Horizontal Reactors

DanChem has the largest fleet of horizontal reactors of any custom chemical contract manufacturer, ranging from 130 liter capacity in our pilot, to 15,000 liter capacity for commercial production.

With these reactors and our expertise, we can go from liquids to slurries to powders in one reactor, saving our customers time and money. One of the main benefits of horizontal reactors is the ease with which processes can be scaled. We have been able to pilot processes in our 130 liter unit, then scale to our largest unit in just a matter of days, with no loss of product quality or unexpected changes in cycle time.

Horizontal reactors lend themselves to a wide variety of chemistries and processes. While their most common usage is for removal of water or solvents to prepare a powder (often while going through a viscous, dough phase), due to their configuration and the resultant high heat transfer rates and efficient mixing, they can be used in a variety of ways.

Our horizontal reactors are used to strip monomers and/or solvents from highly viscous polymers, at viscosities much higher (over 1 million centipoise) than could be processed through a conventional wiped-film evaporator. The efficient agitation of horizontal reactors has enabled their use in powder coating applications, and the combination of agitation with high heat transfer enables their use in difficult coating applications, such as those that require rapid cooling to protect a sensitive material such as a protein.

Horizontal reactors are known for their efficient mixing, and thus we have been able to prepare highly concentrated polymer solutions, at viscosities higher than could be achieved in a traditional stirred tank reactor. The ability to prepare materials at high concentrations often leads to the elimination of a second, solvent stripping step, leading to better economies. We are often able to correlate torque on the reactor agitator with polymer viscosity and ultimately molecular weight, and it becomes much easier to stop a reaction once the desired molecular weight has been reached. Horizontal reactors also lend themselves to processes other than chemical manufacture, such as agglomeration, impregnation, and blending.

What often takes 2 or 3 vessels to prepare in a conventional reactor train can be accomplished with a single horizontal reactor. We combine horizontal reactor technology with traditional vertical reactor technologies to offer unprecedented processing flexibility where appropriate. What can we make for you today?