Reactor & Its Types In API Manufacturing

What is Reactors?
Reactors Type in Pharma Industries?
Glass Lined Reactors
GLR Making Process
GLR Vs SSR
Advantage of GLR
Type of GLR’s
Acid / Base Impact
Thermal Shock
Spark Test
Mechanical Shock
Do & Dont’s for glass lined equipment

1. API Production Mein Kaise Hota Hai Kaam Subscribe Watch Full Video By API Pharmaprenuer Tech

2. API Production Mein Kaam Kese Hota Hai : What is Reactors? Reactors Type in Pharma Industries? Glass Lined Reactors GLR Making Process GLR Vs SSR Advantage of GLR Type of GLR’s Acid / Base Impact Thermal Shock Spark Test Mechanical Shock Do & Dont’s for glass lined equipment

3. Glass Lined Reactors : What is Reactor? A Reactor is a kind of vessel with many auxiliary parts like agitator, baffles, thermo well etc. We Can Say it is essentially an industrial "pressure cooker", where the contents (RM / KSM ) are under gone with pressure and/or temperature to for a new desired substance (API / Intermediate. A critical and very important element in production lines Used in the fields of petrochemicals, light industry, pharmaceuticals, pesticide, food, dyes and scientific research

4. Glass Lined Reactors : Reactor Types? Based on MOC, purpose reactors of reactors used in pharmaceuticals industries could be classified as Stainless Steel Reactor Glass Lined Reactors Hastelloy Reactors

5. Glass Lined Reactors : Glass Lined Reactor? GLR are made by spraying liquid glass (enamels) on surfaces of metal vessel to provide high levels of chemical resistance surfaces. The glass coating is sprayed then fused onto the surface of sub-straight material at high temperature, in a repetitive process until the desired glass thickness is achieved. Glass Lined Reactors have a very high corrosion resistance against acidic media with different concentrations. Used in Diverse range of operating condition Easy to clean due to smooth surface. Less chances of contamination / cross contamination due to inert nature of coated glass. Highly Durable if used in favourable conditions

6. Glass Lined Reactors : Glass Lined Reactor MOC? Outer body could be of metal cs / ms etc. Inner body is coated with borosilicate glass of thickness 1.1-1.2 mm. It has low coefficient of thermal expansion. But sudden jerks in temp. Can damage the glass coating.

7. Glass Lined Reactors : GLR Making Process? Shell Rolling Flaring of Nozzle Agitator Welding Finished Fabricated Vessels & Components Blasting Glass Grinding Liquid Glass Spraying Job Firing Glass Lining Inspection Lathe Machine Shop Agitator Machining Fixing Agitator Assembly Hydro Test Run Test Shaft Alignment Dial guage Painting Internal packing Ready for Dispatch

8. Glass Lined Reactors : GLR Vs SSR? Features GLR SSR Corrosion Resistance Universal resistance to all acids, alkalis or bases. Corrode over time with toxic material GOOD ADEQUATE Flexibility Internal Process Change with no investment Investment is required when process variation is required GOOD ADEQUATE Economy Increased life span due to superior lining Vessel Required changing with increase frequency over time GOOD ADEQUATE

9. Glass Lined Reactors : GLR Vs SSR? Features GLR SSR Contamination No Contamination Increased contamination due to aggressive reactions. Then can lead to incorrect processes thus increase cost. GOOD ADEQUATE Cleaning Smooth surfaces & non corrosive property makes task simple. Increased man hours resulting in increased downtime. GOOD ADEQUATE Cost Cheap than SSR Expensive than GLR GOOD ADEQUATE

10. Glass Lined Reactors : Advantage of GLR: 1. Corrosion Resistance They are of superior corrosion resistance to acids, alkalis, water and other chemical solutions  (with the exception for hydrofluoric acid and hot concentrated phosphoric acid). 2. Flexibility The chemical, mechanical, and thermal properties of glass are proof that this material can handle a  diverse range of operating conditions . Users of GLR are therefore able to make drastic changes to their process with no added investment for new equipment needed.  3. Purity Aggressive reaction environments tend to dissolve metals from unlined mild steel or alloy reactors. Extractable metals, such as chromium, nickel, molybdenum, and copper, can leach into and contaminate your product, producing undesired catalytic effects that can cause harmful fluctuations in the process reactions. These metals can compromise product quality, negatively affect product yield, and in some cases even cause runaway reactions. GLR is inert so it is impervious to contamination .  Additionally, it does not adversely affect flavor or color , which is of extreme importance to food and drug applications where purity is essential. 

11. Glass Lined Reactors : Advantage of GLR: 4. Ease of Cleaning In pharmaceutical processes, cleaning is critical & important. Between batches, each reactor and its associated process equipment must be thoroughly cleaned in order to assure product quality. GLR has been adapted to  cGMP requirements for cleaning, cleanliness, and sterilization . Its high degree of surface smoothness makes it easy to clean using non-corrosive, low pressure cleaning systems. The smooth surface of GLR also resists the buildup of viscous or sticky products, which means less frequent cleaning.  5. Economy When properly handled and maintained, GLR can be a  cost-efficient solution compared to steel and alloy vessels , whose service life can be drastically shortened due to their inability to resist corrosion the way glass lining can.  The combination of glass and steel provides you with the best of both materials of construction; fusing glass to steel produces a composite material with an inside that offers product protection and an outside that provides structural strength and durability. 

12. Glass Lined Reactors : Types of GLR: Blue Coloured GLR: Good corrosion resistance for all kind of pH

13. Glass Lined Reactors : Types of GLR: Sky Blue Coloured GLR: Basically used in pharma industry Improve monitoring facilty for cleaning

14. Glass Lined Reactors : Types of GLR: White Coloured GLR: Used for photochemical reactions for observing changes in fluid colour

15. Glass Lined Reactors : Types of GLR: Green Coloured GLR: Used for reactions having temp above 270 deg C.

16. Impact of Acid : Impact of Acid on GLR: Never use GLR for HF, Conc , Phosphoric acids & Phosphorus acids bcz these acid reacts with glass and damage the coating. Glass lined are resistant to corrosion but rate of corrosion depends on conc. & temp. Of acid.

17. Impact of Base : Impact of Base on GLR: Corrosion due to bases is more severe than acids Greater the conc. & pH, corrosion will be greater. Temp. Plays important role: an increase of 10 deg c will double the rate of corrosion.

18. Thermal Shock: Glass fused on metal substrate at 870Deg C Glass solidifies at 325deg C on the surface of metal substrate As further cooling proceeds glass has low coefficient of thermal expansion than metal Glass is under some stress level. If temp. Change is abrupt the change in compressive stress in glass will also be abrupt causing the glass to break.

19. Spark Test: Done to check any damage in lining Done with 5KV AC/ DC source Where there is damage will generate spark frequent testing must be avoided as it decrease the life of GLR.

20. Mechanical Shock: Damaged due to lifting Damaged due to fall of object inside the reactor Due to use of highly viscous liquid

21. Glass Lined Reactors :

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