Glass Reactor & Glass Pilot Plant Manufacturers

A pioneer and a global leader in designing, manufacturing, and supplying the Kilo Lab Glass Reactor and Pilot Plants, Ablaze Export Pvt. Ltd. is here to serve you better with better quality industrial equipment. We manufacture our products using all premium quality materials such as Borosilicate glass, which is used in designing our Kilo Lab Glass Reactor along with the overhead condensers and the heat transfer systems having attached process controls.

We manufacture and supply customized Kilo Labs designed with all the necessary and cleverly accessible fill-up points, collecting points, and sampling points to gain significant control of all the processes in the Kilo Lab. We manufacture the glass reactors so transparent that you can have an explicit vision of the entire process and can observe, record data, and analyze the process in real-time for the optimization as per the requirement.

Ablaze Export Pvt. Ltd. offers you a wide range of customized distillation systems assembled with the Jacketed Glass Reactor for Kilo Lab. It includes the condensers, vapor column, dean stark, reflux provision, add on and receiver vessels, phase separator, along with various valves placed at an appropriate distance, and all the other supporting metal structures. All our units are supported by the TCU (Thermal Control Unit) that helps the circulation process in the Jacketed reactors. We also manufacture and offer a triple wall glass reactor for the kilo labs and pilot plant that has 50 liters of working capacity.

Pertinent Features of Kilo Lab Glass Reactor

• Suitable for high value, low volume production from 25 liters to 630 liters
• Transparency for Better Understanding during Process Development
• Glass Lined Reactor for Cryogenic (-90ºC) Reaction
• Glass Lined Steel Stirrer for Zero Contamination
• High mechanical stability & heat transfer
• Baffle with PT100 temperature sensor provided
• Twin Distillate Receivers for continuous operation without breaking a vacuum
• CIP Capable

Fundamental Objective

The prime objective of the Kilo Lab Glass Reactor is to produce a simulation for flexibility and agility to guide a compelling portfolio of a resulting potential product along with maintaining the standard Environmental Health and Safety (EHS) Policy and the product quality as well.

Kilo Lab is known to help in manufacturing the small number of Products from the active pharmaceutical elements and also in evaluating the production as well as the development process before starting the commercialization plant.

Kilo labs support the discovery of the fact if the promising product is extensible in the Kilo lab or not and if it can save your business from high expenses and more research time.

We do understand the fact that constructing and running a developing process in Kilo Lab only once will never assure that the product with the same potential and qualities will be created in the cGMP manufacturing process.

That is why we are in a constant race of developing and designing Kilo Lab Glass Reactor in such a manner that you will be able to test your new processes several times even before shifting them to the development stage in the pilot plant.

Ablaze Export Pvt. Ltd. intends to offer the definitive distillation systems with the Glass Lined Reactor along with the other assembly items as same as type AGR. This will undoubtedly help to upscale it up to the production design, and it helps in replicating the conditions of the production process much more closely.

The construction material is indeed a prime aspect in the equipment selection process, exclusively when you are dealing with a product that demands a higher level of corrosion resistance property and purity too. In this case, the glass, as well as glass linings, are the most likely choices among the top ones. Both of them offer similar benefits; however, some distinct differences highlight their characteristics separately.

Pertinent Features of Glass Lined Reactor With Glass Cover

• It is highly suitable to have a significant value, a low volume production level making it work from around 25 liters to 630 liters.
• It has clear visibility or transparency that would work better to have a fair understanding during the development of the whole process.
• The Glass Lined Reactor is capable of working for cryogenic reactions under the temperature around -90°C.
• It has a Glass Lined Steel Stirrer that helps to achieve zero contamination.
• It has excellent mechanical stability and supports the heat transfer.
• It is CIP Capable.
• It is equipped with twin distillate receivers to keep the operation continuing without breaking a vacuum.
• It baffles with the PT100 when the temperature sensors are provided.

Advantages of Glass Lined Reactor With Glass Cover

The mixture of metal-glass material in the production administers the advantages of both of the prime peripherals. Extraneous steel production will offer much-needed strength to the Glass Lined Reactor. At the same time, the lining on the internal glass will surely give them protection against global corrosion and also have a non-contaminating smooth surface. It will result in the following:

• A corrosion-resistant property against both the acids as well as the bases.
• Immense operating pressure and temperature.
• The ability of adding and removing the heat to the batch.

The combination of Glass Reactor with Rectification Column (borosilicate glass 3.3 distillation attachments) is an attractive approach that has been used effectively in the chemical and pharmaceutical industries.

In general, there is an important position in the manufacture of highly refined and highly pure products such as fine chemicals, plant protection agents, vitamins and pharmaceuticals, metal-free and highly corrosion-resistant material.

Best Manufacturer, Supplier & Exporter of Glass Reactor with Rectification Column, providing top notch after sales services to our clients with 100% satisfaction.

The working theory of the laboratory rectification tower: fluid mixing by partial gasification and condensation for several periods, as the various components have different instability characteristics, so that they can achieve the objective of mixture separation.

The rectifying glass reactor is famous for cleaning spices, intermediate pharmaceutical, new material, etc. For practice, the “reaction” and “distillation” processes are often sequentially performed to ensure that the initial materials react to the target products within the same equipment.

Key Features :

• Integrated stainless steel tube, mobile frame structure, reaction vessel cover with 5 necks for re-fluxing, liquid feeding, temperature measurement, etc.
• Borosilicate glass3.3, good chemical and physical properties.
• PTFE seal, to keep high-precision sealing under poor working state.
• Japan technology AC gear reducer motor, strong torsion, no noise.
• PTFE stirring paddle is suitable for stirring and mixing different kinds of materials.
• PTFE discharge valve can discharge materials thoroughly and quick.

Types of Applications :

• Boiling under reflux and coil heat exchanger distillation
• Boiling with shell and heat exchanger under reflux and distillation
• Distillation with phase separation
• Vacuum distillation
• Rectification purpose

Glass Mixing  Reactors (movable) are preferably used for wide applications in laboratory, pilot plant & for small-scale production. They reduce the need for investment in permanent installations & also reduce the pressure & temperature losses resulting from pipeline installation. A mobile vessel is perfect for pilot plant and production use to transport and store products.

These reactors are available with spherical shape & in a cylindrical shape. These reactors are also available in cylindrical jacketed form.

In the pharmaceutical and chemical industries, a Jacketed Reactor is used to control the temperature of its content via a heating or cooling jacket made around the vessel by circulating heating or cooling fluid through the jacket. Agitation is usually used in Jacketed Glass Vessels to improve the level of homogeneity in the properties of fluids such as concentration and temperature.

The essential part of all the chemical processing units is a reactor. Hence it is widely accepted as the ‘heart’ of the processing system because it is considered as the most crucial component in the chemical industry.

A glass reactor made from Borosilicate is known to offer a unique advantage of the visibility of reactions happening inside the reactor, which no reactor made from other materials can give. However, the user’s visibility advantage is compromised when the traditional methods are used to heat the contents inside the glass reactor. This provoked the industrialists to develop the Jacketed Glass Reactor Vessels.

The design of a Jacketed Glass Reactor is made up of a vessel that is bounded by a layer like a jacket made up of glass through which the cooling and heating fluids are passed. The jacket is considered to be an isolated chamber around the vessel inside and is placed in a way that the content present inside of the vessel does not pose a direct contact with the jacket. Concerning various requirements, a nozzle is also provided in the jacket for venting purposes.

The process of heat transfer happens across the walls of glass between the jacket and the inner vessel; moreover, the vessel is manufactured in such a way that the total area of the jacket always covers the ostensible volume of the whole reactor. The nozzles come with the universal M16/M30 connections; hence, you can connect the reactor to any internationally acclaimed Temperature Control Unit (TCU).

Single Jacketed Reactors and double jacketed reactors are both used to perform particular reactions. Usually, in the single jacketed reactors, the area of the jacket is used to circulate fluid that will control the temperature of the reaction within the vessel. However, sometimes the need for an additional jacket arises for insulation purposes; that is when the double jacketed reactor comes to use.

These reactors consist of the usual accessories such as valves, stirrer, and support structure required to build a reaction unit. If you want to install a vapor nozzle, you have the liberty to assemble it as per the requirement.

These reaction units are highly customized, and its design varies from customer to customer as per their requirements. Standard units of 50 Litres capacity can be used for general reactions.

Options of Jacketed Glass Reactors

Jacketed Reactors can be customized concerning various options concerning their size and utility.

Below are the options available in Jacketed Glass Reactor Unit:

• Stirrer Drive: Has a non-flameproof or flameproof Motor, Ex-proof, which runs at 250 RPM with the in-built speed regulator.
• Stirrer for Construction material: It is made up of glass or is lined by PTFE, Hastelloy, SS316L.
• Stirrer shape: It comes in a variety of stirrers such as the Glass Impeller Stirrer with an in-built PTFE Blades, a Vortex Stirrer, a propeller stirrer, and an anchor stirrer.
• Stirring Assembly: Stirring Assembly comes with a mechanical or a bellow seal.
• Supporting Structure: Can be made up of Epoxy coated Carbon Steel, Carbon Steel, Stainless Steel with 304 and 316 variants. All these structures can be made available to you in the Trolley mounted form as per your requirements.
• Closing Valve: It is designed to drain or flush the bottom outlet.

Advantages :

• Pt100 sensor works accurately in measuring high temperatures and small errors, which will improve the work efficiency and make it better;
• The heating or cooling material poured in the interlayer of the reactor can be released after the completion of the reaction; hence, no liquid gets compiled;
• The overall column made with Stainless Steel frame structure is strong enough to last long. It comes with a five reactor lids, a full set of reflux, external addition of liquid, and a tool to measure the temperature;
• It is built with substantial torque and is absolutely noiseless. AC gear reduction motor made with Japanese technology is endorsed;
• Stirring paddle made up of double-tetrafluoroethylene is specially designed for such glass reactors as they are highly suitable for mixing of any liquid material regardless of low or high viscosity.

Salient Features :

• It is built with Borosilicate glass 3.3 and has excellent physical as well as chemical properties.
• It has an inbuilt ATEX Motor, a digital display that shows the mixing speed, a frequency conversion tool, and it is brushless, the mixing system works at a constant rate, it is sparkless, absolutely safe and stable.
• It is manufactured with rugged steel and reinforced PTFE stirrer along with an anchor agitator that favors a variety of material viscosity.
• It has PTFE discharge valves that can discharge or dispose of the materials quickly and thoroughly.
• It is proven to work under pressure as well as in the vacuum conditions, under the vacuum.
• The Ex-proof motors can be attached as an option for 10L, 20L, 30L, 50L, 100L, 150L.
• The whole structure is unique, practical, and beautiful.

Working :

• The cooling or heating liquid is injected in the space between the glass walls of the jack and the inner vessel.
• You can now connect a double lined glass reactor with an external cooling or heating equipment.
• Start the agitator so that the heat generated by the agitator can stir the content inside the vessel at the constant speed.
• It is proven to react and stir under the natural pressure as well as the negative pressure while in a sealed reactor.
• The outlet valve can be used to empty the material from the bottom of the reactor. It is quite an easy task to operate the reactor.
• The reactor can ideally be used as an instrument that is meant for conducting the experiments of modern chemistry, Pharmacy, Biochemical tests, and the advanced synthetic.

Jacketed Glass Vessels can be used in which industries?

Jacketed Glass Vessels are the most common equipment to be used in industries such as petrochemical, pesticide, rubber, pharmaceutical, dye, and also some industries use the Jacketed reactors to complete the process of sulfonation, hydrogenation, nitration, polymerization, alkylation, condensation, and many other means as well.

This is a unique combination for storage most reactive & hazarded chemicals in a glass, we are manufacturing horizontal or vertical borosilicate glass Reactor / Tanks are a cost-effective solution for chemical storage.