SlurryFLO™ Reactor

SlurryFLO™ Reactor
SlurryFLO™ Reactor
Cross-section view
Cross-section view
SlurryFLO™ Reactor
SlurryFLO™ Reactor
SlurryFLO™ Reactor
SlurryFLO™ Reactor
Cross-section view
SlurryFLO™ Reactor
SlurryFLO™ Reactor
  • The SlurryFLO™ reactor is a versatile continuous reactor designed for performing reactions involving slurries.
     
  • Each cell is equipped with impellers which help to disperse reaction media uniformly. Efficient slurry mixing helps distributing the heat generated during the reaction, prevents localized heating, and provides uniform temperature throughout the reactor.
     
  • Volume: 250 mL to 100 L
    Customized reactors are available from 100 L to 1,000 L
     
  • Flow Rates: Up to 300 LPH
     
  • Pressure: Up to 100 bar
     
  • Temperature: -30 °C to 250 °C
     
  • Material: SS316, Hastelloy C, & Glass with Metal. Read more
     
  • Applications: Excellent for heterogeneously catalyzed reactions with finely dispersed catalysts. Reactions such as Hydrogenations, Nucleophilic substitutions, Aldol condensations, and Esterifications. Continuous crystallization (evaporative / antisolvent / cooling) with uniform crystal-size distribution.
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The SlurryFLO™ Reactor is a versatile continuous flow reactor designed for challenging slurry reactions and ideal for process intensification. Its partitioned cell design features impellers installed on a single shaft, enabling active agitation that ensures thorough dispersion of the reaction media. This configuration maximizes heat transfer to the jacketed reactor walls, maintaining precise isothermal conditions essential for multi-phase flow processes.


 


Technical Specifications
 
  • Reactor Volume: 250 mL (Net-filling volume: 175 mL)
  • No. of Cells: 5
  • Utility Holdup : 4 L
  • Pressure Range: Vacuum to 100 bar
  • Wetted Material: SS316/HC276/Glass
  • Temperature Range: -30°C to 250°C
  • Volume Range: 100 mL, 250 mL, 500 mL
    (Customizable volume up to 1,000 L)
  • Flow Rates: 5 mL/min up to 300 LPH
  • Mixing Type: Active mixing
  • Sampling Ports: 1 per cell (1/4’’ OD)
  • Temperature Sensing Ports: 1 per cell (1/8’’ OD)
  • Residence Time Distribution: No. of CSTRs = 10
  • Motor RPM: 150 to 1450
  • Power Supply for Motor: 0.25HP, 0.57 A, 1450 RPM, PF 0.73, 415 V, 50 Hz
  • Bottom-drain: 1/4” BSP
  • Accessories:
     
    • Pressure relieve valve: 4 – 20 bar (settable), FFKM O-ring
       
    • Pressure gauge: 0 – 20 bar (PTFE Coated SS316 Diaphragm)
  • Jacket In & Out: M24
  • Process Inlet Connection: 3/8” OD (2 inlets)
  • Process Outlet Connection: 1/2” OD

 

The SlurryFLO™ reactor is a highly versatile flow reactor designed to handle up to 20% slurry content depending on the slurry type. With five cells, each equipped with two impellers, ports for RTD sensor insertion, sampling/vent valves, and bottom drains, the reactor offers precise control over critical reaction parameters. The reactor's single shaft is connected through a magnetic drive, ensuring the system remains completely leak-proof, even under demanding conditions.

Residence Time Distribution (RTD) Study
 

The SlurryFLO™ reactor demonstrated a near plug-flow behavior when a residence time distribution (RTD) study was conducted to evaluate the flow characteristics. This confirms that the reactor provides consistent and predictable residence times, which are essential for optimizing reaction selectivity and minimizing by-product formation. The RTD results indicate that the SlurryFLO™ reactor is well-suited for processes requiring tight control over reaction time, ensuring reliability and repeatability in continuous operations.

Heat Transfer Study
 

The SlurryFLO™ reactor offers excellent heat transfer capabilities, achieving coefficients as high as 3500 W/m²K (with water as the process fluid). Its design, featuring a high surface area to volume ratio (~ 90 m²/m³) and continuous mixing via dual impellers, ensures efficient thermal regulation.

A temperature profile was developed to further illustrate the reactor’s thermal performance, mapping the temperature gradient along the reactor length. The profile shows a consistent and controlled dissipation of heat, ensuring even thermal distribution throughout the reaction pathway. This is crucial for maintaining optimal reaction conditions and preventing localized hotspots. Additionally, integrated RTD sensors provide real-time temperature monitoring across the reactor, enhancing process stability and control.

Mass Transfer Study
 

The mass transfer coefficient in the SlurryFLO™ reactor was evaluated for a gas-liquid system by studying the pressure drop of CO₂ as it dissolved in water at different motor RPMs. The dual impeller configuration ensures efficient mixing, enhancing gas-liquid contact and improving mass transfer rates. As RPM increases, the dissolution of CO₂ in water becomes more efficient, indicating higher mass transfer coefficients. This capability makes the reactor suitable for gas-liquid-solid reactions, such as hydrogenations, where effective gas dispersion is critical for optimal performance.
With these characteristics, the SlurryFLO™ reactor is particularly suited for reactions such as nitrations, oxidations, and other heat-sensitive chemistries where precise thermal management is key to achieving consistent and high-yield results. The SlurryFLO™ reactor offers significant advantages for continuous flow reactions involving slurries and complex chemistries. Its ability to deliver near plug-flow behaviour, coupled with excellent heat and mass transfer properties, makes it a versatile solution for laboratory-scale proof-of-concept studies as well as industrial-scale applications. The detailed engineering data presented in this technical note—covering pressure drop, residence time distribution, heat transfer, and mass transfer coefficients-illustrates the reactor’s robust performance across a range of process conditions.