Polymerization Kettle
Reaction Equipment
Polymerization Reactor
1. Product Overview
The polymerization reactor is the core equipment for monomer polymerization in polymer production. It consists of a thick-walled vessel, a high-efficiency agitation system, jacket and internal coil heat exchange, a sealing system and a control system. Designed to handle high-viscosity media, it demands precise control of the exothermic reaction.
Typical applications include PVC and PE polymerization, PS production, synthetic rubber polymerization and resin polymerization.
Equipment features: high heat-transfer efficiency, adjustable agitation shear, anti-fouling design, chloride corrosion resistance and suitability for high-viscosity media.
2. Working Principle
Monomers, initiators and dispersants are charged according to the formulation, and the agitation system disperses the monomer droplets evenly in the dispersion medium to control the polymer particle size. As polymerization is exothermic, cooling water circulated through the jacket and internal coils removes the reaction heat promptly to prevent thermal runaway or runaway polymerization. The control system automatically modulates the cooling-water flow in response to the vessel temperature, achieving isothermal or programmed temperature control. When the reaction is complete, the polymer slurry is discharged through the bottom outlet valve.
3. System Classification
By Polymerization Process
| Type | Process Features | Typical Products |
|---|---|---|
| Suspension | Monomer droplets suspended in water | PVC, PS |
| Emulsion | Monomer forms emulsion with emulsifier | SBR, Acrylic emulsion |
| Bulk | No solvent, direct monomer polymerization | PMMA, Polystyrene |
| Solution | Monomer dissolved in solvent | Butyl rubber, Cis-polybutadiene rubber |
By Agitation Configuration
| Type | Features | Application Scenarios |
|---|---|---|
| Bottom-entering | Eliminates top seal leakage risk | Large PVC reactors |
| Top-entering | Traditional structure, easy maintenance | Small-medium reactors |
| Combined | Multi-layer impeller combination, shear + circulation | High-viscosity polymerization |
4. Detailed Technical Parameters
4.1 Common Materials
| Material | Applicable System | Remarks |
|---|---|---|
| 304 SS | Non-chloride systems | PE, PP polymerization |
| 316L SS | Chloride-containing systems | Recommended for PVC |
| Clad steel (SS+CS) | Large reactors | 316L lining, CS outer layer saves cost |
| Glass-lined | Strongly corrosive systems | Special corrosive polymerization |
4.2 Typical Specification Table
| Effective Volume (m³) | Design Pressure | Design Temp (℃) | Agitator Power | Agitator Speed | Heat Exchange Area (m²) |
|---|---|---|---|---|---|
| 0.3～1 | 1.0～1.6MPa | ≤120 | 3～7.5kW | 80～300rpm | 3～8 |
| 3～5 | 1.0～1.6MPa | ≤120 | 11～22kW | 60～200rpm | 15～28 |
| 7～13 | 1.0～1.5MPa | ≤120 | 30～55kW | 50～150rpm | 30～60 |
| 20～30 | 1.0～1.5MPa | ≤120 | 55～90kW | 40～120rpm | 70～110 |
| 50～80 | 1.0～1.5MPa | ≤120 | 90～160kW | 30～100rpm | 130～200 |
Note: Large PVC reactors (above 30 m³) typically use bottom-entering agitation and combined jacket + internal coil heat exchange.
4.3 Design Conditions & Performance Indicators
| Parameter | Specification |
|---|---|
| Temp control accuracy | ±0.5℃ (Exothermic condition) |
| Heat transfer K value | Jacket: 200～400 W/(m²·K); Coil: 400～800 W/(m²·K) |
| Internal surface roughness | Ra≤0.2μm (Electropolished, anti-fouling) |
| Sealing form | Double mechanical seal (with flush fluid) |
| Anti-fouling measures | Electropolishing, high-pressure water cleaning port |
4.4 Electrical Parameters
| Applicable Region | Voltage | Frequency |
|---|---|---|
| China/Russia/Central Asia | 380V | 50Hz |
| Middle East/Southeast Asia/Africa | 400V / 415V | 50Hz |
| South Korea | 380V | 60Hz |
| Americas (if needed) | 440V / 480V | 60Hz |
Please specify your local voltage and frequency when placing an order.
5. Core Component Selection
| Component | Common Brands | Features & Applications |
|---|---|---|
| Reducer | SEW, NORD, Flender | Hardened helical gear for large reactors |
| Mechanical Seal | John Crane, Burgmann | Double seal with flush/quench system |
| Motor | ABB, Siemens | VFD speed regulation, Ex-proof type |
| Temp control | PLC+Smart regulator | Cascade PID, adaptive to exotherm |
| Safety Valve | Sufa | Set at 1.05 times design pressure |
Customers may specify preferred brands; refurbished units are offered subject to inventory availability.
6. Typical Application Fields
Plastics: polymerization of PVC, PS, PMMA and ABS resins; Rubber: SBR, polybutadiene and butyl rubber; Coatings: acrylic and PU emulsions; Chemical fiber: polyester and nylon polymerization; Fine chemicals: synthesis of functional resins
7. Design Standards & Certifications
| Standard | Description |
|---|---|
| GB/T 150-2011 | Pressure Vessels |
| HG/T 20569-2013 | Mechanical stirring equipment |
| GB 50160 | Fire prevention code for petrochemical enterprises |
| ISO 9001:2015 | Quality Management System |
| CE | Available upon request |
| EAC | Available for Russia & Central Asia |
| GOST-R | Available for Russian market |
8. Customizable Options
| Option | Details |
|---|---|
| Body material | 316L / Clad steel / Glass-lined |
| Stirring form | Bottom/Top entering, multi-layer combined |
| Heat exchange | Jacket+coil, half-pipe jacket |
| Sealing system | Double mech seal + flush system |
| Cleaning system | High-pressure water auto-cleaning (CIP port) |
| Online monitoring | Online viscosity, IR conversion rate |
| Safety config. | Emergency terminating-agent injection, rupture disc + safety valve |
9. Warranty Terms
| Equipment Status | Warranty Period | Warranty Scope |
|---|---|---|
| New Equipment | 12 Months | Body, stirring, sealing, heat exchange, electrical |
| Refurbished Equipment | 6 Months | Body, stirring, sealing, heat exchange, electrical |
| Idle Equipment (As-is) | 3 Months | Main functional parts |
Final warranty terms are subject to the contract. All orders include installation guidance and remote debugging support.
10. Packaging & Delivery
| Item | Packaging Method |
|---|---|
| Reactor Body | Bare with steel straps, flange protected |
| Stirring System | Wooden box, shock-absorbing fixed |
| Internal Coils/Accessories | Wooden box |
| Electrical Parts | Waterproof sealed in wooden box |
Container Capacity Estimation (for reference only):
A 5 m³ reactor fits in approximately one 40'OT container or ships as break-bulk; a 30 m³ reactor ships as break-bulk.
Installation: on-site guidance can be provided. For large reactors we recommend dispatching our technicians (travel and accommodation at the buyer's cost).
11. Information Required for Quotation
To get an accurate quote, please provide:
Required effective volume; Polymerization process (suspension/emulsion/bulk/solution); Monomer and initiator types; Working pressure and temperature; Estimated heat of reaction or required hourly output; Agitation objective (particle size requirement); Cooling water temperature and source conditions; Vessel material requirement; Local voltage and frequency; Equipment status preference: new/refurbished/idle; Budget range and brand preference (if any); Delivery terms: FOB/CIF/DDP; Destination port or delivery address (for freight calculation)