What is a Batch Reactor?

The phrase "batch reactor" refers to a type of vessel that is commonly employed in the process industry. Its name is a misnomer because these containers are utilised for a wide range of processes, including solids dissolving, product mixing, chemical reactions, batch distillation, crystallisation, liquid/liquid extraction, and polymerization. They aren't always called reactors; instead, they have a name that represents the function they play.

A batch reactor consists of a storage tank, an agitator and a heat/cool built-in system. The size of these vessels can range from less than 1 litre to over 15,000 litres. Steel, stainless steel, glass-lined steel, glass, or exotic alloys are commonly used. Connections in the reactor's top cover are typically used to charge liquids and solids. Vapours and gases can also escape through the top connections. Typically, liquids are ejected from the bottom.

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A centrally positioned driveshaft with an overhead drive unit is the most common agitator configuration. The shaft is where the impeller blades are mounted. Blades come in a range of shapes and sizes and typically cover roughly two-thirds of the reactor's diameter. Anchor-shaped paddles with a narrow clearance between the blade and the vessel walls are frequently employed while handling viscous goods.

Baffles are also used in most batch reactors. The rotating agitator causes the flow to be broken up by these stationary blades. These can be put on the inside of the side walls or attached to the vessel's cover.

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Despite substantial advancements in agitator blade and baffle design, the amount of energy available to mix in big batch reactors is ultimately limited. Mixing energies of more than 5 Watts per litre in large vessels can impose an undue strain on the cooling system. Shaft stability issues can also be caused by high agitator loads. When mixing is important, a batch reactor isn't the best option. Smaller flowing systems with high-speed agitators, ultrasonic mixing, or static mixers can reach much higher mixing rates.

Even the process of churning liquids that have been stored releases heat. Heat must be provided or removed by a cooling jacket or cooling pipe to keep the reactor contents at the proper temperature. To add or remove heat, heat transfer fluid goes through the jacket or coils.

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The heat transmission coefficient, it may be argued, is also an essential parameter. Large batch reactors with external cooling jackets, on the other hand, have substantial heat transmission constraints due to their design. Continuous reactors, on the other hand, may produce cooling capabilities of up to 10,000 W/litre.

For crystallisation procedures or activities where the product or process is temperature-sensitive, quick temperature control responsiveness and uniform jacket heating and cooling are critical.

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