High Pressure Autoclave Reactor
High Pressure Autoclave Reactor
Main Features
- Ranging from 50 mL to 100 liters
- Pressure of up to 350 bars
- Temperatures up to 500 °C
- Material of Construction (MOC) options include SS-316, SS-316L, Hastelloy B/C, Monel, Nickel, Inconel, Titanium, Tantalum lined, and Zirconium
- Negligible Leakage System
- Magnetic drive coupling with high torque
- Fully automated PC-controlled
Description and Specifications of High Pressure Autoclave Reactor
High Pressure Autoclave Reactor (popular as a polymerization reactor) is a conventional device in the chemical industry that has the primary function of performing mixing procedures for chemical reactions in the liquid phase. A pressure reactor is a chemical reaction vessel that carries out a chemical reaction under high pressure and temperature. Researchers can operate the vessel in batch mode at temperatures ranging from 150 °C to 500 °C. It is manufactured from stainless steel grade 316-L as per the process requirements.
Types of High-Pressure Reactor
Trolley-Mounted Reactor (With Stirrer): This type of reactor has a mechanical stirrer for proper mixing, ultimately improving reaction speed. The trolley design allows easy movement. It is mainly used for flexible setups.
Table-top Reactor (Without Stirrer): This type of reactor come without stirrer. It works well for reactions using pre-mixed substances or natural circulation.
To ensure steady and uniform heating for high-temperature reactions, both trolley and tabletop reactors include a ceramic band heater with a temperature range between 50 °C and 500 °C. Water circulation is also provided to maintain the required reaction temperature. The reactor is controlled by a dedicated control panel that adjusts temperature, pressure, and safety settings. The control panel’s easy interface improves operation and monitoring.
Temperature and pressure are maintained stable through a programmable (Proportional-Integral-Derivative) P.I.D. controller. It reduces fluctuations for consistent results.
The system has a temperature alarm and a pressure sensor for real-time monitoring. If the set limit is exceeded, instant alerts are activated to ensure safety.
The internal wetted parts that come into contact with chemicals are made of SS316 stainless steel, while non-wetted parts are built in SS-304 stainless steel. The reactor is designed for precision and safety and is ideal for chemistry, pharmaceuticals, and material science applications.
We also supply High Pressure Reactor with a Teflon (PTFE) vessel for highly corrosive and sensitive reactions, which has been equipped with a pressure gauge, gas inlet, and outlet. A precision needle valve regulates gas flow to prevent sudden changes, ensuring smooth pressure adjustments.
We supply two types of gaskets with the reactor as per the required temperature. For temperatures above 200 °C, Graphite Gasket is used for strong heat resistance and chemical stability. Teflon Gasket is the best option for temperatures less than 200 °C. Our high pressure reactor has equipped with the rupture disc to provide extra safety during reaction.
Design
The structure of a High-Pressure Reactor consists of a cylindrical lateral shell with a typical Tori spherical/ Ellipsoidal dish at the top ends. The outer side of the reactor has a jacket for heating and cooling. The surface between the shell and the jacket has Stiffener Rings that provide regular heating or cooling media circulation and increase the vessel’s strength.
Assembly Unit
The High Pressure Autoclave Reactor assembly is mounted on the top dish of the Batch Reactor. It consists of a lantern assembly on the top end that supports the shaft. This part also contains a bearing housing with a tapered roller to endure impact and vibratory loads. As a result, there is a smooth rotation of the shaft. Shafts can have several agitators such as single anchor, dual anchor, turbine, and propeller. It also contains baffles within the shell as per requirements.
Advantage
A pressure reactor has various benefits over a standard round-bottom flask. For example, it can perform a reaction above a solvent’s boiling point. Second, pressure can lower the reaction volume, including the liquid phase, increasing concentration and collision frequency while accelerating a reaction. Temperature increases can not only hasten the intended response but also hasten the breakdown of chemicals and starting materials. On the other hand, the pressure might accelerate the desired reaction and only affect decomposition when it includes the release of a gas or interaction with gas in the vessel.
Technical Specification
| Product Name | High Pressure Autoclave Reactor |
|---|---|
| Brand | Techinstro |
| Product Type | High-Pressure Chemical Reaction Vessel |
| Capacity Range | 50 mL to 100 Litres, depending on configuration |
| Maximum Operating Pressure | Up to 350 bar, depending on model and configuration |
| Maximum Temperature | Up to 500°C, depending on model and configuration |
| Heating System | Ceramic band heater for controlled heating |
| Listed Heater Temperature Range | 50°C to 500°C |
| Temperature Control | PID (Proportional-Integral-Derivative) temperature controller |
| Pressure Monitoring | Pressure sensor and pressure gauge, depending on configuration |
| Safety Features | Temperature alarm, pressure monitoring, rupture disc and safety relief valve, as configured |
| Stirring System | Magnetic drive coupling or mechanical stirring, depending on reactor design |
| Stirrer Configuration | Available with stirring or without stirring, depending on model |
| Available Configurations | Trolley-mounted reactor with stirrer and tabletop reactor without stirrer |
| Standard Construction Materials | Stainless steel grades including SS-316 and SS-316L, according to requirements |
| Optional Materials of Construction | Hastelloy B/C, Monel, Nickel, Inconel, Titanium, tantalum-lined construction and Zirconium, subject to availability |
| Wetted Parts | SS-316 stainless steel is specified for wetted parts in the described configuration; other material options may be available |
| Non-Wetted Parts | SS-304 stainless steel in the described configuration |
| Optional Liner | PTFE (Teflon) vessel option for compatible corrosive or sensitive reactions |
| Gasket Options | Graphite gasket for specified higher-temperature applications and PTFE gasket for specified lower-temperature applications |
| Leakage Control | Magnetic drive coupling and low-leakage sealing options, depending on design |
| Cooling | Water circulation or jacket-based temperature management, depending on configuration |
| Control System | Dedicated control panel with temperature, pressure and safety controls |
| Automation | Automated control and PC-based monitoring options, depending on configuration |
| Reactor Operation | Batch chemical processing under controlled temperature and pressure |
| Typical Applications | Polymerization, hydrogenation, catalytic reactions, chemical synthesis and materials research |
| Industries Served | Chemical processing, pharmaceuticals, petroleum, materials science and research laboratories |
Properties
- Reactors have volumes ranging from 50 mL to 100 liters.
- It has a pressure of up to 350 bars, and temperatures up to 500 °C are possible.
- Material of Construction (MOC) options include SS-316, SS-316L, Hastelloy B/C, Monel, Nickel, Inconel, Titanium, Tantalum lined, and Zirconium.
- Magnetic drive coupling with high torque and negligible leakage
- A fully automated PC-controlled high-pressure system/pilot plant constantly monitors, controls, and records factors such as temperature, pressure, motor speed, gas/liquid flow, level, torque, and so on.
Applications of High Pressure Autoclave Reactor
High-pressure reactors find application in the petroleum and chemical industries, biological medicine, and materials science. Science, geology, chemistry, environmental science, food science, commodities inspection, and so on are all examples.
Polymerization reactors are employed in high-pressure and temperature. These autoclave vessels perform chemical reactions like alkylation, bromination, carboxylation, amination, acetylation, and dehydrogenation. It also has esterification, acylation, catalytic reduction, chlorination, ethoxylation, ozonization, polymerization, halogenation, hydrogenation, methylation, nitration, oxidation, sulphonation, and many more.
How To Use High Pressure Autoclave Reactor?
Keep the High-Pressure Reactor together against the gas pressure by tensile load inside the container’s walls. The standard (tensile) stress in the vessel walls of a High Pressure Reactor is dependent on the pressure and diameter of the vessel and indirectly proportional to the thicknesses of the walls. Make sure you use safety measures while performing experiments.
Comparison
| Comparison Parameter | Techinstro High Pressure Autoclave Reactor | Hydrothermal Autoclave Reactor | Standard Round-Bottom Flask | PTFE-Lined High-Pressure Reactor |
|---|---|---|---|---|
| Primary Purpose | High-pressure and high-temperature chemical reactions | Hydrothermal and solvothermal laboratory synthesis | Mixing, heating and reactions under conventional laboratory conditions | Pressure reactions involving compatible corrosive or sensitive chemicals |
| Operating Pressure | Available configurations rated up to 350 bar | Depends on vessel design and manufacturer’s rating | Generally intended for atmospheric or low-pressure laboratory use | Limited by the rated pressure of the vessel, liner and sealing system |
| Temperature Capability | Up to 500°C for specified configurations | Depends on the reactor model and operating conditions | Depends on glass type, heating method and setup; not designed for high-pressure service | Limited by the vessel design, PTFE liner, seals and operating conditions |
| Capacity | 50 mL to 100 litres, depending on configuration | Commonly available in laboratory-scale sizes; exact capacity varies | Available in a wide range of laboratory sizes | Depends on the selected reactor model |
| Construction | Metal pressure vessel with configurable construction materials | Typically a pressure-rated metal shell with a compatible internal vessel or liner | Typically borosilicate glass | Pressure-rated outer vessel with a PTFE liner |
| Stirring | Stirred and non-stirred configurations are available | Depends on the design; many laboratory models are non-stirred | Manual or external stirring arrangements can be used where suitable | Depends on the model; a PTFE liner alone does not imply mechanical stirring |
| Temperature Control | PID control and a dedicated control panel, depending on configuration | Depends on the heating system and controller | Usually requires a separate heating and temperature-control arrangement | Depends on the heating system and the liner’s temperature rating |
| Material Compatibility | Material options can be selected according to process requirements | Depends on the liner, vessel and chemicals used | Depends on glass compatibility and thermal-shock limitations | PTFE offers compatibility with many chemicals, subject to specific chemical and temperature limits |
| Automation | Control panel and optional PC-based monitoring or automation | Depends on the model | Usually requires separate instruments and controls | Depends on the selected system |
| Typical Applications | Hydrogenation, polymerization, catalytic reactions and high-pressure synthesis | Nanomaterial synthesis, crystal growth and hydrothermal research | Solution preparation, reflux and conventional laboratory chemistry | Corrosion-sensitive synthesis and selected high-pressure chemical reactions |
| Best Selection Criterion | Choose when the process requires a suitably rated pressure vessel, temperature control and optional agitation | Choose for compatible hydrothermal or solvothermal synthesis at the required scale | Choose for routine laboratory chemistry that does not require a high-pressure vessel | Choose when a compatible liner is required and the complete assembly meets the process ratings |
Why Choose Techinstro High Pressure Autoclave Reactor?
The Techinstro High Pressure Autoclave Reactor is designed for chemical processing and research applications that require controlled reaction conditions at elevated temperatures and pressures. With configurable capacities, construction materials, stirring arrangements and control systems, it can be specified for a wide range of laboratory and industrial processes.
- High-Pressure Reaction Capability: Configurations rated for pressures up to 350 bar support demanding chemical processes when selected and operated within their specified limits.
- High-Temperature Operation: Specified configurations support temperatures up to 500°C for suitable high-temperature reaction and materials research applications.
- Flexible Capacity Options: Capacities ranging from 50 mL to 100 litres accommodate different experimental scales, from laboratory research to larger process development.
- Multiple Construction Materials: Options including SS-316, SS-316L, Hastelloy, Monel, Inconel, Titanium and other specified materials help address different process and chemical compatibility requirements.
- Stirred and Non-Stirred Designs: Select a trolley-mounted reactor with a stirrer or a tabletop configuration without a stirrer according to the mixing requirements of the reaction.
- Controlled Heating: A ceramic band heating system and PID temperature control, depending on configuration, support regulated reaction temperatures.
- Pressure and Temperature Monitoring: Configurable sensors, gauges and alarms help operators monitor process conditions during operation.
- Overpressure Protection Options: Rupture discs and safety relief valves, as specified for the selected system, provide additional protection against excessive pressure.
- Magnetic Drive Technology: Magnetic drive coupling options support agitation with reduced dependence on conventional rotating shaft seals and help minimize leakage paths.
- PTFE-Lined Reactor Option: A PTFE-lined configuration is available for selected corrosive or sensitive reactions, subject to chemical compatibility and the liner’s operating limits.
- Automation and Monitoring: Dedicated control panels and optional PC-based monitoring or SCADA solutions can support process monitoring, control and data recording.
- Wide Range of Research Applications: Suitable applications may include polymerization, hydrogenation, catalytic reduction, esterification, chemical synthesis and materials science research.
- Configuration Support: Reactor capacity, construction material, stirring arrangement, seals and instrumentation can be selected according to the intended process requirements.
Choose Techinstro High Pressure Autoclave Reactor for configurable high-pressure reaction equipment for laboratory research and industrial process development. Share your required capacity, operating pressure, temperature, chemical compatibility and stirring requirements to identify a suitable configuration.
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Safety Measures
When operating a high-pressure reactor, researchers must keep the following considerations in mind:
- The high-pressure reaction vessel should be kept in a high-pressure operating room that fulfills explosion protection criteria. The operating room must have a direct connection to the outside or route, and the high pressure reactor must have dependable grounding.
- Researchers need to handle extreme care to avoid any impact and damage. A high-pressure reactor is usually shut with conical contact through the sealing ring. Tighten the main screws to make them dense with one another.
- When installing the cover, install the pressure reaction kettle body and the kettle covers in a fixed position. Install it carefully on the kettle body.
- To produce a good sealing effect, tighten the central bolt diagonally, with a consistent force, and without allowing the kettle lid to tilt to one side.
- Heat and pressure the high pressure reactor before using it. Use Nitrogen as the test medium. The use of oxygen and other flammable and dangerous gases is strictly banned.
- Gently increase the temperature and pressure with a temperature rise rate of less than 80°C/h.
- Connect the autoclave’s air intake valve to the cylinder through the connecting pipe during the pressure test.
- To assess the sealing condition, increase the pressure numerous times, with a 20 percent working pressure interval, persisting for 5 minutes at every rising level and staying for 30 minutes when rising to test pressure. The working pressure is 100 – 105 percent of the experimental pressure.
Why Choose Us?
We, Techinstro, design and build high-pressure, high-mass-transfer-area stirred reactors/autoclaves and magnetically connected, seal-less agitators. We have 10+ years of manufacturing experience and are one of the best sellers of High Pressure Reactors. We provide simple-to-use flameproof / non-flameproof control panels. It also has PID-controlled electrical heating & cooling. These control panels offer accurate readings of pressure, temperature, agitator speed, etc. We understand the necessity, and therefore, we also establish alarms for high-pressure and high-temperature set points using these panels. The rupture disc and safety relief valve offer overpressure protection, assuring safety when running high-pressure equipment. We also assist with installation and usage. We offer skid-mounted process systems that are integrated. These systems have automatic or manual temperature, pressure, RPM, gas, and liquid flow controls. We can also provide PC-based SCADA software for monitoring, controlling, and recording almost all parameters. Since we are the sole manufacturer and supplier, we provide reasonable and affordable prices for our products. Avail of worldwide shipment of our products along with assistance with us. To place your orders, visit the contact page and fill out the details.
FAQ's
Reactors are available from 50 mL up to 100 liters.
We can build them to withstand pressures up to 350 bar.
It runs in batch mode at temperatures from 150°C up to 500°C.
Options include SS-316, SS-316L, Hastelloy B/C, Monel, Nickel, Inconel, Titanium, Tantalum-lined, and Zirconium.
Yes, we can supply a PTFE vessel or a corrosion-resistant material such as Hastelloy or Tantalum lining.
Trolley-mounted models have a mechanical stirrer with a high-torque magnetic drive, while tabletop models do not.
A ceramic band heater (50–500°C) gives even heating, with water circulation and an outer jacket for temperature control.
A PID controller keeps both steady, while a pressure sensor and temperature alarm give real-time alerts.
We use graphite gaskets above 200°C and Teflon gaskets below 200°C.
It handles hydrogenation, oxidation, polymerization, nitration, chlorination, esterification, alkylation, and many other reactions.
Install it in a safe room with proper earthing, pressure-test it with nitrogen, and raise the temperature by less than 80°C per hour.
Yes, we customize capacity, pressure, material, and controls, and we assist with installation, skid systems, and SCADA software.
Yes, it is fitted with a rupture disc and a safety relief valve.