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Pilot Reactor

A pilot reactor ( or an Intermediate-scale reaction kettle ) is for chemical reactions and is suitable for scaling up from laboratory to pilot plant production.
Generally speaking, reactors of volume between 100 liters and 500 liters are known as Pilot reactors. Sometimes, people also call reactors with volumes between 50 liters to 1000 liters as the pilot reactor. 
The reason for this difference is largely dependent on the size of the laboratory reactor one had before. If they were using a lab reactor that was between 50 and 100 liters, then obviously they would no longer call a reactor in that volume range a medium reactor.

So, the pilot reactor has a larger capacity than the laboratory reaction kettle and a smaller capacity than the industrial reaction kettle. 
Its capacity usually ranges from tens of liters to several hundred liters. The pilot reactor has a larger size and more advanced process control than the laboratory reaction kettle. It is suitable for pilot-scale production.
Compared to an industrial reaction kettle, it has a smaller capacity, lower cost, and is suitable for small-scale or trial production. 
Pilot reactors are necessary because it is the transitional phase between laboratory experiments and production scale. 
It also enables manufacturers to optimize production processes, evaluate potential commercial opportunities, and test product feasibility before scaling up to industrial production.

The pilot reactor can also be categorized in detail according to the volume, the same as the industrial reactor.

The following two tables are also in accordance with the mechanical seal and magnetic seal to make a general classification.

Pilot with Mechanical Sealed Style
Type FCH 50 FCH 100 FCH 200 FCH 300 FCH 500
Volume (L)
50
100 200 300 500
Working pressure MPa


ATM~ 1.6

Working temperature ( °C )
-10°C~200°C
Stirring speed
0~1000
Motor power  W
1.1
1.5 2.2 3 4
Heating power
9 15 18 18 36
Heating type


Electric heater with thermal oil bath, jacket circulation with thermal oil /steam/melt salt, far infrared heating


Discharging type
sampling from the kettle lid, or discharging from bottom
Shaft
Self-lubricating wear-resistant sleeve, suitable for mixing various media.
Seal type
mechanical seal
Main material
Kettle material is mainly used 0Cr18Ni9 ( 304 )+Mild Steel Q345R , 00Cr17Ni14Mo2 ( 316L )+Mild Steel Q345R, 1Cr18Ni9Ti ( 321 )+Mild Steel Q345R . And this reactor can also be made from special materials including titanium ( TA2), nickel material, tantalum material, zirconium, Hastelloy, lined PTFE, and lined Ni ( Ni6 ), as per different conditions of the experiment.
Ports of kettle lid
Gas port with needle valve, liquid port with needle valve and bottom insert tube, solid feeding port with screw plug, temperature port with platinum resistance PT100, safety port with pressure gauge, burst disc or safety valve, cooling coil with faucet.
Controller Device
Equipped with a PID automatic controller, temperature control accuracy of ±1°C; With speed display and stepless/ frequency speed regulation function; The heating power and heating temperature can be adjusted, can also achieve the purpose of automatic thermostat.
Other accessories
Suppose the user has other special requirements on kettle nozzle and kettle body opening, internal structure, stirring paddle style, and other supporting devices ( such as condensate refluxing unit, constant feeding tank, receiver, condenser, etc.). In that case, we can manufacture reactors according to clients' requirements.


Magnetic Seal Pilot Reactor Technical Parameters
Type GSH 50 GSH 100 GSH 200 GSH 300 GSH 500
Volume (L) 50 100 200 300 500
Structure type Open Style
Design Pressure( Mpa) Negative pressure~ 40.0 Negative pressure~ 20.0
Design temperature ( °C ) -196°C~400°C
Stirring speed 0~1000
Motor power  W 1.1 1.5 2.2 3 4
Heating power 9 15 18 18 36
Heating type
Far infrared electric heating, electric heater with thermal oil bath, jacket circulation with thermal oil/steam/melt salt
Discharging type
sampling from the kettle lid, or discharging from bottom
Shaft
Self-lubricating wear-resistant sleeve, suitable for mixing various media.
Main material
Kettle material is mainly used 06Cr18Ni9 ( 304 )+Mild Steel Q345R , 22Cr17Ni14Mo2 ( 316L )+Mild Steel Q345R, 1Cr18Ni9Ti ( 321 )+Mild Steel Q345R . And this reactor can also be made from specialty materials including titanium ( TA2), nickel material, tantalum material, zirconium, Hastelloy, lined PTFE, and lined Ni ( Ni6 ), as per different conditions of the experiment.
Ports of kettle lid
Gas port with needle valve, liquid port with needle valve and bottom insert tube, solid feeding port with a screw plug, temperature port with platinum resistance PT100, safety port with pressure gauge, burst disc or safety valve, and a cooling coil with faucet.
Controller Device
Equipped with a PID automatic controller, the temperature control accuracy of ±1°C; With speed display of heating and mixing; The heating power and heating temperature can be adjusted, can also achieve the purpose of automatic thermostats.
Other accessories
If the user has other special requirements on kettle nozzle and kettle body opening, internal structure, stirring paddle style, and other supporting devices ( such as condensate refluxing unit, constant feeding tank, receiver, condenser, etc.), we can manufacture reactors according to clients' requirements.


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