10 Tons Reaction Vessel

Description

10 Tons Reaction Vessel also known as a 10-ton capacity reactor is a large-scale, heavy-duty industrial reactor engineered for high-throughput chemical and process manufacturing, where “10 tons” refers to its approximate structural weight, including shell, jacket, agitator, motor, and support system. These vessels are designed for continuous or batch operations in demanding environments requiring precise control over temperature, pressure, agitation, and reaction kinetics. They are widely used in petrochemical, pharmaceutical, polymer, fertilizer, and specialty chemical industries for reactions involving high volumes, viscous materials, or hazardous substances.

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Salient Features of 10 Tons Reaction Vessel

Available in capacities ranging from 10 liters to 20,000 liters (or up to 10–100 KL in some listings). The 10 Ton model corresponds to roughly 10 KL working capacity.
Stainless Steel (SS304/SS316), Mild Steel, or Rubber-lined options as per requirements. Non-corrosive, sturdy, and temperature-resistant.
Top & bottom dish end, top open, or welded types.
High functional accuracy and dimensional stability (supported by legs or lugs).

Low maintenance, easy operation, and compact footprint.
Mirror/polished finishes available for pharma applications.
Agitator with central stirrer (e.g., anchor, paddle, turbine) for excellent mixing, homogenization, and recirculation. Peripheral anchor scrapes walls.
Vertical or horizontal orientation (typically vertical).

Types of Preparation Vessel

Sterile Manufacturing Vessel

Sterile Preparation Vessel

Injectable Preparation Vessel

Jacketed Mixing Vessel

WFI Storage Tank

Oral Liquid Preparation Vessel

Applications of Preparation Vessel

Support Structure of 10 Tons Reaction Vessel

Skirt or lug supports with anti-vibration pads.

Load cells (optional) for real-time mass monitoring.

Ladder & platform for safe access.

Key Features of 10 Tons Reaction Vessel

Capacity and Dimensions:
- Working Volume: 8–15 KL (8,000–15,000 liters), depending on fill ratio (typically 70–80%).
- Total Vessel Weight: ~10 tons (shell + jacket + drive + supports).
- Height: 6–9 meters (including drive and support).
- Diameter: 2.2–3.0 meters (cylindrical with dished ends).
- Configuration: Vertical cylindrical with top-mounted agitator; optional bottom-entry for high shear.

Materials of Construction (MOC)
- Jacket: Carbon steel (insulated) or SS304/316L.
- Internal Surface: Mirror polished (Ra ≤ 0.3 μm) with electropolishing; optional glass-lined (enamel) or PTFE/PFA lining.
- Seals & Gaskets: PTFE, Viton, or Kalrez for chemical compatibility.

Heat Transfer & Pressure Rating:
- Jacket Type: Full jacket, limpet coil, or half-pipe coil (for high heat flux).
- Heating Media: Steam (up to 20 bar), thermal oil (up to 380°C), electric heating.
- Cooling Media: Chilled water, brine, or glycol.
- Operating Pressure:
  - Internal: Full vacuum to +25 bar (ASME VIII Div. 1 or 2).
  - Jacket: Up to 16 bar.
- Design Temperature: -30°C to +350°C (standard); up to 450°C with special alloys.
- Safety Devices: Dual rupture discs, safety valves, pressure/temperature interlocks.

Agitation System:
- Agitator Types:
  - Anchor + scraper (for high-viscosity pastes, up to 100,000 cP),
  - Double helical ribbon (for dough-like materials),
  - High-shear turbine (for emulsions/dispersions),
  - Combination systems (anchor + high-speed disperser).
- Drive: 15–45 kW motor, VFD-controlled, 30–120 RPM.
- Sealing: Dry-running double mechanical seal with thermostat or magnetic drive (zero leakage, ideal for toxic gases).
- Baffles: 4–8 detachable baffles with CIP nozzles.

Ports & Instrumentation:
- Nozzles: DN50–DN300 for inlet, outlet, vent, manhole (≥600 mm), sight/light glass.
- Instrumentation:
  - PT100/RTD (redundant),
  - Pressure transmitters (4–20 mA),
  - pH, conductivity, DO probes,
  - Radar or ultrasonic level sensors,
  - Load cells on supports for batch weighing.
- Bottom Outlet: Zero-dead-leg flush valve (ball, diaphragm, or plug type), PTFE-lined, pneumatically actuated.

Automation & CIP/SIP:
- Control System: PLC (Siemens/Allen-Bradley) with HMI/SCADA; 21 CFR Part 11 compliant for pharma.
- CIP System: 360° rotating spray balls, high-impact nozzles, automated sequencing.
- SIP: Steam-in-place with condensate drainage and sterility validation.

FAQ for 10 Tons Reaction Vessel

What is a 10 Tons Reaction Vessel?

A 10 Tons Reaction Vessel (also known as a 10-ton capacity reactor) is a large-scale, heavy-duty industrial reactor designed for high-volume chemical and process manufacturing. The “10 tons” typically refers to its approximate structural weight (including shell, jacket, agitator, motor, and supports). It offers precise control over temperature, pressure, agitation, and reaction conditions for batch or continuous operations. It is ideal for handling high volumes, viscous materials, or hazardous substances in demanding environments.

What are the key features and specifications of the 10 Tons Reaction Vessel?

Key features include:

Working Volume: Approximately 8–15 KL (8,000–15,000 liters).
Material: SS304/SS316L (internal mirror-polished or electropolished), with optional glass-lined or PTFE lining; jacket in carbon steel or stainless steel.
Agitation: Top-entry agitators (anchor + scraper, helical ribbon, high-shear turbine, etc.) with 15–45 kW VFD-driven motor (30–120 RPM) and baffles.
Pressure & Temperature: Full vacuum to +25 bar (internal); jacket up to 16 bar; temperature range -30°C to +350°C (extendable).
Design: Vertical cylindrical with dished ends, full/limpet/half-pipe jacket, CIP/SIP compatibility, and PLC automation with HMI/SCADA.

What industries use the 10 Tons Reaction Vessel?

This vessel is widely used in the Pharmaceutical, Chemical, Petrochemical, Polymer, Fertilizer, Cosmetic, Ayurvedic, Herbal & Nutraceutical industries. It supports high-throughput production of APIs, specialty chemicals, resins, emulsions, and other complex reactions requiring precise process control.

What heating, cooling, and pressure options does the 10 Tons Reaction Vessel support?

It features advanced heat transfer systems such as full jackets, limpet coils, or half-pipe coils. Supported media include:

Heating: Steam (up to 20 bar), thermal oil (up to 380°C), or electric heating.
Cooling: Chilled water, brine, or glycol.
Pressure Rating: Internal – full vacuum to +25 bar; Jacket – up to 16 bar. Safety features include rupture discs, safety valves, and interlocks. It meets ASME standards and is suitable for cGMP environments.

What support, automation, and compliance features are available?

Support Structure: Skirt or lug supports with anti-vibration pads, optional load cells, ladder, and platform for safe access.
Automation: PLC-based control (Siemens/Allen-Bradley) with HMI/SCADA, 21 CFR Part 11 compliant for pharma.
Additional Features: CIP/SIP with spray balls, zero-dead-leg flush bottom valves, extensive instrumentation (temperature, pressure, pH, level sensors), and double mechanical or magnetic seals. It ensures hygienic, safe, and efficient operation with full traceability.

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