Large reactors usually have a capacity of 500L or more and can be applied mainly for reaction, synthesis, extraction, polymerization, and crystallization processes. They are commonly used in the chemical, pharmaceutical, and new materials industries.

Since most industries have their special temperature demands, temperature control systems should be implemented the assist in elevating, decreasing, and keeping a constant temperature steady. Industrial chillers with precise temperature control are ideal partners for large reactors.

What kind of chiller is required for large reactors? How to select the correct equipment?

How to Control Temperature in Large Reactors？

Chemical reactions for large-scale reactors are usually exothermic or endothermic and require very stringent temperature control for maintenance of reaction rate, product quality, and reaction safety. It is the function of a chiller for maintaining the temperature in the jacket reactor stable within a desired range for a safe reaction process with efficiency.

Cooling Capacity

If the heat generated during the reaction in a large reactor cannot be removed promptly, the reaction temperature will rise rapidly, affecting reaction stability and product quality. Therefore, the chiller’s cooling capacity should be slightly greater than the reactor’s maximum heat load to ensure that the reactant temperature can be quickly reduced to the set value under all operating conditions.

Temperature Uniformity

Larger reactors are big in capacity. When the heat transfer is non-uniform, there can be spots which cool off to the desired temperature whereas spots which remain high can cause variations in reaction rates. This can produce non-uniform distribution of products or side reactions.

Temperature Control Accuracy

Large reactors hold more material, which contributes to a certain lag in responding to changes in temperatures. Additionally, temperatures can be different at various points, but a temperature sensor can only indicate the temperature at a given point. Additionally, material distribution uniformity can contribute towards temperature non-uniformity and a loss of accuracy in temperature control. These factors contribute towards a more difficult temperature control scenario in large reactors compared to small devices.

Suitable for Different Processes

Many times large reactors are employed in a series of applications whose temperature ranges vary. Some need low temperatures, others high temperatures, yet others need continuous cycling between low and high temperatures. For an application of this type, a dynamic temperature control system with a high temperature span along with variable rates of heating and cooling is needed in order to minimize equipment changes, which subsequently can interfere with production run schedules.

Flow Rate and Flow Velocity

In order for heat exchange efficiency and pipeline pressure to be balanced, the chiller’s flow rate and flow velocity have to be rationally designed. Take the pipe lengths and diameters into consideration for ensuring there is sufficient coolant flowing throughout the jacket or coil.

Safety

Large reaction cooling systems operate under conditions of high temperature, high pressure, even corrosive medium. They must be of very good sealing capacity and overall safety features in an attempt to minimize safety hazards. For reaction processes involving flammable, explosive, or toxic reactants, overall safety-certified explosion-proof chillers should be used in an attempt to achieve safe reaction operation.

Automatic Control

In order to reduce errors due to human factors and decrease labor intensity, large reactor chillers are equipped with thorough automated control modes. Automated real-time temperature measurement enables quick changes of cooling/heating parameters without manual intervention. In addition, automated control provides multiple interlockings and alarm features for expedient responding to abnormal states. In addition, it automatically summarizes data for convenience of analysis and optimization of processes.

Common Chillers Used in Large Reactor Systems

Low Temperature Chillers

Low-temperature chillers serve in low-temperature reaction processes with temperatures ranging from as low as -40°C or even lower. They generally employ a glycol-water solution as the cooling agent for the jacket. These serve in condensation industries, cryogenic extraction industries, and freeze-dry industries.

Oil Chillers for Large Chemical Reactor

Thermal oil is employed as the coolant in oil chillers for applications involving high reaction temperatures or extreme temperature changes, for instance high-temperature polymerization, catalytic reaction, and precursor synthesis. It is highly stable at high temperatures and under normal operating conditions will not cause significant oil mist in closed-loop oil chillers.Furthermore, it has a wide operating temperature range, making it an ideal choice for chillers requiring a wide temperature range.

Chiller Heaters

Chiller heaters integrate cooling and heating functions, enabling rapid temperature ramping and cycling based on the real-time temperature of the reactants. Some units feature temperature profile control, allowing for customizable temperature ramp times and rates. This makes them ideal for processes requiring temperature cycling or step-by-step ramping.

LNEYA Temperature Control Solutions for Large Reactors

Looking for a temperature control system suitable for large reactors? LNEYA offers a variety of temperature control equipment, including air-cooled chillers, water-cooled chillers, glycol chillers, oil chillers, and chiller heaters. We can design and manufacture them to your specific needs.

Contact us today for free selection advice and case studies.

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