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High Pressure Reactors are reactors that can withstand internal or external pressure between 1Mpa to 100Mpa. This is a very wide pressure range, so we have a detailed explantion on its concept in a seperate introduction page.
I、Advantages:
ᆞ The most significant advantage of high pressure reactors ( autoclaves ) is their ability to carry out reactions at high pressures, which support higher reaction rates and better product yields than normal reactors.
The reactants' volume is reduced by high pressure, so it requires less solvent including the liquid phase than under normal pressure. The reaction is accelerated because of concentration and molecular collision frequency increasing.
ᆞ Some autoclaves can also provide higher reaction temperatures, allowing some high-temperature reactions to be carried out more efficiently. It can conduct a reaction above the boiling point of a solvent because of high pressure. The increase in temperature can speed up the desired reaction, and also speed up the decomposition of reagents and starting materials.
ᆞ As per the volume of the reactors, many options of the alloy are available for choice.
As a high pressure reactor fabricator, WHGCM has 30 licensed welding technicians for the vessel's fabrication. And the alloy's thickness and welding material need strictly inspected before working.
Besides the high pressure vessels, various high qualified valves or gauges are also needed.
Bellow shows the components of our industry high-pressure reactor.
High pressure reactors are typically hold a cylindrical design. The kettle body is usually of a fully closed structure to prevent leakage to the maximum extent.
The main material is stainless steel or other robust materials, such as Inconel, Monel, Hastelloy, Zirconium, Tantalum, or Titanium to withstand the high pressure, temperature, and other variables encountered in chemical processes.
Due to the high pressure, the reactor's components need to be very strong.
WHGCM engineers will select different materials according to the reaction conditions and calculate the thickness of the plates according to the highest design reaction pressure and temperature.
WHGCM's processing technology fully complies with ASME ( the certificate will be issued in Dec 2023), CE, ISO, and EAC standards, and in strict accordance with the above standards to check and issue quality certificates, material factory certificates, and incoming inspection certificates, certificates of conformity of the main processes, inspection of qualified materials for flaws and so on.
Their components include the reaction vessel, motor, controller, stirrer, pressure gauges, rupture discs, sealings, and safety valves.
The reactor vessel is the heart of the high-pressure reactor, which holds the fluid or solid materials that undergo chemical reactions under extreme pressure.
The high pressure vessels are the key components of the high pressure reactors. To fabricate high pressure vessels, especially the kettle made from alloy, the technicians must be licensed and the plates need non-destructive testing (NDT) before manufacturing.
The fully closed reactor vessel usually complies with an agitator having a magnetic seal shaft. Closed vessels with static magnetic seals (or also called static seals) can prevent the release of toxic gas and explosions, ensuring both zero leakage and a safe operation.
The application of Magnetic Drive Device solves the problem of axial seal leakage with packing seal and mechanical seal, without any leakage nor contamination. So it is the most ideal device to carry out high temperature and high-pressure chemical reaction at present, especially well-performed in chemical reaction such as sulfurization, fluoride, hydrogenation, whose mediums can be flammable, explosive, poisonous, precious, or with strong penetration.
Safety valve, gauges, rupture discs, explosion-proof equipments.
The high pressure reactor for laboratory application and pilot scale are more or less the same. The difference is, for lab application, the technique difficulty is much higher than it is for pilot and industry scale.
WHGCM high pressure reactors provide a safe and reliable environment for various chemical processes requiring high temperatures and pressures.
WHGCM high pressure reactors are widely used in the chemical, petrochemical, and pharmaceutical industries. The benefits of high-pressure reactors include precise temperature and pressure control, faster reaction times, improved product quality, and reduced environmental impact.
High-pressure reactors are used in various fields, which include:
High-pressure reactions can promote faster reactions of chemicals that require long reaction times under atmospheric pressure. High-pressure reactors offer precise pressure, temperature, and mixing control, which is essential in developing new drugs, synthesizing high-performance materials, and improving industrial processes.
ᆞ For pharmaceutical applications, high pressure reactors could synthesize drug-active substances, improve the purity of APIs, and control the microstructure of APIs.
ᆞ High pressure reactors are able to prepare new energy materials, study the chemical reaction process, and improve the efficiency of energy conversion.
Polymerization reactions can be performed to produce unique polymer materials with specific properties, which are difficult to achieve using standard polymerization techniques. High-pressure reactors facilitate unique polymerization mechanisms that result in high-performance polymers with excellent mechanical properties.
High-pressure reactors are used to synthesize materials with unique properties such as uniform-size nanoparticles and nanostructured materials. Their control over pressure and temperature conditions leads to the production of unusual materials with excellent properties, including strength, hardness, electrical, and magnetic properties.
High-pressure reactors can also handle a broader range of chemical reactions, including hydrogenation and material development. These reactors are essential tools for industrial-scale production, process optimization, and material development, where high-pressure conditions are required.
WHGCM has a decade of experience in providing customized solutions for high pressure reactors and can design and fabricate the product as per your specific needs.
Please download our Reactor Modular Customization Form from our download center. Fill it and Email it to us.
We will follow the information you fill in and make a preliminary design of your autoclave.
A quotation will be offered as soon as the drawing is approved by you.
Preliminary drawing: 2 working days.
Quotation: 1 working day.
Construction period: 40 working days or less.
After the products are finished, we will issue the inspection report.
Warranty: 1 year.
Installation:
We provide remote installation guidance.
If you need on-site installation, we will charge an installation service fee, whose amount needs to be negotiated based on actual situation.
Due to its high-pressure characteristics, special attention should be paid to observing safe operating procedures. Our engineers have given a convenient and effective way of memorizing the complicated operating procedures to ensure that the operator does not forget them.
