Anaerobic Reactors
Anaerobic reactor vessel is the widely used equipment in Biopharma , Biogas & Biotechnology Industry.
Anaerobic reactors are essential systems used in wastewater treatment and biogas production, functioning without the need for oxygen. These reactors employ microbial activity to break down organic matter into simpler compounds, yielding biogas as a valuable byproduct.
At JALARAM PHARMA, we work with our customers on projects of all sizes and scope.
As a premier Anaerobic reactor vessel manufacturer, whether you need a Small pilot vessel or a Industrial scale large Bioreactor tank package, our knowledgeable team can provide you with a custom quote for your unique project.
In addition, we provide extensive aftermarket service and support, including spare parts, equipment upgrades, servicing and maintenance, as well as customer training.
Capacity of Anaerobic reactor Vessel
Bench top Bioreactor
Jacketed / Non jacketed
Capacity – 5 to 10 litres
Pilot Bioreactor
Jacketed / Non jacketed
Capacity – 15 to 50 litres
Industrial Bioreactor
Jacketed / Non jacketed
Capacity – 100 to 20,000 litres
Control Parameters
- Effective control of anaerobic reactors involves monitoring and optimizing several parameters.
- These include temperature, pH levels, hydraulic retention time (HRT), and organic loading rates (OLR).
- Maintaining suitable temperature ranges (typically 30-40°C for mesophilic and 50-60°C for thermophilic reactors) ensures optimal microbial activity.
- Controlling pH between 6.5 and 7.5 stabilizes microbial communities, while adjusting HRT and OLR balances organic input and microbial growth rates to maximize reactor performance and biogas production.
Key Features
- Anaerobic reactors are characterized by their ability to operate in the absence of oxygen, relying on anaerobic microorganisms to degrade organic substances.
- Key features include high organic matter removal efficiency, low energy consumption, and production of biogas rich in methane.
- Different reactor designs such as UASB (Upflow Anaerobic Sludge Blanket) and anaerobic digesters cater to diverse operational needs, accommodating varying waste types and treatment scales.
Jacket Heating
Our vessel is equipped with Jacket for uniform temperature environment during reactions.
- Steam Heating: Hot steam is circulated through the jacket to provide consistent and efficient heating. Ideal for rapid heat-up and maintaining high temperatures.
- Hot Water or Oil: For more precise temperature control, hot water or thermal oils can be used, circulating through the jacket at predetermined temperatures.
- Uniform Heating: Ensures even distribution of heat, preventing hot spots and ensuring consistent reaction conditions.
- Safety: External heating reduces the risk of direct contact between the heat source and the reactants, enhancing operational safety
Jacket Cooling
Our vessel is equipped with Jacket for uniform temperature environment during reactions.
- Cooling Water: Cold water is circulated through the jacket to remove excess heat from the reactor. This method is effective for moderate cooling requirements.
- Rapid Heat Removal: Efficiently dissipates heat, crucial for exothermic reactions where excess heat can alter or halt the desired chemical process.
- Temperature Stability: Helps maintain a constant temperature, crucial for reactions that are sensitive to temperature fluctuations.
- Prevents Overheating: Protects temperature-sensitive materials by quickly reducing temperatures when necessary, preserving the integrity of the product.
Salient Features. Peripherals
Customized Agitator / Mixing Blades ( Rushton, Marine, Anchor, etc )
Peristatic Pumps , Magnetic couplings & Seals
PH / DO / Temperature / OD / Pressure / Reaction / Vacuum sensors
Jacket Heat distribution system & Safety Valves
HMI Panel & Process Control monitoring
Automated Actuators & Feed Control Valves
Sampling valve
Gas Manifold
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Technical Specification
Type: Sterilization in Place (SIP) and Cleaning in Place (CIP)
Design Code: ASME BPE-2019
Temperature: 0 to 150 °C
pH: 4 to 12 ( 6 to 8 )
DO2 : 0-100%
MOC: SS 316L/304 & ASTM grade
Automation Grade: Manual, Semi-Automatic & Fully Automatic
Surface Finish: Inner surface 420 grit mirror-finished Ra 0.25 to 0.5μm and External 120 to 180 grit hairline matt finish.
Features
- Automated control of process parameters like temperature, aeration, pH, DO, Foaming, pressure, Online Turbidity, Redox, etc.
- Top driven Agitator is provided through a single mechanical dry seal/double mechanical wet seal.
- Feed addition through a precise flow control meter for accuracy of feeding.
- Zero dead leg sampling valves and harvesting valves with in place steam sterilization system.
- Highly energy-efficient agitator drive, with a combination of specially designed Impellers like Rushton turbines, Marine, BT-6, PBT/HE-3, etc., is provided for proper media mixing and economical operation
- PLC-based panels are provided with a color touch screen HMI to provide the operator with monitoring and control of various parameters.
- Mobile App/web server is provided for data monitoring purposes.
- Alarms SMS alert on mobile is provided.
- Reserve data logging with SCADA software is also provided so that no important data of the batch is lost out.
- All wet parts are made of SS316/316L and non-wet parts are made of SS304.
Expertise
- Process engineering (functional analysis)
- Electrical and control system design, programming
- Piping manufacture and wiring
- Commissioning and after-sales service
- Qualification and Validation (cGMP, GAMP, CFR21 part 11)
- Design Qualification (DQ)
- Installation Qualification (IQ)
- Operational Qualification (OQ)
- Factory Acceptance Test (FAT)
- Site Acceptance Test (SAT)
- Performance Qualification (PQ)
Controls
- Automatic Temperature Control
- Aeration Control through rotameter/MFC
- Automatic Nutrient Feeding Control
- Automatic Exhaust Gas Pressure Monitoring & Control
- Automatic Agitation Control
- Automatic Back Pressure Monitoring
- Automatic DO Control (Cascade Control)
- Automatic OD/Turbidity Measurement
- Automatic pH Control
- Automatic Redox Monitoring & Control
- Automatic Vessel Sterilization Control
- Batch Recipe System
- Control Panel – Independent / Combined
- Mobile Application
- SMS Alert Facility
- Supervisory Control And Data Acquisition (SCADA)
Microbial configuration
It is meticulously configured for microbial applications, ensuring optimal growth conditions. This specialized setup encompasses precise control over crucial parameters such as pH, temperature, Dissolved Oxygen (DO), and foam. pH is diligently maintained through the addition of acids or bases, with the integration of mass flow controllers for accurate air and oxygen supplementation.
The bioreactor features a jacketed vessel, incorporating a double-wall in varying sizes, accompanied by a 3x 6-blade Rushton impeller. The agitation dynamics are under precise control through a Servomotor. Elevate your microbial processes further with optional enhancements, including a microsparger for the generation of finer bubbles, an external pump for feeding, additional sensors and off-gas analysis for continuous monitoring and adjustment of the cultivation environment.
Cellular configuration
Tailored for cellular applications, We present a specialized configuration designed to optimize cellular growth. This distinctive setup includes meticulous control over essential features such as pH, temperature, Dissolved Oxygen (DO), and foam. pH regulation involves the addition of acids or bases, complemented by mass flow controllers for precise air, oxygen, nitrogen, and carbon dioxide incorporation.
Featuring a jacketed vessel with a double-wall option based on size, the bioreactor is equipped with a 2x pitched-blade impeller, and agitation dynamics are expertly controlled by a Servomotor. The system incorporates a SIP version of sterilization with external steam. Explore additional options such as a microsparger for finer bubble generation, additional sensors and off-gas analysis, providing comprehensive monitoring and adjustment capabilities for the cultivation environment.
Why Choose Us ?
Lab Tested Material with TC reports
We provide products with TC reports for better transparency and quality.
Quality assurance with precision
We make the products with highest accuracy and precision.
Experienced professionals
We have experience professionals in all domains from Metal to Plastic
Highest quality fabrication
All our working professionals are Skilled and experienced
Client Testimonials
Precise Welding - TIG / MIG ( Technology )
We provide RT (Radiographic) / DP (Dye Penetrant) test reports of Welded Joints of our Reactor vessel .
Our welding is performed by experienced professionals, supervised by highly skilled experts to ensure top quality.