Technical Specification – 7 KL Chemical Reactor
The reactor shall be a vertical, jacketed chemical process reactor having a gross capacity of 7, 000 litres (7 KL) with a working capacity of approximately 5, 600 to 6, 300 litres. The reactor shall be designed, fabricated, inspected, and tested in accordance with ASME Section VIII Division 1 or IS 2825 standards. The product contact surfaces shall be manufactured from SS 316L stainless steel, while the jacket shall be constructed from SS 304 stainless steel or carbon steel, depending on the heating and cooling service requirements. The vessel shall be provided with torispherical dished top and bottom ends and shall be suitable for operation under both pressure and full vacuum conditions.
The reactor shall be designed for a shell pressure ranging from full vacuum to +3 kg/cm²(g) and a jacket pressure of 4 kg/cm²(g). The design temperature shall be -10°C to 200°C, with a normal operating temperature of up to 180°C. The jacket shall be of conventional, limpet coil, or half-pipe construction and shall be suitable for heating by steam or thermic fluid and cooling by cooling water or chilled water.
The reactor shall be equipped with a top-mounted agitator designed to provide efficient mixing for chemical processing applications. The agitator shall be manufactured from SS 316L and may be of anchor, paddle, pitched blade turbine, or other suitable design based on process requirements. The agitator shall be driven through a helical geared motor fitted with a Variable Frequency Drive (VFD) to provide a variable speed range of approximately 20 to 150 RPM. The drive motor shall be flameproof, with a minimum protection rating of IP55 and Class F insulation. A double mechanical seal with an appropriate barrier fluid system shall be provided to ensure leak-free operation.
The reactor shall be provided with all necessary process connections, including product charging nozzle, solvent charging nozzle, vent nozzle, vacuum connection, condenser connection, reflux return connection, sampling valve, flush bottom outlet valve, temperature sensor, pressure gauge, vacuum gauge, safety relief valve, rupture disc, sight glass with illumination, and a quick-opening manhole. Internal baffles shall be provided where required to improve mixing efficiency. A rotary or static CIP spray ball shall be installed to facilitate cleaning in place.
The vessel shall be insulated with 50 to 100 mm mineral wool insulation and externally clad with SS 304 stainless steel sheets. The internal surface finish shall be Ra ≤ 0.8 µm or better, while the external surface shall have a standard matt finish. The reactor shall be mounted on a suitably designed skirt support complete with lifting lugs and earthing terminals.
All fabrication shall be carried out using qualified welding procedures employing GTAW/TIG and SMAW processes. Welds shall be subjected to non-destructive testing, including dye penetrant testing, radiographic examination where specified, and hydrostatic testing at 1.3 times the design pressure. Upon completion, the reactor shall be supplied with all required documentation, including general arrangement drawings, fabrication drawings, material test certificates, quality assurance plan, hydrostatic test certificate, inspection reports, operating and maintenance manual, and other relevant manufacturing records.
