Part 4

Comprehensive background study on the Batch Reactor

A reactor can be defined as a device or vessel that is primarily used to react two or
more substances chemically with each other with or without the influence of pressure and
temperature control (Dictionary, 2023). Reactors can be categorized into two types which is
the batch system and flow system. Both types have different purpose and operation system.
Batch reactor is an example of a batch system reactor. It is called batch system due to its
closed system operation where there is no flow in or out of reactants or products from the
reactor throughout the process making it works in a constant volume. Batch reactors has an
unsteady state process where energy and mass in the system are changing proportionally with
time as there is no flow through the system. In batch reactors, there is no spatial variation in
concentration and temperature making the substances in the vessel are well mixed, thus, time
is the greatest manipulated variable which controls the conversion of products in the system
(J.M. Douglas, 1966). Moreover, batch reactor are suitable slow and time consuming
reactions enabling reactants to achieve high conversion to product in respect to time. It is
usually used to test new products as batch reactor is the most suitable vessel for the purpose.
Engineers and technologists have been using batch reactors in studying the behavior of
substances under diverse conditions of pressure, temperature and time (Richard Smith, 2013).

Aside from all the advantages a batch reactor has, it also has its own downside such as
product variation from batch to batch. Conducting a batch reactor is very delicate as they do
not have flow through the process. Every conditions and variables such as temperature and
mixing process would affect the end product for each different batches making it is more
suitable for small scale operations (Mockus, 2014). Basically, it is not practical for use in
industries for the unreliability aside from having high labor costs per batch (Fogler, 2016).
Operating batch reactor also requires a decent number of manual labors as it is a closed
system operation. Loading and unloading of reactants and products need to be done manually.
In addition, control conditions such as temperature and pressure need to be constantly
monitored to avoid messing up the end product.
Application of the Batch Reactor in industries

Batch reactors are currently being used widely in various industries for their
performance and ability in processing diverse range of products. It is commonly used in the
chemical, pharmaceutical and food industries for its high-quality products they can produce.
For example, in the chemical industry, batch reactors are usually used to study and test a new
process they will be conducting for its conditions of temperature and pressure. It is also used
to create specialty chemicals such as fragrances, flavors, and pigments for its flexibility in
producing chemicals in smaller quantities (WkieLab, 2020). Batch reactors are more cost
effective and pose less risk compared to using continuous flow reactors when experimenting
on a new product. This way, the most practical method in manufacturing a new product can
be determined.

In pharmaceutical sector, the same reason is applied for the usage of batch reactors
which is the ability to produce pharmaceutical drugs in small batches. Thus, allows
pharmacists to control the quality and safety of the product by trialing in small amounts and
imply modification if needed which is more efficient and practical (Dr. Ryan L. Hartman,
2011). Flow reactors are not utilized much in this sector as it may pose huge cost lost
potential if the product manufactured does not reach its standard quality and qualifications.
Producing medical products is a delicate process as the dose is prescribed differently for each
type. Exceeding the dosage may imply other complications while low on dosage may appear
ineffective. Other than that, the production rate of medicinal drugs can be controlled as some
products are under distribution control such as amphetamine and meperidine (Le, 2022).

Furthermore, the usage of batch reactors in the food industry has been implemented
for a long time. In instance, the cooking pot we have been using at home is considered to be a
form of batch reactor including the oven, rice cooker and kettle. However, in industrial use,
batch reactors have served multiple purposes and tasks in various processes besides cooking
such as brewing and fermentation. There are several products that have been manufactured by
brewing such as coffee, soup, sauce, and jams. The advantages of using a batch reactor is that
a consistent final product quality can be maintained. The precision control of elements that
affect the concoction can be surveilled and preserved resulting in the best grade of products
processed. Being a reactor with unsteady state process, the chemicals reacted inside has no
spatial variations in concentration and temperature leaving time as the significant
manipulated variable. Thus, it is the ideal unit to conduct fermentation process which
consumes a long period of time. The reactants can be reacted in the reactor until the desired
product is formed. In addition, the reaction conditions can be controlled specifically
throughout the duration of fermentation allowing high quality product.

Safety considerations on the Batch Reactor

Batch reactors have been used for a very long period in multiple industries and have
served so many purposes. While batch reactors have a number of advantages over other
reactor types, there are a few safety issues that need to be taken into account in order to avoid
accidents and maintain safe operation. Safety is the highest priority during the conduction of
any type of activity no matter how low the risk it poses. A few areas in managing the batch
reactor will be discussed of its safety consideration including basic equipment handling
temperature, and pressure.

Firstly, basic equipment handling is the proper conduct when operating a batch
reactor. It is fundamental to have permission and legal clearance for a person to operate a
batch reactor. Next, wearing the proper personal protective equipment when managing a
batch reactor is the most basic rule. Failure to do so would expose the operator to safety and
health hazards when operating a unit using hazardous substances. Reactants and products
must be handled safely to prevent spills or releases that can pose a risk to operators or the
environment. Other than that, every member of staff needs to always be prepared for any
emergencies or unwanted events that would arise during the process. Accidents cannot be
predicted; thus, operators need to be prepared for any worst-case scenario that may happen.

Next is temperature control. As a reaction being conducted, the temperature may pose
a threat to the safety of the surrounding. Operating under high temperature, a significant risk
exists to the operator and equipment. Managing staff needs to know the maximum
temperature the unit can handle to avoid accidents such as thermal runaway which results in
uncontrollable temperature and mass ejection of gas (Jiang, Wu, Ni, & Zou, 2018). Therefore,
the equipment should be surveyed and be in the best condition before conducting any
reaction. The cooling systems and emergency shutdown system must be confirmed online to
prevent the rise of temperature beyond safety limits.

Furthermore, pressure control needs to be considered highly as it presents notable

risks on par with temperature control. Conducting a highly pressured reaction comes with a
lot of risks. Pressure should be monitored closely as it could damage both the operator and
the equipment itself. For example, trauma wounds on the vessel due to fragmentation and
disruption in the result of using high pressure reaction. This would corrode the durability of
the reactor making it fragile. Operating a fragile reactor at high pressure has the risk of it to
rupture and burst open. This would follow the spillage or even worse explosion of the
reactants inside the vessel which would harm the people around the area (Pressure Systems
Risk Assessment | Croner-i, 2023). Therefore, safety measures entailing the pressure control
of a batch reactor should be considered highly. In example, installing pressure relief valves
and carry out maintenance regularly.

In conclusion, batch reactors are frequently employed to conduct chemical reactions

in a variety of sectors. To ensure safe operation and avoid accidents, operators must be aware
of the safety factors involved. Maintaining a safe working environment depends on proper
design, monitoring, and control of pressure, temperature, and other section such as mixing,
and handling of reactants and products, as well as emergency readiness. Without any safety
preparation, a process cannot be conducted, and it is highly risky with a chance of even a
fatal accident.

References
Dictionary, C. (2023). Definition of reactor. Retrieved from Collinsdictionary.com:
https://www.collinsdictionary.com/dictionary/english/reactor

Dr. Ryan L. Hartman, J. P. (2011). Deciding Whether To Go with the Flow: Evaluating the Merits of
Flow Reactors for Synthesis. Flow Chemistry.

Fogler, H. S. (2016). Elements of Chemical Reaction Engineering, 5th Edition. Pearson.

J.M. Douglas, D. R. (1966). Unsteady state process operation. Chemical Engineering Science, Volume
21, Issue 4, 305-315.

Jiang, J., Wu, H., Ni, L., & Zou, M. (2018). CFD simulation to study batch reactor thermal runaway
behavior based on esterification reaction. Process Safety and Environmental Protection.

Le, J. (2022). Drug Distribution to Tissues. Retrieved from MSD Manual Professional Edition:
https://www.msdmanuals.com/professional/clinical-pharmacology/pharmacokinetics/drug-
distribution-to-tissues

Mockus, L. P. (2014). Batch-to-Batch Variation: A Key Component for Modeling Chemical

Manufacturing Processes. Organic Process Research & Development.

Pressure Systems Risk Assessment | Croner-i. (2023). Retrieved from Croneri.co.uk:

https://app.croneri.co.uk/topics/laboratory-equipment/pressure-systems-risk-
 assessment#:~:text=The%20principal%20hazards%20arising%20from,leaks%20from%20seals
%20and%20connections

Richard Smith, H. I. (2013). Chapter 2 - Systems, Devices and Processes. Supercritical Fluid Science
and Technology, 55-119.

WkieLab. (2020). WkieLab. Retrieved from The Various Application of Batch Reactor in Industry:
https://wkielab.com/the-various-applications-of-batch-reactors-in-the-industry/