Insights into Resin Reaction Kettles: Structure, Materials, and Applications
Ⅰ.Overview of Resin Reactor
The broad understanding of a reactor is a stainless steel container for physical or chemical reactions. The structural design and parameter configuration of the container are carried out according to different process conditions. The design conditions, process, inspection, manufacturing and acceptance must be based on relevant technical standards to achieve the heating, evaporation, cooling and low-speed mixing reaction functions required by the process.
The reactor is a comprehensive reaction vessel. The design of the reactor structure, function and accessories is based on the reaction conditions. From the initial feeding-reaction-discharging, all the pre-set reaction steps can be completed with a high degree of automation, and important parameters such as temperature, pressure, mechanical control (stirring, blowing, etc.), reactant/product concentration, etc. during the reaction process can be strictly regulated.
Its structure is generally composed of kettle, transmission device, stirring device, heating device, cooling device and sealing device. The corresponding auxiliary equipment includes fractionation column, condenser, water separator, collection tank, filter and so on.
Resin reactor material:
Reactors are generally made of carbon manganese steel, stainless steel, zirconium, nickel-based (Hastelloy, Monel) alloys and other composite materials. Reactors can be made of stainless steel materials such as SUS304 and SUS316L. Agitators include anchor type, frame type, paddle type, turbine type, scraper type, combined type, etc., rotating mechanism reducer and stepless speed reducer or frequency conversion speed regulation, etc., which can meet the special reaction requirements of various materials. The sealing device can adopt sealing structures such as mechanical seal and packing seal.
Heating and cooling can adopt structures such as jacket, half pipe, coil, Miller plate, etc. The heating methods include steam, electric heating, and heat transfer oil to meet the process requirements of different working environments such as acid resistance, high temperature resistance, wear resistance, and corrosion resistance. It can also be designed and manufactured according to user process requirements.
At present, there is a stainless steel reactor with a capacity of up to 10m3 and built-in cooling and heating coils. The exchange effect is much better than that of the interlayer, and the production efficiency is higher, but the cost is also high. Large rubber producers can consider this type of reactor. It is convenient to manufacture and maintain, but it requires a higher level of operation. Since the reaction is not easy to control, the relevant cooling facilities must keep up.
For some adhesives, impurities or metal ions may affect the normal polymerization reaction, so all pipelines, valves and reactors are required to be made of stainless steel or acid-resistant enamel to ensure product quality.
Ⅱ. Classification of resin reactors
Resin reactors are divided into high temperature resin reactors (150~300℃) and low temperature resin reactors (60~150℃) according to the reaction temperature. Resin reactors are key equipment for the production of unsaturated polyester resins, phenol resins, epoxy resins, ABS resins, and paints.
The complete set of resin equipment consists of a reaction pot, a vertical fractionating column, a horizontal condenser, a water storage tank, an oil overflow tank, a pipeline (a dilution kettle, also called a dilution kettle), etc. The parts of the whole set of equipment that come into contact with the materials are made of stainless steel. Stainless steel coils can be set in the reaction pot or in the jacket.
The reactor series 50-10k little includes 17 types: stainless steel reactor, electric heating reactor, steam reactor, jacketed reactor, coil reactor, external coil reactor, silicone oil reactor, resin reactor, polyester reactor, additive reactor, viscose reactor, raw rubber reactor, latex reactor, 107 glue reactor, PU glue reactor, varnish reactor, shoe glue reactor, etc.
The following focuses on the classification based on different production processes.
(1) According to the heating/cooling method, reactors can be divided into electric heating, hot water heating, thermal oil circulation heating, far infrared heating, external (internal) coil heating, jacket cooling and internal coil cooling. The choice of heating method is mainly related to the heating/cooling temperature required for the chemical reaction and the amount of heat required.
(2) According to the material of the reactor body, it can be divided into carbon steel reactor, stainless steel reactor, glass-lined reactor (porcelain reactor), steel-lined PE reactor, and steel-lined ETFE reactor.
① Carbon steel reactor is applicable to environments without corrosive liquids, such as some oil processing
② Stainless steel reactor (KCFD series high pressure reactor)
a. Heating structure types include electric heating type, jacket type, external coil type, internal coil type, and the volume is 0.01~45m°.
b. Material: carbon steel, stainless steel, high temperature resistant stainless steel, strong acid and alkali resistant stainless steel, enamel or PP material, etc.
c. The stirring types include inclined blade type, anchor type, frame type, propulsion type and single (double) screw type. Other types of blades can be designed and manufactured according to customer requirements.
d. Scope of application: It is suitable for high temperature and high pressure chemical reaction tests in petroleum, chemical industry, medicine, metallurgy, scientific research, colleges and universities, etc., to complete the process of hydrolysis, neutralization, crystallization, distillation, evaporation, storage, hydrogenation, alkylation, polymerization, condensation, heating mixing, constant temperature reaction, etc., and it is suitable for the treatment of viscous and granular
③ Glass-lined reactor, its applicable scope: widely used in petroleum, chemical, food, and medical quality to achieve high stirring effect.
④ Steel-lined PE reactor is applicable to: acid, alkali, salt and most alcohols and liquid pesticides, scientific research and other industries. Food and medicine refining. It is the ideal material for rubber-lined, glass fiber reinforced plastic, stainless steel, titanium steel, enamel, plastic welding plate.
⑤ The applicable scope of steel-lined ETFE reactor: It has extremely excellent anti-corrosion performance and can resist substitutes of various concentrations.
Acids, alkalis, salts, strong oxidants, organic compounds and all other highly corrosive chemical media. (3) According to the internal pressure during operation, it can be divided into normal pressure reactor, positive pressure reactor and negative pressure reactor. (4) According to the stirring form, it can be divided into paddle type, anchor paddle type, frame type, screw belt type, turbine type, dispersed type and combined type.
(5) According to the heat transfer structure, it can be divided into jacket type, external half-tube type, internal coil type and combined type.
Ⅲ. Structural characteristics and material characteristics of resin reactor
1. Structural characteristics
(1) The transmission mechanism is composed of a motor, a reducer, a frame, a coupling, a bearing, a connecting plate, etc. (2) The thickness of the plate of the reaction vessel (kettle) is determined according to the capacity and the design pressure required for the material reaction; the material is generally stainless steel (304 stainless steel, 321 stainless steel, 316L stainless steel) and carbon steel (A3) (3) The heat transfer device includes a jacket, an inner coil, an outer coil, etc.; it adopts organic heat carrier circulation (heat transfer oil or steam, hot water, etc. for heating and cooling water, chilled water, cold heat transfer oil or natural wind, etc. for cooling (4) The stirring device includes a double propeller stirring, an anchor propeller stirring, a double propeller stirring, a turbine propeller stirring, a dispersion plate, a butterfly propeller, etc.
(5) Stirring speed The stirring speed is selected according to the material stirring requirements. Generally speaking, when several liquid materials need to be mixed and reacted, 50~85r/min is selected. If it is required to disperse powder into liquid, 500~1500r/min is generally selected. If it is required to emulsify oil in water or emulsify and mix two incompatible liquids, 2500~3500r/min is generally selected.
(6) Sealing devices include mechanical seals, packing seals, etc.
(7) The accessories of the complete set of reactor equipment generally include distillation columns, heat exchangers, water separators, etc.
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2. Material characteristics
(1) Material: Stainless steel has excellent mechanical properties and can withstand high working pressure and the impact of bulk solid materials when they are fed.
(2) It has good heat resistance and a wide operating temperature range (-196~600℃). It will not oxidize or peel at higher temperatures and can be used for direct open flame heating.
(3) It has high wear and corrosion resistance.
(4) Good heat transfer effect and fast heating and cooling speed.
(5) It has excellent processing performance and can be made into reactors of various shapes and structures according to different process requirements, and can also be ground and polished.
Ⅳ.Technical parameters of resin reactor
Reactor temperature: room temperature ~ 300℃ or higher, depending on working conditions.
Reactor reaction pressure: 0.001~0.8MPa.
Reactor equipment material: SUS304 stainless steel, SUS321 stainless steel, SUS316L stainless steel or Q235-B carbon steel.
Reactor stirring forms: paddle type, anchor paddle type, frame type, screw ribbon type, turbine type, dispersed disc type, combined type and other forms of stirring.
Reactor heating: electric heating, steam heating, water bath heating.
Heat transfer medium for reactor: thermal oil, steam, hot water, electric heating.
Reactor heat transfer structure: jacket type, outer semi-coil type, inner coil type.
Reactor complete equipment accessories: generally include distillation column, heat exchanger, water separator, etc.
Reactor stirring speed: The stirring speed is selected according to the need for stirring and mixing the materials; for conventional liquid material polymerization reactions, the speed is 63~85r/min; when mixing powder materials with liquids to achieve a dispersion effect, the speed is 500~1500r/min; when mixing oil and liquid or two incompatible liquids to achieve an emulsification effect, the speed is 2500~2800r/min.
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Ⅴ.Conclusion:
The resin reaction kettle is an essential component in the chemical and industrial sectors, offering versatile functionality to meet diverse processing needs. Its robust structural design, high material adaptability, and precise control mechanisms ensure efficient and reliable production of resins and other chemical compounds. With advancements in material technology and customization options, these kettles are poised to support increasingly complex and high-performance industrial processes.
At Z-MIXER, our dedication is to enhance the quality of your product to the utmost standards. Whether it involves milling, mixing, dispersion, or agitation, arrange for your product to be evaluated in one of our demonstration machines to personally experience the distinctive Z-mixer advantage.
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