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:
- Decomposition reactions
Examples of Proven Pilot Reactor Modular Plants by EPIC:
A 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
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
Batch 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
While 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
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.
|Type of Reactor||Uses|
|General batch reactors|
|Type of Reactor||Uses|
|General continuous reactors|
|Continuous stirred tank reactors (CSTR reactors)|
|Plug flow(PFR reactors)|
|Packed bed flow reactors (fixed bed reactor)|
|Fluid bed reactor (FBR)|
Contact an engineer to start designing your custom reactor system today.