Evolution of the reactor
Our
original mixer "Esterizer V1.0" was conceived in 2000 for
an installation with a production capacity of 10,000 tonnes/annum.
The pressure-resistant model allows processing above the boiling
point of methanol or ethanol (lower catalyst consumption) and by
doing so prevents
methanol fumes from escaping, something that often occurs with
atmospheric batch reactors. In addition, the mixers are filled right
up with liquid, which represents a considerable safety benefit.
A comparison between the current mixer model and the separate stages of development over the course of the past few years shows how rugged the first construction was. The Atex guidelines for the Ex-protection that came into force in 2003 had a special impact on the construction. They prevented the use of simple, robust caulking packs. Various solutions with slip-fit ring seals led to the current hydrodynamic drive, which made a shaft bushing in the mixing container a thing of the past.
Esterizer reactor V 1.0 in use for 5 years (24 hrs/day). |
2.2 kW engine and stuffing box packing as shaft bushing |
Model 2005 V3.0 with mounted premixers |
Retrofitted premixer alongside a V2.0 model |
The introduction of the premixers boosted the transesterification rate during the first transesterification stage by 13% without increasing the catalyst or the amount of methanol. This mixer combination simultaneously enabled a simple transesterification.
In the context of technical progress, version V4.0 – built in 2006/7 – substituted the intricate shaft bushing for a pump/turbine combination along similar lines to the converter principle.
Esterizer V4.0 SuperNova: inspection prior to despatch following test run |
Special
premixer with increased shear force and loop |
Although the principle of premixer/main mixer and the size of the modules have been retained (continuity and endorsement of the original construction), it was possible to implement a number of essential improvements: greater shear force thanks to increased number of revolutions, absolute air-tightness due to replacement of the shaft bushing, modular construction and versatile adaptation to plants of any size.
The success that was achieved through the use of block pumps was resolutely followed up with version 5.1. It was clear that the processing required reaction time and energy. It is only possible to shorten the reaction time through energy input up to a certain point.
Esterizer V5.1: Venturi reactor with pumps on top |
Special premixer with increased shear force. 5 loop mixers |
V6.0 is a variation on the V5.1 model. The most conspicuous difference is in the low-lying pumps. This change in the construction was undertaken to prevent the pumps running dry when the mixer is only partly full. Further improvements include the option of mounting the mixers on the right or the left, which means the apparatus is easier to integrate in the production hall. In addition, the base "floats" on I-beams, so the assembly team was delighted with the ease with which the installation could be positioned using 2 lifting carts.
Version V6.1 is the first model to respect the demand for bigger machinery. The modular construction of the mixer can now handle almost any capacity (at least within the range of plant sizes encountered so far.)
The installations illustrated above display the customer's choice of colours.
Esterizer
V6.0 Venturimi reactor with low-lying pumps
|
Esterizer
V6.1 Venturi reactor, Up-Scale with low-lying
pumps
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