5000 Kgs Reaction Vessel

Q: What are the key features and specifications of the 5000 Kgs Reaction Vessel?

Key features include: Working Volume : 3,000–8,000 liters (3–8 KL) at 70–80% fill ratio. Dimensions : Shell diameter 1.8–2.5 meters; overall height 4.5–7.0 meters. Material : SS304/SS316L (mirror-polished Ra ≤ 0.4 μm), with optional glass-lined, PTFE, or Hastelloy linings; jacket in carbon steel or SS. Agitation : Anchor with scrapers, turbine, helical ribbon, or dual systems; 7.5–18.5 kW VFD motor (50–150 RPM). Pressure & Temperature : Full vacuum to +10–16 bar (internal); jacket up to 10 bar; temperature -20°C to +300°C. Design : Jacketed (full/limpet), CIP/SIP ready, PLC automation, and ASME/cGMP compliant.

Q: What support, automation, and compliance features are available for the 5000 Kgs Reaction Vessel?

Support Structure : Skirt support with earthing lugs and anti-vibration pads; optional load cells and ladder/platform access. Insulation with mineral wool + SS cladding. Automation : PLC-based control (Siemens/Delta) with HMI; optional 21 CFR Part 11 compliance and SCADA integration. Additional Features : CIP/SIP with rotating spray balls, zero-dead-leg flush valves, extensive instrumentation (PT100 sensors, pressure transmitters, pH/level probes), double mechanical or magnetic seals, and vapor recovery condensers. It ensures hygienic, safe, leak-proof, and traceable operation.

Description

5000 Kgs Reaction Vessel commonly designated as a 5-Ton Reactor is a large-capacity, heavy-duty industrial reactor engineered for high-volume batch or semi-continuous chemical processing, where “5000 Kgs” (5 metric tons) refers to the total structural weight of the vessel assembly (~5,000 kg), including shell, jacket, agitator, drive system, supports, and instrumentation. This size is ideal for medium-to-large scale production in industries requiring robust, reliable, and precisely controlled reaction environments under elevated temperature, pressure, and mixing conditions.

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Salient Features of 5000 Kgs Reaction Vessel

Working volume typically 3–8 KL (3000–8000 liters), with the 5000 Kgs model suited for ~5000-liter batches (70–80% fill ratio). Overall range across models: 10 liters to 20,000+ liters.
Jacketed (full, half, or limpet coil) design for efficient heat transfer. Supports steam, thermal oil, hot water, chilled water, brine, or electric heating.
Vertical cylindrical with top & bottom dish ends (torispherical/ellipsoidal), top open, or welded types.
Agitator options: Anchor + scraper (for high viscosity), turbine, paddle, helical ribbon, or combinations. Top-mounted with VFD for variable speed (typically 30–150 RPM).

Dimensional stability with legs, lugs, or skirt supports.
High-grade Stainless Steel (SS304 / SS316 / SS316L), Mild Steel, or Rubber-lined options.
Mirror-polished or electropolished internal surfaces (Ra ≤ 0.3–0.8 μm) for pharma-grade applications; optional glass-lined or Hastelloy for corrosive duties.
It is a medium-to-large scale industrial reactor designed for chemical, pharmaceutical, resin, and process industries.
The “5000 Kgs” typically indicates working/batch capacity or approximate structural weight.

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 5000 Kgs Reaction Vessel

Support Type: Skirt support with earthing lug and anti-vibration pads.

Insulation: 50–100 mm mineral wool + stainless steel cladding.

Condenser: Vertical shell-and-tube or coil-in-shell for reflux/vapor recovery.

Control Panel: PLC-based (Siemens/Delta) with HMI; optional 21 CFR Part 11 compliance.

Key Features of 5000 Kgs Reaction Vessel

Capacity and Dimensions:
- Working Volume: 3,000 – 8,000 liters (3–8 KL) (70–80% fill ratio).
- Total Vessel Weight: ~5,000 kg (5 Tons).
- Overall Height: 4.5 – 7.0 meters (including motor and support).
- Shell Diameter: 1.8 – 2.5 meters.
- Configuration: Vertical cylindrical with dished top and bottom heads (torispherical or elliptical); optional conical bottom for slurry discharge.

Materials of Construction (MOC):
- Shell & Heads: SA240 TP316L or SUS316L (pharma/food grade); SA516 Gr.70 (carbon steel) for non-corrosive applications.
- Jacket: SA516 Gr.70 or SUS304, insulated with rockwool + SS cladding.
- Internal Finish: Mirror polished (Ra ≤ 0.4 μm) with electropolishing for GMP/FDA compliance.
- Optional Linings: Glass-lined (WWG enamel), PTFE/PFA spray-coated, or Halar for aggressive chemicals.

Heat Transfer & Pressure Rating:
- Jacket Design:
  - Full conventional jacket,
  - Limpet coil (half-pipe),
  - Internal coil (optional for high heat duty).
- Heating Media: Saturated steam (≤15 bar), thermal oil (≤350°C), electric heating rods.
- Cooling Media: Chilled water, brine, or glycol.
- Operating Parameters:
  - Internal Pressure: Full vacuum to +10–16 bar.
  - Jacket Pressure: Up to 10 bar.
  - Design Temperature: -20°C to +300°C (standard); up to 350°C with high-temp seals.
- Safety: Dual rupture discs, safety relief valves, emergency vent, and burst detection.

Agitation System:
- Agitator Types:
  - Anchor with PTFE scrapers (for viscous pastes, ≤50,000 cP),
  - Propeller or pitched blade turbine (for liquid mixing),
  - Helical ribbon (for dough-like materials),
  - Dual agitation (anchor + high-speed disperser).
- Drive: 7.5 – 18.5 kW, VFD motor, 50–150 RPM.
- Shaft Sealing:
  - Double mechanical seal with barrier fluid system,
  - Magnetic drive (leak-proof, ideal for toxic or sterile processes).
- Baffles: 4–6 removable, jacketed or with CIP nozzles.

Ports & Fittings:
- Top Nozzles: Feed inlet, vent, manhole (≥500 mm), sight glass, light glass, sensor ports.
- Bottom Outlet: Flush-mounted zero-dead-leg ball/diaphragm valve (PTFE-lined), pneumatically or manually operated.
- Instrumentation:
  - PT100 temperature sensors (duplex),
  - Pressure transmitter,
  - pH/conductivity probes,
  - Radar level sensor,
  - Load cells (optional on supports).

Cleaning & Sterilization:
- CIP System: 360° rotating spray balls, high-pressure nozzles, automated wash cycles.
- SIP Capability: Steam-in-place with condensate traps and sterility validation.

FAQ for 5000 Kgs Reaction Vessel

What is a 5000 Kgs Reaction Vessel?

A 5000 Kgs Reaction Vessel, also known as a 5-Ton Reactor, is a large-capacity, heavy-duty industrial reactor designed for high-volume batch or semi-continuous chemical processing. The “5000 Kgs” (5 metric tons) primarily refers to the total structural weight of the vessel assembly (shell, jacket, agitator, drive system, supports, and instrumentation). It provides a robust, precisely controlled environment for reactions under elevated temperature, pressure, and mixing conditions, making it ideal for medium-to-large scale production.

What are the key features and specifications of the 5000 Kgs Reaction Vessel?

Key features include:

Working Volume: 3,000–8,000 liters (3–8 KL) at 70–80% fill ratio.
Dimensions: Shell diameter 1.8–2.5 meters; overall height 4.5–7.0 meters.
Material: SS304/SS316L (mirror-polished Ra ≤ 0.4 μm), with optional glass-lined, PTFE, or Hastelloy linings; jacket in carbon steel or SS.
Agitation: Anchor with scrapers, turbine, helical ribbon, or dual systems; 7.5–18.5 kW VFD motor (50–150 RPM).
Pressure & Temperature: Full vacuum to +10–16 bar (internal); jacket up to 10 bar; temperature -20°C to +300°C.
Design: Jacketed (full/limpet), CIP/SIP ready, PLC automation, and ASME/cGMP compliant.

What industries commonly use the 5000 Kgs Reaction Vessel?

It is widely used in the Pharmaceutical, Chemical, Cosmetic, Ayurvedic, Herbal & Nutraceutical industries. It is also suitable for resin production, polymers, specialty chemicals, and other processes requiring high-volume, controlled reactions with viscous materials or hazardous substances.

What heating, cooling, and pressure options does the 5000 Kgs Reaction Vessel support?

The vessel features advanced jacket designs (full conventional, limpet coil, or half-pipe) for efficient heat transfer. Supported options include:

Heating Media: Saturated steam (≤15 bar), thermal oil (≤350°C), or electric heating.
Cooling Media: Chilled water, brine, or glycol.
Pressure Rating: Internal – full vacuum to +10–16 bar; Jacket – up to 10 bar. Safety features include dual rupture discs, safety valves, and interlocks. It meets ASME standards and is suitable for cGMP environments.

What support, automation, and compliance features are available for the 5000 Kgs Reaction Vessel?

Support Structure: Skirt support with earthing lugs and anti-vibration pads; optional load cells and ladder/platform access. Insulation with mineral wool + SS cladding.
Automation: PLC-based control (Siemens/Delta) with HMI; optional 21 CFR Part 11 compliance and SCADA integration.
Additional Features: CIP/SIP with rotating spray balls, zero-dead-leg flush valves, extensive instrumentation (PT100 sensors, pressure transmitters, pH/level probes), double mechanical or magnetic seals, and vapor recovery condensers. It ensures hygienic, safe, leak-proof, and traceable operation.

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