical reactions through stirring and mixing different reactants.
Stirred tank reactors in pharmaceutical industries
In the pharmaceutical industry, stirred tank reactors play a crucial role in drug synthesis and production. The reactors ensure uniform mixing and interaction of raw materials during chemical reactions, resulting in the formation of active pharmaceutical ingredients. The preservatives and probiotics in pharmaceuticals make use of stirred tank reactors fermentation. The stirred tank reactor allows microorganisms to grow and produce probiotic products. Moreover, stirred tank reactors perform extraction and separation processes in pharmaceutical companies. Without destroying the active components of the extracts, the reactors work by mixer and diffusing the raw materials.
Petrochemical industry stirred tank reactors applications
Petrochemical stirred tank reactors apply the polymerization approach. Small monomers combine through chemical reactions and chain growth with the help of heat and pressure to form large polymer molecules. The petroleum refining processes in the petrochemical industry adopt chemical reaction processes like catalytic cracking and hydrocracking. Catalysts in these processes increase the speed of chemical reactions by stirring the mixtures.
Power industry stirred tank reactor applications
Power industries use stirred tank reactors for desulfurization. Stirred tank reactors present a variety of methods for handling flue gas. Sulfur dioxide is reacted with lime milk inside the stirred tank to produce calcium sulfate. Calcium sulfate is calcium's salt compound. Products of desulfurization can be recycled and used for construction material like gypsum.
Business buyers need to consider various factors when choosing stirred tank reactors for their specific needs. This is because their performance, efficiency, and suitability for different applications depend on these factors.
Process Requirements
Business buyers should first consider the process requirements. These include the nature of the reaction, volume, working temperature, pressure, and desired residence time. They should go for stirred tank reactors that can meet their processes' specific volume and temperature needs.
Mixing Requirements
Go for a reactor that has an appropriate impeller design. The choice of impeller will depend on the intended purpose. For instance, a reaction that needs to be heated or cooled can use a cylindrical stirred tank reactor with a bottom heating-cooling jacket. Also, the impeller will have a high-speed one for highly viscous materials and a low-speed one for low-viscosity ones.
Materials of Construction
Choose a stirred tank reactor whose material of construction will offer compatibility with corrosive or toxic substances. This also includes selecting the proper coating, linings, or flocking.
Agitation System
Buyers should choose agitation systems that will ensure uniform mixing and heat transfer throughout the reactor.
Sealing System
Select an appropriate sealing system, such as mechanical seals or packing glands, that will prevent leakage and maintain reactor integrity. In this case, mechanical seals can be better because they minimize wear and reduce maintenance requirements.
Safety Features
Safety features such as pressure relief valves, rupture discs, and safety interlocks should be prioritized. These can assist in preventing overpressure or overheating.
Instrumentation and Control
Choose reactors that have advanced control and monitoring systems. These include automated control loops, data acquisition capabilities, and built-in safety interlocks.
Energy Efficiency
If the process requires it, consider the energy efficiency of the reactor. Go for models that have features like optimized impeller designs and double jacketed walls that minimize energy consumption.
Q1 What is the difference between a CSTR and a mixed flow reactor?
A CSTR is a specific type of reactor based on continuous stirring and blending of contents while a mixed flow could be based on other forms of mixture. The mixed flow reactor also has a feed that flows continuously in and out of the reactor.
Q2 What is the difference between a stirred tank reactor and batch reactor?
Contrary to a batch process where materials are fed and processed in segregated quantities throughout the entire duration of the reaction, in continuous stirred tank reactors, materials are fed in and out of the reactor on a continuous basis. There is usually constant monitoring and regulation of temperature, pressure, and other properties within CSTRs to ensure optimal chemical reaction and set outcomes.
Q3 What are the trends affecting the stirred reactor market?
In the pharmaceutical industry, stirred tank reactors are being utilized for numerous complex syntheses in the food and beverage industry. The demand for food preservatives, nutrients, flavor compounds, and chemical processing are on the rise, resulting in the constant need for efficient stirred tank reactors. The need for clean energy is also giving rise to the trend of large-scale production of biofuels across the globe, thus making stirred tank reactors specific to biofuel production essential.
Q4 How do CSTR efficiencies compare with those of batch reactors?
For some reactions, CSTRs can be more efficient than batch reactors. The continuous input and output of material in CSTRs can lead to higher production rates compared to the segregated process in batch reactors. However, the efficiency of CSTRs relative to batch reactors can depend on the type of chemical reaction and nature of chemicals being processed.
