Multi-phase reactor systems are widely used in fine chemicals, oil and gas, petrochemical refineries, pharmaceutical, pesticides and in research centres. With the evolving needs of the industry for enhanced productivity and lower cost of production; Amar offers tubular reactor systems in continuous manner for various applications with system integration and automation which maximizes the efficiency and accuracy of research and production operations
Fixed Bed Reactor volume from 5cc to 100 litres. Higher volumes optional
Designed up to 350 bar & 1200 °C. Higher ratings optional
Various MOCs such as Glass, SS 316, Inconel, Hastelloy etc.
Explosion proof plants for highly explosive reactions/hazardous area
Table-top or skid mounted plants
Either a standard or customisable unit can be offered for gas liquid feed combinations, product outlets, series or parallel reactors, multi zone heating furnaces etc. with integrated controls, high level of safety, automation and SCADA software
Trickle bed reactors are extensively used in chemical and associated industries such as petroleum, petrochemical, oil and gas, mineral and coal industries, pharmaceuticals, fine and specialty chemicals, biochemicals, and waste treatment. Applications may vary considerably from industry to industry and may include cracking of large organic molecules into useful desired products, upgrading petroleum feedstock, conversion of unsaturated organics into saturated products, conversion of coal-derived products, conversion of gaseous reactants into fuels, hydrodeoxygenation (HDO) of bio-oils (upgrading), polymerization of monomers for a variety of commodity applications, stripping of unwanted chemicals, purification of feedstocks, manufacturing pharmaceutical and their intermediates, aromatization and dearomatization of organic materials used typically in specialty chemicals, oxidation, demetallization, denitrification, dewaxing, desulfurization, removal of pollutants, and wastewater treatment. Trickle bed reactors are preferred for large volume processes. Scales and key operational characteristics of trickle bed reactors used in different applications cover a broad range.
Salient Features
Trickle Bed Reactor volume from 5cc to 100 litres. Higher volumes optional
Designed up to 350 bar & 1200 °C. Higher ratings optional
Various MOCs such as SS 316, Inconel, Hastelloy etc.
Explosion proof plants for highly explosive reactions/hazardous area
Table-top or skid mounted plants
Either a standard or customisable unit can be offered for gas liquid feed combinations, product outlets, series or parallel reactors, multi zone heating furnaces etc. with integrated controls, high level of safety, automation and SCADA software
Applications And Chemistry
Catalyst testing, oxidation, reforming, hydrogenation, dehydrogenation, liquefaction, Fischer-Tropsch process, hydro-cracking, carboxylation, catalyst screening, fluid catalytic cracking (FCC), micro reactor system, syngas reactor system, pyrolysis reactor system, packed bed reactor system, vapour rig system, biomass gasification system, hydro-processing catalyst testing system, catalyst-reduction unit, multi-purpose reactor unit, vapor phase reaction system etc.
Fluidized Bed Reactor
A fluidized bed reactor system manufactured by Amar ensure even temperature distribution throughout the burning zone, while solid catalyst particles are freely suspended using gas of high velocity.
A fluidized bed reactor suspends small particles of catalyst by the upward motion of the fluid to be reacted
The fluid is typically a gas with a flow rate high enough to mix the particles without carrying them out of the reactor
It is a technology that converts carbon containing Bio solids into syngas. A fluidizing medium, such as air is preheated and is introduced in to the gasifier. The organic solid feedstock, is then fed into the gasifier at a controlled flow rate. With enhancements in technology for green energy, fluidized bed reactors are one of those kind, which converts the solid fuel in to Syngas, which has numerous further applications.
Salient Features
Fluidized Bed Reactor volume from 5cc to 100 litres. Higher volumes optional
Designed up to 10 bar & 1200 °C. Higher ratings optional
Various MOCs such as SS 316, Inconel, Hastelloy etc.
Explosion proof plants for highly explosive reactions/hazardous area
Table top or skid mounted plants
Either a standard or customisable unit can be offered for gas liquid feed combinations, product outlets, series or parallel reactors, multi zone heating furnaces etc. with integrated controls, high level of safety, automation and SCADA software
Applications And Chemistry
Combustion of solid fuels, Pyrolysis reactions, coal gasification, biomass gasification.
Table Top Reactor System (TTRS)
The table top reactor system is very compact & complete semi or fully automated system for vapor phase catalyst evaluation and continuous flow process analysis. The reactor and feed lines are mounted within an isothermal oven.
System Specifications:
Reactor Volume: 5-50ml
System Pressure: Upto 200 Bar
Temperature Rating (Reactor): Upto 650°C
Temperature Rating (Oven): Upto 200°C
Description:
Feeding section:
Feed streams are provided for 4 reactants (2 liquids, 2 gases), the purge gas and the GC carrier gas
Feed lines includes bulk head union connectors, inline filters, metering valve, 3- way ball valve and check valve
Reactor section inside oven:
Preheater & vaporizer: This section includes 2 coils for preheating gases and 2 coils for vaporizing liquids
Reactor: volume available from 5 – 50 ml
Reactor status valve: The optional multiport reactor status valve can permit reactor bypass
Sample valve: Sampling valve can be provided for transfer of sample of product to GC unit
Back pressure regulator: Manually operated (standard) with optional automatic control
Product collection section:
Gas liquid separator: Volumes upto 250 ml will be placed after reactor and before back pressure regulator
Heated transfer line: It connects the sample valve to the gas chromatograph unit (supplied by client)
Optional Accessories
Gas Pressure Regulator (FPR)
To manually charge different gases at desired pressures upto 140 bar / 2000 psi or higherinto the reactor from gas cylinder. Nitrogen, Oxygen & Hydrogen can be charged throughsame regulator (with special adaptor). The regulator is made from SS316 & comes with inlet -outlet pressure gauges & flexible SS braided Teflon PTFE high pressure hose pipe (4m long) with non return valve.
Optional
Regulators upto 350 bar, automated regulator
Regulator for other gases like NH , CO etc. & MOC of Hastelloy C
Pressure reducing station with auto changeover
Gas Booster (GB)
Gas boosters are useful when the cylinder pressures are much lower than the autoclave ratedpressures. In such case the booster takes gas at lower pressure from cylinder & compresses thesame to deliver at higher pressures. They are generally pneumatically operated. Special gasbooster pumps are available for liquid CO used in supercritical fluid extraction system. The 2booster systems are supplied with air filter regulator, pressure relief valves, inlet-outlet pressuregauges, valves & flexible hose pipe.
Optional
Boosters upto 700 bar pressure
Thermal Gas Mass Flow Meter (MFM) / Controller (MFC)
MFM can be used to measure accurate mass flow rate of gas (in gm/hr or LPH) & totalized quantity of mass / volume (in gms/ltr) charged in the autoclave at any point. Mass flow controller (MFC) is used to charge the set flow rate of gas into the autoclave at high pressures up to 100 bar or it can be used in pressure control mode to indicate the gas flow & total gas uptake to maintain desired set pressure inside the autoclave (ideal for hydrogenation). The same MFM / MFC can be used for multiple gases by just entering the conversion factor for different gas densities provided the gases are inert to each other. The MFM/MFC comes with high pressure flexible hose, inlet filter with digital gas flow indicator cum totalizer & additional pressure PID controller with pressure sensor if the MFC is used in pressure control mode. User has to specify the maximum flow rate range, pressure, gas & mode (flow control or pressure control) for ordering MFM/MFC.
Optional
Ex-proof MFM / MFC can be offered on request
MFM/MFC upto 300 bar pressure
Coriolis Gas - Liquid Mass Flow Meter / Controller (CFM / CFC)
These are used for higher & accurate gas or liquid flow rate indication or control in cases where thermal mass flow meters are not suitable. A common meter can be used for different gases & liquids for a particular range of flow.
Optional
Ex-proof CFM/CFC can be offered on request
Digital Pressure Indicator / Controller (DPI)
It consists of SS316 pressure sensor (transmitter) & digital pressure indicator/ controller (mounted on common control panel) with pressure alarm & optionally heater cut off for safety. Digital pressure indicator has pressure reading in bar & psi, where as controller reads any one ofthe units. The controller is normally used with mass flow controllers (MFCs) or solenoid/flow control valves to maintain constant pressure inside the autoclave. With MFC, gas flow indicator & totalizer are also provided on the same panel. The pressure sensor has temperature limitation upto 100°C & hence the same is provided with water cooling jacket.
Optional
Intrinsically safe pressure sensor.
Pressure sensors with Hastelloy C / Inconel wetted parts can be offered on request.
Liquid Metering Pump System (LMP)
This system is used to charge liquid at a desired rate from as low as 1 ml/hr to 100 ltr/hr, when the autoclave is under pressurized condition. The system comes with a metering pump, flow indicator, controller, liquid sump, pressure gauge, strainer & high pressure hose.
Pressure safety valve, flow totalizer can be offered on request. Types of pumps offered are:
Diaphragm metering pumps for pressures upto 100 bar & minimum flow range of 60-600 ml/hr to maximum 10-100 lit/hr. The flow rates are varied by varying the motor speed with variable frequency drive. Materials: SS316, option: Hastelloy C, Titanium, PTFE
High pressure more accurate HPLC type low flow metering pumps for high pressures upto 350 bar & flow range from 0.01 upto 100ml/min. These pumps can be used along with precision weighing scales to measure the total liquid charged at any point of time. Materials: SS316, option: Hastelloy C, Titanium
High pressure syringe, PTFE diaphragm, gear, peristaltic pumps can be offered for pumping corrosive chemicals at low / high pressures for specific application & flow rate condition.
In line flow meters can be connected to measure & control the flow of the liquids.
Heating Cooling Circulators
Open Bath Heating Circulator
It is used to heat jacketed autoclave from ambient to 150°C by circulating thermic fluid inside thejacket. It consist of bath, pump, level switch, heater & internal cooling coil for cooling from hightemperature to ambient temperature using chilled water or brine solution.It is suitable for reactors up to 5 liter volume.
Optional
Ex-proof heating bath
Closed Loop Heating Circulator (CLH)
It is used to heat jacketed autoclave from ambient to 350°C by circulating thermic fluid. Itconsist of a closed pressure withstanding tank, magnetically coupled pump, heater, levelindicator & internal cooling coil for cooling from high temperature to ambient temperatureusing chilled water or brine solution.
Suitable for reactors up to 100 ltr volume.
Optional
Ex-proof circulator
Low temperature open bath circulator (CB)
It is used to cool or control reactor temperature to -50°C by circulating thermic fluid cooled toup to -75°C inside the jacket or internal coil. It consists of a bath, pump, compressor, condenser& level switch.
Suitable for reactors up to 100 ltr volume
Heating Cooling open bath circulator (HCB)
It is used to heat, cool & control reactor temperature by circulating thermic fluid in theautoclave jacket. It consists of a bath, pump, heater, compressor, condenser & level switch.
Temperature range: -25°C to 175°C.
Suitable for reactors up to 5 ltr volume
Closed loop heating cooling circulator (CLS)
It is used to heat, cool & control reactor temperature by circulating thermic fluid in theautoclave jacket. It consists of a bath, pump, heater, compressor, condenser & level switch.
Temperature range: -35°C to 200°C / -80°C to 180°C.
Suitable for reactors up to 1000 ltr volume.
Flow Control Valves (FOV / FCV)
These valves can be connected at jacket inlet for controlling flow of steam/ hot oil/ water fortemperature control from PID or at the inlet or outlet of the autoclaves for control of pressure.
Optional
(FOV) On/off pneumatic ball valve actuated by 230V output from panel to solenoid valveinline of air supply
(FCV) Pneumatic proportionate flow control valves with I to P convertor (for accuratetemperature / pressure control)
Condenser (CN)
It is a SS-316 shell & tube reverse flow heat exchanger for distillation/condensing vent vapours from the autoclave upto 10 bar pressure. It is offered in different surface areas such as 0.1, 0.2, 0.5, 1 & 2 m². The condensate can be collected separately in a receiver or optionally refluxed back into the reactor.
Higher area & pressures upto 350 bar
Different materials
Corrugated tubes heat exchangers for better efficiency / compact size
Receiver Pot (RP)
SS 316 receiver pot can be connected at the outlet of the shell & tube or reflux condensor to collect the condensate separately. It is also provided with a port to apply vacuum & offered in 250 ml, 500 ml, 1 ltr, 2 ltr & 5 ltr volumes. Higher volumes & other materials can be offered onspecial request. It can be optionally provided with level indication.
Back Pressure Regulator (BPR)
It is SS 316 regulator mounted on the vent line of the autoclave & is used for maintainingconstant pressure inside the autoclave upto 350 bar. The pressure is maintained by releasing theexcess pressure into the atmosphere or through a hose to safe area. The pressure can be setinitially on the gauge, by manually varying the knob until the gas comes out. Once the setpressure is exceeded the excess pressure is released until the autoclave pressure becomes equalto or below the set pressure. The pressure release is slow & gradual & the set pressure can bevaried at any point.
Optional
Electronic actuated digital pneumatic back pressure regulator, where the pressureis set digitally & can be released at preset rate of pressure release (6 bar air supplyis required)
Pneumatically actuated pilot operated back pressure regulator (air / N gas supply 2for rated pressure is required to activate the same)
Electronic control unit & forward pressure regulator with 4 mtr. hose for activating (b) above
Materials: Hastelloy C, PTFE etc.
Pressure Safety Valve (PSV)
High pressure autoclaves are provided with built in safety rupture disc, however additionalsafety can be offered by providing pressure safety valve for which release pressure can be setmanually by increasing or decreasing the spring tension or by simply changing the spring. Theset pressure should normally be around the design pressure. Safety relief valves are standardsupply for glass autoclave & shaker hydrogentor where rupture discs are not available for lowpressures. These valves come with PTFE / Kalrez O-rings.
Optional:
Materials: Hastelloy C, inconel
SCADA Software for remote operation & recording (SCD)
SCADA is a supervisory control & data acquisition software with all controllers / indicatorshaving RS 485 modbus communication port or PLC & HMI / touch panel, for online display, setpoint changes & data logging of various parameters like pressure, temperature, motor RPM,motor current / torque, liquid / gas flow rate with totaliser, heater temperature, level, pH, ORP,turbidity, IR etc. remotely from PC as well as locally from panel. It gives continuous online datalogging at predefined (variable) time interval, online graphical representation as well ashistorical data & graphs on PC for single or multiple autoclaves. RS 485-232 convertor & cableupto 50 m or higher is also supplied.
Optional:
Wireless data communication from PC to panel or mobile alerts can be supplied onrequest
Purge cabinet
Ex-proof certified gas purge panels for electrical accessories / utilities like heating cooling circulators etc.
Optional Accessories
Gas Pressure Regulator (FPR)
To manually charge different gases at desired pressures upto 140 bar / 2000 psi or higherinto the reactor from gas cylinder. Nitrogen, Oxygen & Hydrogen can be charged throughsame regulator (with special adaptor). The regulator is made from SS316 & comes with inlet -outlet pressure gauges & flexible SS braided Teflon PTFE high pressure hose pipe (4m long) with non return valve.
Optional
Regulators upto 350 bar, automated regulator
Regulator for other gases like NH , CO etc. & MOC of Hastelloy C
Pressure reducing station with auto changeover
Thermal Gas Mass Flow Meter (MFM) / Controller (MFC)
MFM can be used to measure accurate mass flow rate of gas (in gm/hr or LPH) & totalized quantity of mass / volume (in gms/ltr) charged in the autoclave at any point. Mass flow controller (MFC) is used to charge the set flow rate of gas into the autoclave at high pressures up to 100 bar or it can be used in pressure control mode to indicate the gas flow & total gas uptake to maintain desired set pressure inside the autoclave (ideal for hydrogenation). The same MFM / MFC can be used for multiple gases by just entering the conversion factor for different gas densities provided the gases are inert to each other. The MFM/MFC comes with high pressure flexible hose, inlet filter with digital gas flow indicator cum totalizer & additional pressure PID controller with pressure sensor if the MFC is used in pressure control mode. User has to specify the maximum flow rate range, pressure, gas & mode (flow control or pressure control) for ordering MFM/MFC.
Optional
Ex-proof MFM / MFC can be offered on request
MFM/MFC upto 300 bar pressure
Coriolis Gas - Liquid Mass Flow Meter / Controller (CFM / CFC)
These are used for higher & accurate gas or liquid flow rate indication or control in cases where thermal mass flow meters are not suitable. A common meter can be used for different gases & liquids for a particular range of flow.
Optional
Ex-proof CFM/CFC can be offered on request
Digital Pressure Indicator / Controller (DPI)
It consists of SS316 pressure sensor (transmitter) & digital pressure indicator/ controller (mounted on common control panel) with pressure alarm & optionally heater cut off for safety. Digital pressure indicator has pressure reading in bar & psi, where as controller reads any one ofthe units. The controller is normally used with mass flow controllers (MFCs) or solenoid/flow control valves to maintain constant pressure inside the autoclave. With MFC, gas flow indicator & totalizer are also provided on the same panel. The pressure sensor has temperature limitation upto 100°C & hence the same is provided with water cooling jacket.
Optional
Intrinsically safe pressure sensor.
Pressure sensors with Hastelloy C / Inconel wetted parts can be offered on request.
Liquid Metering Pump System (LMP)
This system is used to charge liquid at a desired rate from as low as 1 ml/hr to 100 ltr/hr, when the autoclave is under pressurized condition. The system comes with a metering pump, flow indicator, controller, liquid sump, pressure gauge, strainer & high pressure hose.
Pressure safety valve, flow totalizer can be offered on request. Types of pumps offered are:
Diaphragm metering pumps for pressures upto 100 bar & minimum flow range of 60-600 ml/hr to maximum 10-100 lit/hr. The flow rates are varied by varying the motor speed with variable frequency drive. Materials: SS316, option: Hastelloy C, Titanium, PTFE
High pressure more accurate HPLC type low flow metering pumps for high pressures upto 350 bar & flow range from 0.01 upto 100ml/min. These pumps can be used along with precision weighing scales to measure the total liquid charged at any point of time. Materials: SS316, option: Hastelloy C, Titanium
High pressure syringe, PTFE diaphragm, gear, peristaltic pumps can be offered for pumping corrosive chemicals at low / high pressures for specific application & flow rate condition.
In line flow meters can be connected to measure & control the flow of the liquids.
Heating Cooling Circulators
Open Bath Heating Circulator
It is used to heat jacketed autoclave from ambient to 150°C by circulating thermic fluid inside thejacket. It consist of bath, pump, level switch, heater & internal cooling coil for cooling from hightemperature to ambient temperature using chilled water or brine solution.It is suitable for reactors up to 5 liter volume.
Optional
Ex-proof heating bath
Closed Loop Heating Circulator (CLH)
It is used to heat jacketed autoclave from ambient to 350°C by circulating thermic fluid. Itconsist of a closed pressure withstanding tank, magnetically coupled pump, heater, levelindicator & internal cooling coil for cooling from high temperature to ambient temperatureusing chilled water or brine solution.
Suitable for reactors up to 100 ltr volume.
Optional
Ex-proof circulator
Low temperature open bath circulator (CB)
It is used to cool or control reactor temperature to -50°C by circulating thermic fluid cooled toup to -75°C inside the jacket or internal coil. It consists of a bath, pump, compressor, condenser& level switch.
Suitable for reactors up to 100 ltr volume
Heating Cooling open bath circulator (HCB)
It is used to heat, cool & control reactor temperature by circulating thermic fluid in theautoclave jacket. It consists of a bath, pump, heater, compressor, condenser & level switch.
Temperature range: -25°C to 175°C.
Suitable for reactors up to 5 ltr volume
Closed loop heating cooling circulator (CLS)
It is used to heat, cool & control reactor temperature by circulating thermic fluid in theautoclave jacket. It consists of a bath, pump, heater, compressor, condenser & level switch.
Temperature range: -35°C to 200°C / -80°C to 180°C.
Suitable for reactors up to 1000 ltr volume.
Flow Control Valves (FOV / FCV)
These valves can be connected at jacket inlet for controlling flow of steam/ hot oil/ water fortemperature control from PID or at the inlet or outlet of the autoclaves for control of pressure.
Optional
(FOV) On/off pneumatic ball valve actuated by 230V output from panel to solenoid valveinline of air supply
(FCV) Pneumatic proportionate flow control valves with I to P convertor (for accuratetemperature / pressure control)
Condenser (CN)
It is a SS-316 shell & tube reverse flow heat exchanger for distillation/condensing vent vapours from the autoclave upto 10 bar pressure. It is offered in different surface areas such as 0.1, 0.2, 0.5, 1 & 2 m². The condensate can be collected separately in a receiver or optionally refluxed back into the reactor.
Higher area & pressures upto 350 bar
Different materials
Corrugated tubes heat exchangers for better efficiency / compact size
Receiver Pot (RP)
SS 316 receiver pot can be connected at the outlet of the shell & tube or reflux condensor to collect the condensate separately. It is also provided with a port to apply vacuum & offered in 250 ml, 500 ml, 1 ltr, 2 ltr & 5 ltr volumes. Higher volumes & other materials can be offered onspecial request. It can be optionally provided with level indication.
Back Pressure Regulator (BPR)
It is SS 316 regulator mounted on the vent line of the autoclave & is used for maintainingconstant pressure inside the autoclave upto 350 bar. The pressure is maintained by releasing theexcess pressure into the atmosphere or through a hose to safe area. The pressure can be setinitially on the gauge, by manually varying the knob until the gas comes out. Once the setpressure is exceeded the excess pressure is released until the autoclave pressure becomes equalto or below the set pressure. The pressure release is slow & gradual & the set pressure can bevaried at any point.
Optional
Electronic actuated digital pneumatic back pressure regulator, where the pressureis set digitally & can be released at preset rate of pressure release (6 bar air supplyis required)
Pneumatically actuated pilot operated back pressure regulator (air / N gas supply 2for rated pressure is required to activate the same)
Electronic control unit & forward pressure regulator with 4 mtr. hose for activating (b) above
Materials: Hastelloy C, PTFE etc.
Pressure Safety Valve (PSV)
High pressure autoclaves are provided with built in safety rupture disc, however additionalsafety can be offered by providing pressure safety valve for which release pressure can be setmanually by increasing or decreasing the spring tension or by simply changing the spring. Theset pressure should normally be around the design pressure. Safety relief valves are standardsupply for glass autoclave & shaker hydrogentor where rupture discs are not available for lowpressures. These valves come with PTFE / Kalrez O-rings.
Optional:
Materials: Hastelloy C, inconel
SCADA Software for remote operation & recording (SCD)
SCADA is a supervisory control & data acquisition software with all controllers / indicatorshaving RS 485 modbus communication port or PLC & HMI / touch panel, for online display, setpoint changes & data logging of various parameters like pressure, temperature, motor RPM,motor current / torque, liquid / gas flow rate with totaliser, heater temperature, level, pH, ORP,turbidity, IR etc. remotely from PC as well as locally from panel. It gives continuous online datalogging at predefined (variable) time interval, online graphical representation as well ashistorical data & graphs on PC for single or multiple autoclaves. RS 485-232 convertor & cableupto 50 m or higher is also supplied.
Optional:
Wireless data communication from PC to panel or mobile alerts can be supplied onrequest
Purge cabinet
Ex-proof certified gas purge panels for electrical accessories / utilities like heating cooling circulators etc.