To manually charge different gases at desired pressure upto 140 bar (Kg/cm²) / 2000 psi or higher into the reactor from gas cylinder. Nitrogen, Oxygen & Hydrogen can be charged through same regulator(with special adaptor). Regulator for other gases like NH3, CO2 etc. can also be offered. The regulator comes with SS braided teflon high pressure hose pipe (4m long), by pass valve, non return valve (NRV), quick release coupling (QRC) & pressure gauges.
Gas boosters are useful when the cylinder pressures are much lower than the autoclave rated pressures. In such case the booster takes gas at lower pressure from cylinder & compresses the same to deliver at higher pressures upto 5000 psig. They are generally pneumatically operated. Special gas booster pumps are available for liquid CO2 used in supercritical Fluid Extraction System.
Mass Flow Meters (MFM) can be used to measure the accurate mass flow rate of gas (in gm/hr or / LPH) & totalised quantity of mass (in gms or ltr.) charged in autoclave at any point. Mass flow controller (MFC) is used to charge the set flow rate of gas into the autoclave at high pressures up to 350 bar / Kg/cm² or it can be used in pressure control mode to indicate the gas flow & total gas uptake to maintain desired set pressure inside the autoclave. The same MFM / MFC can be used for multiple gases by just entering the conversion factor for different gas densities provided the gases are inert to each other. The MFM/MFC comes with high pressure flexible hose, inlet filter, NRV & QRC with digital gas flow indicator cum totaliser & additional pressure PID controller with pressure sensor if the MFC is used in pressure control mode. User has to specify the max. flow rate range, pressure & gas for ordering MFM/MFC.
It consists of pressure sensor (transmitter) & digital pressure indicator/ controller (mounted on common control panel) with pressure alarm & optionally heater cut off for safety. Digital pressure indicator has pressure reading in bar & psi. where as controller reads any one of the units. The controller is normally used with mass flow controller (MFC) or solenoid/flow control valve to maintain constant pressure inside the autoclave. With MFC, gas flow indication & totaliser are also provided on the same panel. The pressure sensor has temperature limitation upto 80°C & hence the same is provided with water cooling jacket. Optionally intrinsically safe pressure sensor with IIC certification is provided. Pressure sensor with Hastelloy C-276 / Tantalum/ Monel diaphragm & wetted parts can be offered on request.
»
All standard high pressure hose supplied are flexible SS braided Teflon hose with 2000psi pressure rating unless specified.
»
Complete mounting of all the accessories shall be done on autoclave stand / trolley.
»
All the indicators / controllers are mounted on a common SS panel.
It is used to transfer liquid or gases in to the autoclave under pressure. It consists of high pressure SS-316 pot designed for working pressure 100bar (kg/cm2) or higher with port for Nitrogen gas (N2) pressure vessel, liquid inlet, liquid outlet, pressure gauge, pressure safety valve, high pressure hose, QRC, & NRV. The liquid to be charged is fed into the pot from top funnel & pressurised with N2 gas until its pressure is higher than the autoclave pressure & then under pressure the liquid is charged into the autoclave. The quantity & rate of flow of liquid charged is not known precisely in this system. However a level indicator or sight glass or weighing balance can be provided optionally to approximately measured the liquid charged or it's flow rate. Pots of different pressure, M.O.C. & sizes can be offered. These pots can also be used for storage of gases when gas cylinders are far off. With this option approximate quantity or flow of gas consumed can also be determined by measuring the pressure drop. Sizes : ½ ltr., 1 ltr., 2 ltrs., 5 ltrs., 10 ltrs.
It consist of SS 316 ethylene oxide horizontal pot with inlet, outlet, gas inlet with dip tube, thermowell, pressure gauge & high pressure hose pipe with NRV & QRC for 10kg/cm² working pressure. It is used for ethoxylation. It can be supplied with flame proof weighing balance. Sizes : 2 ltrs. & 5 ltrs.
This system is used to charge the liquid at desired rate from as low as 1ml/hr. to 100Ltr./hr, when the autoclave is under pressurised condition. The metering system comes with pump, flow indicator, controller, liquid sump, pressure safety valve, pressure gauge, strainer, high pressure hose, NRV & QRC. Optionally flow totalizer is also provided. AMAR offers 2 types of pumps.
»
Low cost Diaphgram pumps for pressure upto 100 bar & min. flow range of 60-600ml/hr. to max. 10-100 lit/hr. The flow rates are varied by varying the motor speed with variable frequency drive.
»
High pressure more accurate HPLC type low flow metering pumps for high pressures upto 350 bar & flow range from 0.01 upto 100ml/min. These pumps can be used along with precision weighing scales to measure the total liquid charged at any point of time.
The control panel of the autoclave gives 230V, 1Ø output to connect external auto-cooling system. AMAR gives 3 options:
»
Solenoid valve, Flameproof IIC (for autoclaves upto 25 litr) or
»
Pneumatically actuated ball valves (for autoclaves above 25 litr ) connected at the inlet of the internal cooling coil with external source of chilled water supply. This is standard for 50ml & 100ml autoclaves, however for bigger autoclaves if the cold water line pressure is <2bar then it is better to opt for external pump & tank water cooling system. Normal tap water cooling is not effective at higher temperature due to steam back pressure whereas pump & tank autocooling system gives positive pump pressure & faster cooling.
»
Pump & Water Cooling Tank : This system is used to control the overshoot in the autoclave & to cool it rapidly to lower temperature after the reaction is over. It circulates water to the internal cooling coil of reactors. It is a very essential feature for highly exothermic or runaway reactions. Cooling starts automatically if the rate of heating rises suddenly. It comes with ½ H.P non FLP monoblock pump or FLP IIC motor coupled pump, tank, pipeline & flexible hose pipes with QRC & is mounted on the autoclave trolley itself. It can also be used to circulate water in the cooling coil of external aluminum cast heater when internal coil is not possible.
It is used to reduce the autoclave temp. to as low as upto -500C from room temperature to carry out reactions at lower temp. It consist of single/double stage compressors, expansion valve, condensor, stirrer, circulation pump with control panel to control the temp. of the media in the bath. Cooling media/oil is cooled in the bath and then circulated to the internal coil/jacket of the autoclave through 6ft. Flexible SS hoses with insulation. Common single fluid heating & cooling system (open bath/closed loop) for temperatures from -50 to 200°C inside the reactor can be offered.
It is a jacketed tube SS-316 (0.01m², 0.02m² or 0.05m² area) heat exchanger used to reflux the condensate back into the reactor & vent off the uncondensed vapours. It is connected directly on the autoclave lid & works under full autoclave pressure. Reflux condensers can be offered in different MOC & area.
It is a SS-316 shell & tube reverse flow heat exchanger for distillation/condensing the vent vapours from the autoclave upto 10Kg/cm² pressure. It can be offered in all different MOC, higher pressure & different surface areas such as 0.1, 0.2, 0.5, 1 & 2 m2. The condensate can be collected separately or optionally refluxed back into the reactor.
SS 316 receiver pot can be connected at the outlet of the shell & tube or Reflux condensor to collect the condensate separately. It is also provided with port to apply vacuum & offered in ½ ltr., 1 ltr., 2 ltrs. & 5 ltrs. sizes. Higher sizes & other MOC can be offered on special request. It can be optionally provided with level indication.
It is opted only if heating is jacket type & the area is totally flameproof or direct electric band heaters are not permissable. Heating can be done by circulating hot oil through the jacket of the autoclave. The system comes with SS tank with electric heaters, level switch, pump, temperature controller & 6ft SS braided flexible hoses with insulation. Heating bath can be placed at a distance. Standard system have max. bath temp. 250°C & autoclave temp. 225°C & suitable only upto 500L autoclaves. Thermic oil for high temp. can also be supplied along with the bath. The heating system is non FLP & can be kept at a distance in safe area, if the reactor is in flame proof area. Common single fluid heating & cooling system (open bath/closed loop) for temperatures from -50 to 200°C inside reactor can be offered..
These valves can be connected at jacket inlet for controlling flow of steam/ hot oil/ water for temperature control from PID or at the inlet or outlet of the autoclaves for pressure control.
Amar gives 2 options.
»
On/off pneumatic ball valve actuated by 230V output from panel to FLP IIC solenoid valve inline of air supply
»
Pneumatic proportionate flow control valves with I to P convertor (for accurate temperature / pressure control).
It is opted only if heating is jacket type & the area is totally flameproof or direct electric band heaters are not permissable. Heating can be done by circulating hot oil through the jacket of the autoclave. The system comes with SS tank with electric heaters, level switch, pump, temperature controller & 6ft SS braided flexible hoses with insulation. Heating bath can be placed at a distance. Standard system have max. bath temp. 250°C & autoclave temp. 225°C & suitable only upto 500L autoclaves. Thermic oil for high temp. can also be supplied along with the bath. The heating system is non FLP & can be kept at a distance in safe area, if the reactor is in flame proof area. Common single fluid heating & cooling system (open bath/closed loop) for temperatures from -50 to 200°C inside reactor can be offered..
It is mounted on the vent line of the autoclave & is used for maintaining constant pressure inside the autoclave. The pressure is maintained by releasing the excess pressure into the atmosphere or through a hose to safe area. The pressure can be set initially on the gauge, by manually varying the knob until the gas comes out. Once the set pressure is exceeded the excess pressure is released until the autoclave pressure becomes equal to or below the set pressure. The pressure release is slow & gradual & the set pressure can be varied at any point. Alternately electronic digital back pressure regulator can be offered on request, where the pressure is set digitally.
High pressure autoclaves are provided with built in safety rupture disc, however additional safety can be offered by providing pressure safety valve whose release pressure can be set manually for a wide range by increasing or decreasing the spring tension. The set pressure should normally be around the max. allowable working pressure. Safety relief valves are standard supply for glass, rocker & fabricated reactors where rupture discs are not available for low pressure. These valves come with Viton orings which may not be suitable for certain gases & solvents.
It consist of a software with all controllers / indicators having RS485 modbus communication port or PLC & HMI, for online display, set point changes & data logging of pressure, temp., Motor RPM, motor torque % & optionally liquid / gas flow rate with totaliser, heater temperature etc. remotely from PC as well as locally from panel. It gives continuous online data logging at predefined variable time interval, online graphical representation as well as historical data on PC for single or multiple autoclaves. RS 485-232 convertor & cable upto 10m or higher is also supplied.
Removable Teflon / Hast C liners can be offered for autoclaves from 100ml - 5Ltrs. size. These liners can be used for reactions that are corrosive, to prevent only the autoclave body from corrosion. Teflon liner can be used upto 200°C & Hast C upto 500°C. The heat transfer is also very poor with teflon liners. Hence, Amar recommends the use of complete corrosion resistance metal autoclaves made from special alloys like Hastelloy, Inconel, Titanium etc. over glass/teflon liners. Liners should be used only if cost is the constraint or corrosive chemicals are to be used sparingly.
It is provided to improve the efficiency of the catalysts & for holding the catalyst so that it will not be destroyed or changed by the stirring action of impeller. The baskets are made from SS wire mesh & connected to the stirrer so that it rotates with the stirrer. It is available for 400ml-100Ltrs. Autoclave. The catalyst basket can be static which is stationery & dynamic which rotates with the impeller.
These are small 7 microns sintered cup filters which are threaded at bottom of the sampling dip tube so that while sampling liquid, the catalyst does not come out. It is very good system since the catalyst is normally very expensive or pyrophoric. These filters may reduce the rate/ flow of the sampling liquid due to the resistance offered by the fine mesh. Filters are available for 400ml-100Ltrs. autoclaves
It is used for charging catalyst under pressure during the reaction. It consists of a 3ml to 150ml (depending on Autoclave size) small container with airtight cap, that is openable. The powder is filled in the container which is then threaded to the autoclave head from below to a separate port with needle valve on the top. Under atmospheric & pressurized conditions the powder remains inside the container as the cap remains closed. One has to apply gas pressure greater than autoclave pressure from the needle valve on that port so that the cap opens & releases the catalysts inside the autoclave under pressure. Depending on the optional accessories selected, sometimes the catalyst addition device may not be possible due to space constraint on the head. Available for autoclave sizes 100 ml - 100 ltr. & upto 250°C.
It consists of vertical SS sintered filter cartridges in a SS housing. After the batch is over the reactor liquid is transferred to the catalyst filter under reactor/nitrogen pressure. After the filtration is over, the catalyst is taken back in to the reactor by back washing, thus recycling the same & making it available for the next batch. Generally this system is suitable & available for 20L & above reactor volumes.
It is a pressure reactor with Mag. drive stirring, inlet & outlet valves, pressure gauge & nitrogen/vent. Solvent & catalyst are charged in the vessel & the slurry formed by mixing is transferred under nitrogen pressure into the ractor. The volume of this reactor is around 50% of the Autoclave volume & is designed for pressure equal to or less than autoclave design pressure.
This system is suitable for 50L & above reactor volume.
It is used to collect the vent vapours / gases from the autoclave vent / rupture disc / safety valve port, when the vapour / gas is highly hazardous to release directly into the atmosphere.
It is a pressure vessel, taken almost double the volume of the autoclave & designed for less than half the reactor working pressure. It is provided with inlet, outlet, vent, pressure gauge, safety valve & optionally a frame arrestor. It is normally filled with water. The gases / vapours collected are safely released through the flame arrestor to avoid any hazard. It is suitable & available for autoclaves from 10 Ltr. to 1000 Ltr.
Suitable rotary vane, water ring or diaphragm vacuum pumps can be supplied for vacuum from 700mm of Hg upto 10-3 mm of Hg in the reactor depending on the pump type selected. It is used either before the charging in the reactor or for vacuum distillation. Suitable analogue or digital vacuum indicator with controller can be offered on request.
