Build Catalyst & Chemical Batch Reactor Systems
Batch reactor systems offer a reliable and flexible way to manufacture a wide range of chemical products, making them an ideal choice for many chemical manufacturers.
Batch Reactor Systems
When to Use Batch Reactor Systems
Batch reactor systems are often used for chemical manufacturing with long reaction times because they allow for better control over the reaction conditions, particularly temperature, and pressure. Long reaction times are often required for complex chemical reactions, and maintaining stable reaction conditions over an extended period is crucial for achieving the desired product quality and yield.
In a batch reactor system, the reactants are loaded into the reactor vessel and allowed to react for a specified period. During this time, the temperature, pressure, and other reaction conditions can be closely monitored and adjusted as needed to ensure optimal product formation. This level of control is essential for reactions that require a longer reaction time, as even small variations in the reaction conditions can lead to significant changes in the product quality or yield.
Moreover, batch reactor systems are well-suited for chemical processes that require multiple steps or intermediate reactions. In such processes, the reaction mixture can be transferred to different reactors for subsequent reactions, allowing for better control over each reaction step.
Benefits of Batch Reactors
Flexibility: Batch reactors are highly versatile and can handle a wide range of reaction conditions, making them suitable for producing a variety of products. They allow for easy changes in reactant concentrations, reaction times, and temperature control, making it possible to produce different products using the same equipment.
Safety: Batch reactors are safer than continuous reactors because they allow for better control over the reaction conditions, such as temperature and pressure. In case of an unexpected event, such as a runaway reaction, a batch reactor can be shut down quickly, minimizing the risk of a catastrophic failure.
Quality control: Batch reactors allow for better quality control since each batch can be carefully monitored and adjusted to meet the desired product specifications. This is particularly important for chemical products that require a high level of purity or consistency.
Cost-effectiveness: Batch reactors are typically smaller and less complex than continuous reactors, which makes them less expensive to manufacture and maintain. Additionally, batch production is often more cost-effective for small-scale or specialty chemicals that do not require large volumes of production.
Bring Us Your Challenge
Why Batch Reactor Systems From Applied Catalysts?
Rapid Changeover
From One Chemistry to Another
Rapid changeover from one chemistry to another is a crucial factor for batch reactor systems, especially in a multi-product manufacturing facility where different products are produced in the same equipment. The ability to quickly and efficiently switch between different chemistries is vital to maximize the productivity of the equipment and reduce the downtime required for cleaning, maintenance, and setup.
Overall, rapid changeover in batch reactor systems enables manufacturers to be more agile and responsive to changing market demands, reduce costs, and improve product quality and environmental sustainability.
Just-In-Time Manufacturing
Just-in-time (JIT) manufacturing is a production strategy that aims to minimize inventory costs and improve production efficiency by producing goods only when they are needed. In the context of batch reactor systems, JIT manufacturing means that the required quantities of the product are produced in batches only when the customer demand exists. This approach can significantly reduce inventory costs and minimize the amount of time that finished products are held in inventory, resulting in lower storage costs, reduced waste, and improved cash flow.
Seamless Process Scaleup
We ensure that the production process can be scaled up from laboratory-scale to commercial-scale without any significant changes to the process conditions, equipment design, or operating procedures. This approach can help to reduce the risks and costs associated with process development and commercialization, as well as improve the efficiency and quality of the production process.
Process Performance Guarantee
We provide our clients with the assurance that their equipment will meet their specific process requirements. Our guarantees include specifications for process parameters such as temperature, pressure, flow rate, and reaction time, as well as product quality characteristics such as yield, purity, and impurity levels. By providing these guarantees, we give our clients the peace of mind that they need to invest in our equipment, knowing that it will perform as intended and meet their production goals.
Our Process for Building Catalyst Batch Reactor Systems
Let's Have a ConversationDiscovery
Which chemistry do you want to run in the batch reactor system?
This will help us determine the type of equipment and materials needed for the reaction.
What are your volumes?
We’ll need to know the desired production volumes to determine the appropriate size and capacity of the batch reactor system.
What’s your timeline for implementation?
Understanding your timeline will ensure that the batch reactor system can be designed, manufactured, and delivered in a timely manner.
What utilities do you have available?
To ensure that the batch reactor system can be properly installed and operated, we’ll need to confirm available utilities, such as electrical power, water, and steam.
Share your current batch reactor system with us. We’ll ask for details about the current equipment and its performance to better understand your needs and requirements.
Identifying Milestones
Is the batch reactor technology already in-house?
We need to know if the client currently has a batch reactor system in place or if they will need to acquire a new one.
If not, we’ll run experiments.
If the client does not have an existing batch reactor system, we’ll recommend running experiments to determine the reaction conditions and establish a design basis for the new system.
Project proposal.
Once we have a design basis for the new system, we can produce a proposal. Based on the results of the experiments and the client’s requirements, Applied Catalysts will develop a design basis for the new batch reactor system and produce a proposal outlining the equipment, materials, and costs involved in the project.
What’s In the Project Proposal?
Our proposal outlines the scope, details, and costs involved in designing, manufacturing, and installing a batch reactor system.
The proposal includes an opportunity summary that provides a brief overview of the project, a process schematic that outlines the process flow and equipment configuration, the required utilities needed to operate the system, the required footprint area, and the required timeline for the project’s completion.
Additionally, the proposal includes a budgetary price, which can be either for the sale or rent of the equipment, that provides a cost estimate for the system’s design, manufacturing, delivery, installation, and ongoing support. All of these items are critical to ensuring that the client understands the scope and costs of the project and can make an informed decision about whether to move forward with the batch reactor system proposal.
Catalysts
Activated Carbon Monolith Catalysts (ACMC)
In addition to the ACMC monolith based catalysts, Applied Catalysts can provide particulate catalysts to solve the customers catalytic needs. Applied Catalysts will provide Industry Standard catalysts when available from a number of participating Catalyst Vendors in addition to proprietary catalysts manufactured by Applied Catalysts.
Granular Activated Carbon Catalysts (GACC)
In addition to the ACMC monolith based catalysts, Applied Catalysts can provide particulate catalysts to solve the customers catalytic needs. Applied Catalysts will provide Industry Standard catalysts when available from a number of participating Catalyst Vendors in addition to proprietary catalysts manufactured by Applied Catalysts.
Metal Oxide Catalysts (MOC)
In addition to the ACMC monolith based catalysts, Applied Catalysts can provide particulate catalysts to solve the customers catalytic needs. Applied Catalysts will provide Industry Standard catalysts when available from a number of participating Catalyst Vendors in addition to proprietary catalysts manufactured by Applied Catalysts.
Custom & Industry Catalysts
With a proven record of Custom Catalyst manufacturing services and a foundation of knowledgeable chemists and researchers, Applied Catalysts’ monolithic catalyst supports even the most challenging design and processing needs from manufacturing to development, ensuring high performance.
Services
Applications & Industries Served
Hydrogenation
The hydrogenation process involves the addition of hydrogen to organic substrates. The functional groups being converted in the organic substrates can be olefinic to aliphatic groups, aromatic compounds to aliphatic compounds, nitro groups to amines, nitrile groups to amines, acids to aldehydes, and aldehydes and ketones to alcohols and ethers. Hydrogenation can also be used to remove sulfur, nitrogen, and chlorine content in molecules.
Pharmaceuticals
The manufacture of pharmaceuticals often contains one or more catalytic hydrogenation steps. Monolith catalysts convert the functional group of a molecule selectively into a new one to produce the starting material for the next synthetic step. Applied Catalysts can provide ACMC monolith-based catalysts for continuous flow process chemistry, enhancing the sustainability and low cost of manufacturing pharmaceutical products.
Process-Performance Guaranteed
Batch Reactor Systems
We give our clients the peace of mind that they need to invest in our equipment, knowing that it will perform as intended and meet their production goals.
- Rapid changeover from one chemistry to another
- Just-in-time manufacturing
- Seamless process scaleup
Let's Have a Conversation