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Reaction

Don’t jeopardize proving your process technology by producing inferior product in your pilot plant. Optimized reaction equipment will keep your reaction in-control and happening at a rate viable for commercialization. Our process experts implement proven pilot plant reactor solutions that balance reaction kinetics while selecting commercial-level equipment that meets your measurement, production and budget goals.

We work with a variety of reactions for demonstration modules and pilot skids, including:

  • pilot plant reactorDecomposition reactions
  • Double-replacement
  • Neutralization
  • Oxidation
  • Precipitation
  • Synthesis
  • Single-replacement

To get started on a quote for your custom pilot plant reactor today, call (314) 845-0077 or contact an EPIC engineer.

Examples of Proven Pilot Reactor Modular Plants by EPIC:


Catalytic Reaction Technology Commercialized with Batch Pilot Plant Reactor 

pilot reactor modular systemsA proprietary catalytic technology involving an ion-exchange reaction was proven commercially successful with a batch reactor pilot plant by EPIC. The pilot plant allowed the chemical company client to successfully scale from lab-sized and demonstrate the feasibility of a full manufacturing facility. With over fifteen sampling points, the system also allowed extensive data collection on the hazardous end-product. A full-scale production facility for the process followed the pilot plant tests.

Key Features: Catalytic reactor, scale-up of R&D process, low flow, highly corrosive, effluent treatment system, Teflon lined piping, tight footprint

Flexible Demonstration Plant Increases Production by 60%

pilot scale reactor

An automotive chemicals company needed a solution for producing small-run custom formulations for it’s end customers. EPIC provided a pilot skid that replaced an existing semi-automated system and featured better batch management software. This module expanded production by 60% for the company, allowing it to further refine internal product testing and sell larger amounts of customized formulations.

Key Features: Batch reactor, batch management software, permanent pilot plant.

Styles of Reactors:

Reactors come in two styles; batch or continuous. EPIC works with both technologies, though batch is more common in pilot plant scale. Read more details below, or contact an engineer today to start discussing your specific project.

Batch reactor systems


pilot reactorBatch reaction can be semi-automated or fully automated, depending on your needs. With expert integration of batching equipment and batch management software, you can easily track product runs, end-product and scrap from washout.

Controlling your reaction and providing high-quality end-product while meeting your budget is our goal. Reactions with extremes like full vacuums and high pressure can be handled by our proven pilot plants as well. EPIC’s engineers have over 20 years of experience designing reaction system for commercial environments and will guide your system through the necessary steps to reach fully commercial realization.

Continuous reactor systems

pilot plant reactorWhile less common in pilot plants, continuous reaction systems can be integrated into demonstration modules. Continuous stirred reactors (CSTR) and in-line reaction systems are the most common systems we work with.

Like with batch reactors, our team has over twenty years of experience designing reactor systems for manufacturing environments. We will scale your continuous reaction system to successfully work at production levels, while equiping your system with the instrumentation to take key measurements that will help you perfect end-product.

Contact EPIC by filling out a contact form or calling (314) 845-0077 to discuss your specific reaction technology and get started on a quote for a pilot plant today.

 

Next Steps: Custom Pilot Plant Design


The starting place for every project is a discussion about our fit your technical and commercial goals. Contact an Engineer (314) 312-3370 to start this discussion. If we both decide to move forward, your project will progress through our turnkey design/build process which includes:

  • EPIC’s Front-End Engineering
  • Demonstration plant design
  • Process controls engineering
  • Modular fabrication and testing
  • System installation
  • Start-up and commissioning

Reaction Equipment:

Listed below are the major types of reactors and a simplified guide to when they are appropriate. We work with most major reaction equipment, depending on the application.

Batch Reactors

Type of ReactorUses
General batch reactors

  • Relatively slow reactions

  • Include heat transfer mechanisms to maintain steady temperature range

  • Majority = liquid phase

  • Most flexible reactor type – can have wide range of reaction times for a wide-variety of reactions

Continuous Reactors

Type of ReactorUses
General continuous reactors

  • For large quantities

  • Feed rate controls reaction rate

  • Residence time and volume are relatively fixed

  • Product is more consistent in quality

  • Generate less waste than batch

Continuous stirred tank reactors (CSTR reactors)

  • Used for greater production rates with relatively short reactions

  • Can be used singularly or in-series

  • Steady state reactions in liquid phase are the most common application

  • Best for immiscible liquids

Tubular

  • Gas-phase and liquid phase reactors

  • Short reaction times are typical

  • Elevated temperatures

  • Frictional pressure drop is an important factor for this type of reactor

Plug flow(PFR reactors)

  • Low and medium temperature capabilities

  • Variable residence times

  • Low cost

  • Best used with diluted reactants

Packed bed flow reactors (fixed bed reactor)

  • Similar to a plug flow reactor, but packed with catalyst beads

  • Catalyst helps maintain reaction at a level temperature

Fluid bed reactor (FBR)

  • Used for multi-phase reactions

  • Catalysts are optional

  • Medium to high velocity

  • Uniform particle mixing and uniform temperature gradients

Contact an engineer to start designing your custom reactor system today.

Case Studies: See More Examples of Past Projects

case-studiesDetailed descriptions of turnkey pilot plants, demonstration modules and commercial plants that EPIC has built.

Video Gallery: Watch Clips of Projects, Methods & More

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Pilot plant videos of turnkey projects and the proven design & construction process EPIC follows to successfully create them.

Press Releases: Read the Latest News from EPIC

Press Releases

Completed pilot plant projects, company accolades and job openings – read about them all here.

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