used reactors

Types of used reactors

A reactor vessel serves as a chemical plant built to facilitate chemical reactions such as the coupling of feeds and catalysts and heating, among others. The used reactors are second-hand reactors but can still serve a purpose in chemical processes.

• CSTRs

  A continuous stirred-tank reactor is an example of a used chemical reactor that carries out chemical reactions in a mixed flow. The flow can either be open or closed. When the CSTR is in an open situation, the reactants flow in with the products flowing out. In batch processing, the flow is closed. The CSTR can handle various fluids, including gases, solids, and liquids, and it is an excellent choice for chemical processes that require heat transfer. When the CSTR doesn't have any heat exchange capabilities, it is defined as an adiabatic CSTR.

• Semibatch Reactors

  A semibatch reactor is a chemical reactor where some reactants are continuously fed into the vessel during the reaction, while others are not. These types of used reactors can be either stirred or flow reactors. They are typically used in processes where the reaction conditions need to be precisely controlled.

• Plug Flow Reactors

  A plug flow reactor is a chemical reactor where fluids move in a cylindrical tube. The process that takes place in a PFR is unidirectional, and there is no back-mixing of the fluids. Since the used plug flow reactors are not stirred, they are easy to scale up, and designers typically have an easy time using them in chemical processes. Plug flow reactors are suitable choices for food processing, wastewater treatment, and petrochemical applications.

• Batch Reactors

  In a batch reactor, all the ingredients are added simultaneously, and the reaction takes place in a closed vessel. Used batch reactors are highly versatile and are used in a wide variety of chemical processes.

• Photochemical Reactors

  A photochemical reactor vessel is used to execute photochemical reactions in organic compounds. These types of reactions can either take prolonged or brief periods, and the reactor can also be distinctively designed based on the process being carried out. Up to this day, there is no standardized method used to construct photochemical reactors, yet the vessel is essential for solar energy harvesting and environmental remediation.

Specification and maintenance of used reactors

The specifications of second-hand reactors for sale differ based on the type of reactor, manufacturing company, and intended industry usage. Below are some general specifications used reactors.

• Sizes: Used industrial reactors come in a variety of diameters to match the requirements of specific production volumes and processes. Typical sizes have a diameter that varies from 1 to 4 meters.
• Volumes: The volumes of a used reactor are also diverse, beginning with small-scale reactors with volumes of several hundred liters to large-scale reactors with volumes exceeding several thousand liters. The choice of volumes depends on production demands and the intended use.
• Materials of construction: Used reactors are made from a variety of materials, including carbon steel, stainless steel, glass-lined steel, and alloys like Hastelloy or Inconel. The choice of materials ensures that the reactors can be used to meet different chemical processes and durability requirements.
• Operating pressures: Second-hand reactors may work at different pressures, from atmospheric pressure to higher pressures, depending on chemical reactions. High-pressure reactors can work at up to 20 bar or even higher.
• Operating temperatures: Industrial reactors work at different temperature ranges. Some reactors can work at high temperatures up to 300°C or even higher. Others can work at subzero temperatures to meet the requirements of low-temperature reactions.
• Auxiliary equipment: The second-hand reactor also has some auxiliary fittings, such as heating and cooling devices, separating devices, molecules filling device, temperature and pressure control, plugging, and leakage control, which cooperate with the chief function of the reactor to ensure the smooth progress of chemical reactions and the safety of the equipment.

Maintenance

Periodic inspection and routine maintenance are required for any used reactors, especially industrial ones that might work at tougher conditions or for longer time periods. See the schedule below as an example of a standard maintenance schedule for used reactors:

• Daily inspection: Daily visual inspection is necessary for a second-hand reactor. The routine inspection would usually include a look at the surrounding environments of the reactor, access to any abnormalities or hazards, and observing whether the pressure, temperature, etc., displayed by the instruments are normal.
• Weekly maintenance: Perform the cleaning and disinfection of the exterior surface of the used reactor weekly to ensure the cleanliness and operating efficiency of the equipment. Weekly checks for pressure vessels and safety valves are also a must for used reactors because they are the key components that are directly related to the pressures inside. Users should ensure that they are functioning correctly.
• Monthly maintenance: Monthly inspections and tests of the used reactors' key components like agitators, sealing elements, and heating/cooling systems should be done. Users can check whether the agitators are operating normally, such as their smoothness and operation noise. Sealing elements like gaskets and sealing rings should be inspected for wear and tear, and the connections should be bolted tightly. Users should check whether the heating/cooling tubes are blocked or leaked and if the pumps are running smoothly.
• Quarterly maintenance: Members performing quarterly maintenance for used industrial reactors should monitor the performance of reactor auxiliary devices. They should inspect the circulating system, filtering units, separation system, etc., ensuring that the auxiliary equipment is operating normally.
• Annual shutdown for overhaul: Conduct a comprehensive inspection and cleaning of the entire used reactor, including but not limited to the pressure vessels, the system piping, the heating/cooling tubes, the filtering and separating devices, the auxiliary machinery, etc. In addition, Replace aging components such as sealing elements and gaskets to ensure that the used reactor operates correctly and stably.

Usage scenarios of used reactors

The used chemical reactors have applications in various industries.

• Chemical Industry

  Chemical reactors are the backbone of the chemical manufacturing industry. They are used to carry out a wide variety of chemical processes such as polymerization, synthesis, oxidation, reduction, hydrodimerization, cyclization, and dehydrogenation, to name a few. Different types of reactors are used depending on the specific chemical process, such as batch reactors for processes that require frequent changing of chemicals, continuous reactors for stable operations, and plug flow reactors for quick reactions.

• Biotechnology and Pharmaceuticals

  In the pharmaceutical industry, chemical reactors are used to manufacture active pharmaceutical components (APIs), intermediates, and fine chemicals. Additionally, the biopharmaceutical industry relies on biochemical reactors where bioreactors play a pivotal role. These reactors provide an ideal environment for microorganisms, bacteria, or other biological entities to thrive as they ferment sugar to produce antibiotics, hormones, vitamins, and other bioproducts. Moreover, chemical reactors are employed to carry out enzymatic reactions, cell cultures, and genetic engineering processes.

• Food Industry

  Food processing companies utilize chemical reactors to produce food additives, flavoring agents, preservatives, and other chemical products related to the food industry. For instance, bioreactors are employed to ferment sugars into alcohol, vinegar, lactic acid, and other organic compounds. Furthermore, chemical reactors are also used in the production of food-related chemical products such as emulsifiers, enzymes, and stabilizers.

• Petrochemical Industry

  Petrochemical reactors are widely used in the petrochemical industry. This includes reactors for oil cracking, polymerization, and refining. Such chemical reactors help convert crude oil and natural gas into various chemical products and raw materials, such as plastic, synthetic fibers, and rubbers.

• Environmental Protection

  Chemical reactors are crucial in waste treatment and pollution control. They are used for wastewater treatment, flue gas desulfurization, catalytic incineration, and solid waste treatment, among other processes. Using chemical reactors facilitates the degradation, transformation, or neutralization of harmful pollutants, which helps protect the environment.

How to choose used reactors

There are several factors used to choose industrial reactors. They include the following:

• Choice of materials

  The materials used for constructing reactors have a great impact on their performance and longevity. As a result, both the reactors' interiors and exteriors must be built of materials well-suited for the processes they'll be involved in. For instance, in instances where corrosive substances are utilized, corrosion-resistant alloys or coatings may be considered to ensure that the reactor remains intact and functional over time.

• Control options and automation

  When selecting an industrial reactor, it's important to think about the control systems and automation features. These elements can have a significant impact on how well the reactor works, how safely it operates, and how easily it can be maintained. Consider the available control options and degree of automation when deciding which reactors to choose.

• Energy efficiency

  Energy efficiency is an important consideration when selecting industrial reactors, as it can impact operational costs, environmental sustainability, and overall productivity. Energy-efficient reactors consume less energy during chemical processes, contributing to cost savings. Choosing reactors with efficient heat exchange systems can help recover and utilize energy from processes. Additionally, optimizing the reactor's stirring and mixing mechanisms reduces energy consumption while improving process efficiency.

• Throughput and capacity

  These two factors are very important when choosing industrial reactors. The term capacity refers to the maximum quantities of material most reactors can process. A small-scale production facility may find that a reactor with a lower capacity is more suitable for its needs. On the other hand, larger-scale industrial facilities would prefer reactors with higher capacities so as to meet their higher demands.

• Flexibility and scalability

  Flexibility and scalability are important factors to consider when choosing industrial reactors for industrial processes. Flexibility refers to a reactor's ability to accommodate different types of chemical reactions and processes. Scalable denotes the capacity to meet changing production demands by adjusting the size and quantity of the reactors deployed. These two characteristics are important for supporting a variety of chemical transformations, thereby ensuring that businesses are capable of adapting to market demands. This way, they'd be able to invest in reactors that are both versatile and scalable, meeting a wide range of process requirements while supporting future growth.

Q&A

Q1: How does a used chemical reactor work?

A1: A used chemical reactor works by providing the ideal conditions for a chemical reaction to take place. It does this by mixing the reactants, maintaining the right temperature and pressure, and allowing enough time for the reaction to occur.

Q2: What are the types of used reactors?

A2: There are two broad categories of chemical reactors: batch reactors and continuous flow reactors. Batch reactors are used by a wide range industries, including the food processing industry. Batch reactors use a chemical reaction to convert raw materials into used chemicals or compounds. Continuous flow reactors, on the other hand, have a fixed volume

Q3: Can someone do DIY chemical reactors?

A3: It is not advisable to build a chemical reactor on DIY. Chemical reactors are complex industrial equipment. Building a chemical reactor requires advanced knowledge of chemistry and engineering. Also, chemical reactors need to meet certain safety standards and regulations.

Q4: What are some signs that a used reactor needs replacement?

A4: A used reactor that has deep scratches or gouges is probably up for replacement. Also, if the liners or coatings of the reactor are delaminating or blistering, it may need replacement. A used reactor with deteriorating or damaged valves andUsed Used Reagents ResponseReflectors also needs to be replaced.