Reaction Distillation Unit – 20 L to 500 L

The Reaction Distillation Unit is an integrated process system designed for applications where a chemical reaction and subsequent or simultaneous distillation are required within the same processing arrangement.

The system is available in capacities ranging from approximately 20 litres to 500 litres, making it suitable for pilot-scale research, process development, scale-up studies and suitable production applications.

At the center of the system is a reaction vessel equipped with a motor-driven agitation arrangement. Agitation helps mix the reaction contents and promotes uniform contact between the materials during processing.

The vessel is provided with a suitable heating arrangement to supply the thermal energy required for reaction and distillation. As volatile components are generated or vaporized, they travel upward through the fractionation column.

The fractionation column promotes vapour-liquid contact to improve separation. Vapours then enter the condenser, where they are cooled and converted back into liquid.

A reflux divider allows part of the condensed liquid to be returned to the column while the remaining portion can be directed toward product collection. This arrangement provides greater control over the distillation and purification process.

The system also incorporates a product cooler and final receiver for cooling and collecting the recovered material.

Key Features

• Combined reaction and distillation system
• Capacity range from 20 L to 500 L
• Integrated reaction vessel
• Motor-driven agitation
• Fractionation column
• Reflux divider arrangement
• Condenser assembly
• Product cooler
• Final product receiver
• Vacuum connection provision
• Controlled heating arrangement
• Bottom discharge outlet
• Drain valve
• Suitable for batch processing
• Suitable for pilot and process applications

Main Components

Capacity Range

20 L to 500 L

The Reaction Distillation Unit can be configured with process capacities ranging from approximately 20 litres to 500 litres.

This capacity range makes the equipment suitable for:

• Process development
• Pilot plant trials
• Scale-up studies
• Research batches
• Small-scale manufacturing
• Chemical processing
• Pharmaceutical process development

Working Principle

1. Material Charging

The required process materials are charged into the reaction vessel according to the selected formulation or process.

2. Mixing

The motor-driven agitator mixes the vessel contents to promote uniform contact between the process materials.

3. Controlled Heating

Heat is supplied to the reaction vessel according to the process requirement. The heating system can support both reaction and subsequent distillation.

4. Reaction Process

The materials react under the selected temperature, mixing and operating conditions.

5. Vapour Generation

Volatile components generated during the reaction or subsequent heating move from the vessel into the fractionation column.

6. Fractionation

The fractionation column provides repeated vapour-liquid contact, helping improve separation of volatile components.

7. Condensation

Vapours leaving the column enter the condenser and are converted back into liquid.

8. Reflux Control

The reflux divider controls the proportion of condensed liquid returned to the column and the amount withdrawn as product.

9. Product Cooling & Collection

The recovered liquid passes through the product cooler before being collected in the final receiver.

Technical Specifications

Exact vessel volume, material of construction, agitator speed, motor rating, operating temperature, pressure/vacuum rating, column design and condenser area depend on the selected process configuration.

Reaction Vessel

Process Reaction Chamber

The reaction vessel provides the main chamber where chemical processing takes place under controlled operating conditions.

Motor-Driven Agitation

The vessel incorporates an agitation system driven by a suitable motor. Agitation promotes mixing and can help improve heat and mass transfer during suitable processes.

Bottom Outlet

A bottom outlet provides convenient discharge of residual material or final vessel contents after completion of the process.

Fractionation System

Fractionation Column

The column provides vapour-liquid contact that helps separate volatile components according to their relative volatility.

Reflux Divider

The reflux divider enables controlled return of condensate to the column, helping optimize separation according to process requirements.

Condenser & Product Cooler

Condenser

Process vapours are passed through the condenser, where cooling converts them into liquid.

Product Cooler

The product cooler further reduces the temperature of the condensed liquid before it enters the collection receiver.

Vacuum Operation

Vacuum Provision

The illustrated system incorporates a vent/vacuum connection, allowing the equipment to be connected to a suitable vacuum source where reduced-pressure processing is required.

Vacuum operation can be beneficial for suitable:

• Heat-sensitive materials
• High-boiling solvents
• Temperature-sensitive chemicals
• Solvent recovery processes

Benefits

• Reaction and distillation in one system
• Reduces separate process handling
• Controlled mixing during reaction
• Efficient vapour condensation
• Fractionation capability
• Adjustable reflux arrangement
• Product cooling before collection
• Vacuum processing capability
• 20 L to 500 L capacity range
• Suitable for process development
• Useful for pilot-scale studies
• Suitable for solvent recovery
• Supports scale-up applications

Scope of Application

• Chemical Reactions
• Reaction Distillation
• Solvent Recovery
• Solvent Purification
• Chemical Separation
• Product Purification
• Process Development
• Pilot Plant Studies
• Batch Processing
• Specialty Chemical Processing
• Pharmaceutical Process Development
• Research & Development

Applications

• Chemical Industries
• Pharmaceutical Industries
• Fine Chemical Industries
• Specialty Chemical Processing
• Pharmaceutical R&D
• Research Laboratories
• Pilot Plants
• Process Development Laboratories
• Chemical Research Facilities
• Solvent Recovery Plants
• Industrial Research Centers
• Production Facilities

Optional Configurations

• Different vessel capacities
• Alternative agitator designs
• Variable-speed agitation
• Different fractionation columns
• Alternative heating systems
• Vacuum system
• Temperature monitoring
• Process instrumentation
• Alternative receiver configurations
• Customized condenser capacity
• Different materials of construction
• Customized supporting structure

Frequently Asked Questions

What is a Reaction Distillation Unit?

A Reaction Distillation Unit combines a reaction vessel with a distillation system so that chemical reaction, separation and product recovery can be carried out within an integrated process setup.

What capacities are available?

The shown system is available in capacities ranging from approximately 20 litres to 500 litres.

Does the unit have an agitator?

Yes. The illustrated configuration includes a motor-driven agitation system for mixing the contents of the reaction vessel.

What is the purpose of the fractionation column?

The fractionation column promotes vapour-liquid contact and helps improve separation of volatile components.

What is the purpose of the reflux divider?

It controls the amount of condensed liquid returned to the column and the amount withdrawn for product collection.

Does the unit have a condenser?

Yes. A condenser is included to cool process vapours and convert them back into liquid.

Can the system operate under vacuum?

The illustrated unit includes a vacuum connection provision. The permissible vacuum level depends on the engineered configuration and equipment rating.

Can it be used for solvent recovery?

Yes. The unit can be configured for suitable solvent recovery, purification and separation processes.

Is it suitable for pilot plants?

Yes. Its capacity range makes it suitable for pilot plant trials, process development and scale-up applications.

Can the system be customized?

Yes. Capacity, agitation, heating, column design, condenser, receivers, vacuum arrangement, instrumentation and materials of construction can be configured according to process requirements.

Why Choose Micro Technologies?

• Combined reaction and distillation system
• 20 L to 500 L capacity range
• Motor-driven agitation
• Fractionation column
• Reflux divider
• Condenser and product cooler
• Vacuum provision
• Product collection system
• Suitable for process development
• Pilot-scale configurations
• Custom engineering options
• Industrial supply
• Technical assistance

Call to Action

Choose the Reaction Distillation Unit – 20 L to 500 L from Micro Technologies for integrated chemical reaction, distillation, purification and solvent recovery applications. Contact us with your required capacity, process material, operating temperature, vacuum/pressure requirement and application for a suitable configuration and quotation.