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The reactor system is the heart of the chemical synthesis API facility. The challenge is to design the system in a cGMP manner utilizing equipment, piping, and electrical equipment appropriate for solvent-based operations. Some of the organic chemistries to be performed in the reactor system fall outside the range of conventional reactions. Parsons has extensive experience in the design of conventional chemistries as well as some more challenging operations, such as:
- Azide chemistries
- Chlorination
- Cryogenic temperatures
- High energy chemistries
- High temperatures
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- Hydrogenation
- Phosgenation
- Water reactive materials
- Super-critical carbon dioxide extraction/ crystallization
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Reactor/Receiver Vessels
The vessels are the backbone of the process equipment. Vessels come in assorted sizes and shapes, and their construction is typically carbon steel, stainless steel, hastelloy, or more exotic alloys such as titanium and tantalum. The selection is based upon the chemistries to be performed and their reactivity with certain metals. Additionally, the vessel must contain the process in a cGMP manner. Parsons has taken advantage of the recent technology advances that have allowed the use of dry seal systems for containment without product contamination.
Most chemical synthesis reactor systems operate in a narrow temperature range. This is accomplished by incorporating a single fluid heating/cooling system into the design. Parsons has experience designing systems utilizing a variety of heating/cooling fluids to achieve reactant operating temperatures from over 200°C to cryogenic temperatures below -100°C. The key component in controlling reactor temperature is a robust and well-designed Temperature Control Unit (TCU). The jacket fluid is heated or cooled by the TCU and pumped through the vessel jacket to automatically maintain a pre-selected reactant temperature. Parsons has experience working with both electric TCUs and steam/chilled water driven units and can recommend the best design for each application.
Proper agitation is required to assure proper yields and optimum reaction times. Proper agitator blade configurations and tip speeds are essential. Parsons' engineers work with you to model these parameters utilizing demonstration facilities provided by the agitator vendors to assure proper mixing before the reactor system is built.
Key to the successful operation of the reactor system is the process condenser. It is essential that the proper type, materials, and configuration are selected to provide proper condensation of the vents and also to allow for proper cleaning per cGMP. Parsons' designs typically utilize a vertical shell and tube configuration to provide for optimum operation as well as cleanability.
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