Continuous Stirred Tank Reactors

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Amar has been a pioneer, largest manufacturer and exporter of continuous flow reactors in India since many years. Amar Flow Reactors are used by various industries like fine & speciality chemicals, bulk drug (API) pharmaceuticals, dyes, intermediates, paints, agrochemicals, etc. to convert their batch chemistries to continuous flow.

  • Volume : 500 ml to 1000 ltr
  • Pressure Range : up to 100 bar
  • Temperature Range : -30°C to 300°C
  • Flow Rate : Upto 10,000 lph
  • Material : SS316, Hastelloy C276
  • Multiple CSTRs connected in series (cascaded setup) for faster reactions.
  • Sampling valves in each cell to monitor reaction progress.
  • Can handle slurries in high concentration.
  • Residence times could range from a few seconds to as high as few hours.

Working

Stirred tanks commonly used in the industry are completely back-mixed reactors meaning the concentration in the reactor is same as the outlet of the reactor – this greatly reduces the reaction rates. Plug flow reactors are an alternative to stirred tanks where the concentration varies in the axial direction of the reactor. Tubular reactors showcase a plug-flow behaviour but tubular reactors have couple of challenges

  • When it comes to handling concentrated slurries, tubular reactors can clog
  • Performing slow reactions: as mixing is compromised due to low velocities in the tubular reactors

In such cases, conventional CSTRs are chosen, however multiple CSTRs in series provide a plug-flow like behaviour and also help in increasing the reaction rates by limiting the back-mixing. At Amar, we design CSTRs or cascaded CSTRs from lab to commercial scale.

Accessories

Apart from our standard specifications we also provide additional value-added optional accessories to enhance the versatility and functionality of the equipment for various applications. Some of the components that we provide as a part of our flow reactor systems :

This system is used to charge liquid at a desired rate from as low as 1ml/hr, is under pressurized condition.

  • a) Diaphragm metering pumps for pressures up to 100bar & minimum flow range of 60-600ml/hr to maximum 10-100 lit/hr. The flow rates are varied by varying the motor speed with variable frequency drive. Materials: SS316, options: Hastelloy C, Titanium, PTFE.
  • b) High pressure more accurate HPLC type low flow metering pumps for high pressures up to 350 bar & flow range from 0.01 up to 100ml/min. Materials: SS316, option: Hastelloy C, Titanium.
  • c) Low/High pressure syringe, pumps can be offered for pumping corrosive chemicals.
  • Single Fluid closed loop system from -90°C to 250°C.
  • Heating Cooling bath circulators from 70°C to 175°C.
  • High temperature circulators from ambient to 350°C.
  • Chillers up to -15°C.
  • Suitable for reactor volume from 10 ml to 3000 ltr.

It is SS316 regulator mounted on the vent line of the reactor &is used for maintaining constant pressure inside the reactor up to 350bar. The pressure is maintained by releasing the excess pressure into the atmosphere.
Optional

  • a) Electronically actuated digital pneumatic back pressure regulator, where the pressure is set digitally & can be released at preset rate of pressure release (6bar air supply is required).
  • b) Pneumatically actuated pilot operated back pressure regulator (air/N2 gas supply for rated pressure is required to activate the same).
  • c) Electronic control unit & forward pressure regulator with 4mtr.
  • Materials: Hastelloy C, PTFE etc.

MFM can be used to measure accurate mass flow rate of gas (in gm/hr or LPH) & totalized quantity of mass/volume (in gm/ltr) charged in the reactor at any point. Mass flow controller (MFC) is used to charge the set flow rate of gas into the reactor at high pressures up to 100bar. The same MFM/MFC comes with high pressure flexible hose, inlet filter with digital gas flow indicator.

It consists of SS316 pressure sensor (transmitter) & digital pressure indicator/ controller (mounted on common control panel) with pressure alarm.

This unit is used to separate plug flow of two immiscible liquids used in biphasic reaction or two phases of an extraction flow.
MOC: ETFE, PFA & PTFE, pressure @ 300 psi.

Control Panel consists of programmable PID temperature controller cum indicator with temperature alarm system (settable), safety alarm & heater trip system for malfunctioning of controller/sensor/ temperature rise beyond set limit. Digital pressure indicator/ controller, gas/liquid flow indicator, totalizer, heater, level, pH etc. Indicators are provided additionally on same common control panel depending on the optional accessories are selected.
Optional :

  • a) Touch screen panel with SCADA software.
  • b) PLC based control panel with touch panel HMI or remote SCADA software & PC Control.
  • c) Complete Ex-proof-flame proof (FLP) group IIA/IIB or IIC, ATEX zone 1, class 1 div. 2 certified.

Note : All accessories may not be applicable for the selected model. For more details Contact US.

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