Reactor Design Services

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✅ Process Engineering & Design for Reactors

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1. As Process engineer with responsibilities of preparation /Review of process flow diagrams from FEED consultant/contractor, Detail engineering consultant/ contractor.

2. Preparation /Review of P&IDs from FEED consultant/contractor, Detail engineering consultant/ contractor.

3. Preparation/ Review of material selection and relief load calculation from FEED consultant/contractor, Detail engineering consultant/ contractor.

4. Preparation of Process specification of different process specifications like reactor, pumps, compressors, heat exchangers etc.

5. Process studies involving evaluation of current plant operating data and revamp projects for energy optimization and capacity enhancement.

6. Experience of different reforming technologies like SMR, HTER, HTCR, ATR​

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📐 Mechanical Design & Calculations for Reactors

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1. Reactor Mechanical Design – Designing the reactor vessel, internals, and related components to meet specifications.

2. Pressure Vessel Design for Reactors – Ensuring compliance with ASME Sec VIII Div 1 & 2 for reactor pressure vessels.

3. Reactor Design Calculations – Performing critical design calculations for reactor systems, including thermal and mechanical load analysis.

4. Pump Selection & Design for Reactors – Sizing and selecting pumps for reactor cooling and circulation.

5. Reactor Cooling Design – Designing cooling systems, including heat exchangers and pumps, for efficient temperature management.

6. Compressor and Blower Design for Reactors – Design of compressors and blowers for gas handling and reactor operations.

7. Reactor Nozzle Design – Designing reactor vessel nozzles for fluid entry, exit, and instrumentation.

8. Stress Analysis for Reactor Components – Performing finite element analysis (FEA) for reactor vessel and internals to ensure structural integrity.

9. Reactor Thickness Calculations – Calculating the thickness of reactor walls, vessels, and internals based on pressure and thermal conditions.

10. Materials Selection for Reactor Components – Selecting appropriate materials for reactor components, considering corrosion, temperature, and pressure factors.

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🧰 Reactor Engineering: Detailed Design

1. Basic Reactor Design (BED) – Initial design phase including process and mechanical specifications for the reactor.

2. Front-End Engineering Design (FEED) – Developing detailed engineering designs for the reactor system, equipment, and utilities.

3. Detailed Engineering Design (DED) – Creating detailed design packages for reactor construction and installation.

4. Piping and Instrumentation Diagram (P&ID) for Reactors – Designing and drafting detailed P&ID layouts for reactor systems.

5. Piping Design for Reactors – Designing reactor-related piping systems, including pipe sizing, routing, and material selection.

6. Reactor Equipment Layouts – Planning and designing reactor equipment placements for optimal operational efficiency.

7. Reactor Flow Diagrams (RFD) – Creating detailed flow diagrams of reactor systems and fluid pathways.

8. Reactor Layout Design – Creating layouts for reactor systems, including space planning and safety considerations.

9. 3D Plant Modeling for Reactors – Using 3D CAD tools (AutoCAD, PDMS, or SolidWorks) to model reactors and associated systems.

10. Reactor Support Structure Design – Designing structural supports for reactor equipment and piping systems.

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⚙️ Utilities and Infrastructure Design

1. Utility Design for Reactors – Planning and designing utilities such as cooling, steam, and gas systems for reactors.

2. HVAC Systems Design for Reactors – Designing heating, ventilation, and air conditioning (HVAC) systems for reactor facilities.

3. Reactor Fluid Handling Systems Design – Designing systems to handle gases, liquids, and slurries within reactor operations.

4. Electrical Distribution Systems for Reactors – Designing electrical systems, including power supplies, MCCs, and distribution panels.

5. Control and Instrumentation Systems – Designing the control and instrumentation systems for reactor monitoring and operation.

6. Power Generation System Design – Designing auxiliary power systems to support reactor operations.

7. Cooling Tower & Chiller Design for Reactors – Designing cooling systems for efficient temperature regulation in reactors.

8. Water Treatment Systems for Reactors – Designing water treatment and filtration systems for reactors utilizing water as coolant or reactant.

9. Backup Power Systems for Reactors – Designing backup systems such as diesel generators and UPS to ensure reactor safety during power outages.

10. Waste Heat Recovery Systems for Reactors – Designing systems to recover and reuse heat generated in reactors for efficiency.

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🏗️ Civil and Structural Engineering for Reactors

1. Foundation Design for Reactors – Designing reactor foundations and supports to meet seismic and operational requirements.

2. Civil Layouts for Reactor Facilities – Planning and designing the layout of civil infrastructure for reactor facilities, including roads and utility access.

3. Reactor Building Design – Structural design of reactor buildings, including safety, access, and maintenance considerations.

4. Reactor Shielding Design – Designing radiation shielding around reactors to ensure safety for personnel and the environment.

5. Structural Steel Design for Reactors – Designing and detailing the structural steel framework for reactor supports and equipment.

6. Earthquake Design for Reactor Structures – Incorporating seismic design standards into reactor structural design

 

 

Reactor Design Services

At Sandhya Engineering Services, we specialize in the design and engineering of various reactor types, catering to diverse industries such as chemical processing, petrochemicals, pharmaceuticals, and nuclear energy. Our expertise encompasses a wide array of reactor designs, including:

• Catalytic Reactors: Designed for processes requiring catalysts to accelerate chemical reactions.

• Fixed Bed Catalytic Reactors: Utilize stationary catalyst beds for continuous flow reactions.

• Hydrotreating Reactors: Employed in refining processes to remove sulfur and nitrogen impurities.

• Steam Reformers: Facilitate the production of hydrogen and syngas from hydrocarbons.

• Polymerization Reactors: Used for the synthesis of polymers from monomers.

• Fluidized Bed Reactors: Offer enhanced heat and mass transfer for various reactions.

• Plug Flow Reactors: Provide uniform flow and concentration profiles for continuous reactions.

• Batch Reactors: Suitable for small-scale, high-purity production processes.

• Sequencing Batch Reactors: Employed in wastewater treatment for efficient nutrient removal.

Catalytic Reactor Design

Catalytic reactors are fundamental in processes where catalysts are used to increase the rate of chemical reactions without being consumed. These reactors are designed to optimize contact between reactants and catalysts, ensuring efficient conversion rates. The design considerations include:

• Catalyst Selection: Choosing appropriate catalysts based on reactivity and selectivity.

• Temperature and Pressure Control: Maintaining optimal conditions to enhance catalyst activity.

• Flow Distribution: Ensuring uniform distribution of reactants across the catalyst bed.

Fixed Bed Catalytic Reactor Design

In fixed bed catalytic reactors, the catalyst is stationary, and reactants flow over it. This design is commonly used in processes like ammonia synthesis and oxidation of sulfur dioxide. Key design aspects include:

• Bed Geometry: Determining the appropriate bed height and diameter for desired residence time.

• Heat Management: Addressing exothermic reactions to prevent hot spots.

• Pressure Drop: Minimizing resistance to flow to reduce energy consumption.

Fluidized Bed Reactor Design

Fluidized bed reactors suspend solid catalyst particles in an upward-flowing gas, creating a fluid-like behavior. This design is advantageous for reactions requiring high heat and mass transfer rates. Considerations include:

• Fluidization Velocity: Ensuring the gas flow is sufficient to suspend particles without causing excessive wear.

• Particle Size Distribution: Selecting appropriate particle sizes to achieve desired fluidization characteristics.

• Temperature Control: Managing heat distribution to prevent thermal gradients.

Plug Flow Reactor Design

Plug flow reactors are characterized by the movement of reactants through a cylindrical pipe, with minimal back mixing. This design is ideal for continuous processes requiring high conversion rates. Design factors include:

• Reactor Length and Diameter: Calculating dimensions to achieve desired residence time.

• Flow Profile: Ensuring uniform velocity distribution to maintain plug flow conditions.

• Heat Transfer: Designing jackets or internal coils for effective temperature control.

Batch Reactor Design

Batch reactors are used for processes where reactants are added in batches and products are removed after completion. This design is suitable for small-scale production with high product purity. Design considerations include:

• Mixing Efficiency: Ensuring thorough mixing to achieve uniform reaction conditions.

• Temperature and Pressure Control: Implementing systems to maintain desired conditions throughout the reaction.

• Safety Systems: Incorporating relief valves and pressure monitoring to handle exothermic reactions.

Sequencing Batch Reactor Design

Sequencing batch reactors are employed in wastewater treatment to remove nutrients in a controlled sequence. Design aspects include:

• Cycle Time: Determining appropriate durations for each phase of the treatment cycle.

• Aeration Systems: Designing efficient aeration to promote biological activity.

• Sludge Management: Implementing systems for sludge removal and handling.

Nuclear Reactor Design

In the nuclear energy sector, reactor design is critical for safe and efficient power generation. Our expertise includes designs such as:

• AP1000 Reactor Design: Advanced pressurized water reactor with enhanced safety features.

• CANDU Reactor Design: Heavy water reactor utilizing natural uranium fuel.

• Pebble-Bed Reactor Design: High-temperature gas-cooled reactor with inherent safety features.

• Molten Salt Reactor Design: Utilizes molten salt as both coolant and fuel for efficient heat transfer.

• Fusion Reactor Design: Focuses on achieving controlled nuclear fusion for energy production.

Advanced Reactor Designs

We also specialize in cutting-edge reactor designs, including:

• Small Modular Reactors (SMRs): Compact and scalable reactors offering flexible deployment options.

• Natrium Reactor Design: Integrates nuclear and renewable energy sources for sustainable power generation.

• TerraPower Reactor Design: Advanced reactor utilizing traveling wave technology for efficient fuel use.

• Oklo Reactor Design: Compact reactor design emphasizing simplicity and safety.

• Fusion Reactor Design: Exploring magnetic confinement and inertial confinement approaches for fusion energy.

Reactor Modeling and Simulation

To ensure optimal reactor performance, we employ advanced modeling and simulation techniques, including:

• Computational Fluid Dynamics (CFD): Analyzing fluid flow and heat transfer within reactors.

• Kinetic Modeling: Simulating chemical reaction rates and mechanisms.

• Thermal-Hydraulic Analysis: Assessing heat generation and removal to prevent overheating.

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At Sandhya Engineering Services, we are committed to delivering innovative and efficient reactor designs tailored to meet the specific needs of our clients. Our expertise spans a wide range of reactor types and applications, ensuring optimal performance and safety. Contact us today to discuss how we can assist with your reactor design requirements.

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1. Catalytic Reactor Design

2. Fixed Bed Catalytic Reactor Design

3. Hydrotreating Reactor Design

4. Steam Reformer Design

5. Polymerization Reactor Design

6. Fixed Bed Reactor Design

7. Fluidized Bed Reactor Design

8. Reactor Design

9. Oklo Reactor Design

10. Batch Reactor Design Equation

11. NuclearCraft Fission Reactor Design

12. Natrium Reactor Design

13. Nuclear Reactor Design

14. Plug Flow Reactor Design

15. Safest Nuclear Reactor Design

16. Fusion Reactor Design

17. Hydrotreating Reactor Design

18. TerraPower Reactor Design

19. Air Core Reactor Design

20. Fluidized Bed Reactor Design