Description:Field of the Invention

[0001] The present invention relates to the field of chemical and pharmaceutical laboratory equipment, specifically to glass reactor vessels used in experimental and production environments where precise temperature control and efficient heat management are required.

Background of the Invention
[0002] In the area of glass reactors used in chemical and pharmaceutical industries, there are two commonly used designs, namely, plain jacketed reactors and ring-baffled reactors. Plain jackets, typically lack any of the flow-directing structures, are hampered by inefficient heat transfer capabilities. A significant proportion of the heat transfer fluid in these reactors tends to move directly towards the exit valve, thereby inadequately utilizing the available surface area for optimal heat exchange. This inefficiency due to an uncontrolled flow pattern does not adequately satisfy the vessel's thermal needs.

[0003] On the other hand, reactors equipped with ring baffles incorporate horizontal parallel rings along the outer wall of the thermal jacket. This configuration allows the thermal fluid to enter through a bottom inlet, sequentially filling each ring from the bottom upwards. Although this design aims to create a more organized flow pattern, it inadvertently leads to a compartmentalized distribution of the thermal fluid. Each ring fills independently, which can result in uneven heat transfer across the reactor. Moreover, the construction of ring baffles, especially in glass reactors, involves complex and costly manufacturing processes. These methods not only increase the production expenses but also limit the flexibility in reactor design, making it a less adaptable solution for varying laboratory and industrial applications.

[0004] The CN patent application CN214681662U titled “Reaction kettle heat transfer press from both sides cover with ejector” describes a reactor jacket with a jet mechanism that enhances heat transfer by structuring the flow within the jacket through the impact and induction action of jets. This patent describes a jacket structure that uses curved spiral heat transfer channels, optimizing heat exchange by manipulating fluid dynamics inside the jacket. However, inclusion of jet injectors adds complexity to the reactor's structure. This complexity can lead to increased costs in manufacturing and maintenance, as well as potential challenges in ensuring long-term reliability and performance stability of the jet mechanisms.

[0005] Another CN patent application CN214553554U titled “Reaction kettle capable of being cooled rapidly” describes a rapidly cooling reactor vessel that incorporates a cooling shaft with internal circulation channels and an external motor that drives the cooling mechanism. However, dependence on mechanical parts for essential operations introduces points of failure, such as motor or shaft malfunctions, which could disrupt the entire cooling process. Further, the integration of multiple components like rotating motors, cooling shafts, and circulation systems makes the reactor assembly complex and increases the maintenance cost.

[0006] Such shortcomings in existing glass reactor designs emphasize the need for an improved system that optimizes heat transfer efficiency, simplifies manufacturing processes, and reduces operational costs while maintaining or enhancing the reactor's functional integrity.

Summary of the Invention
[0007] The following presents a simplified summary of the disclosure to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure, and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description presented later.

[0008] It is an object of the present invention to provide a triple wall vacuum jacketed helical baffle glass reactor vessel that addresses the inefficiencies and limitations of current glass reactor designs.

[0009] According to an aspect of the present invention, the triple wall design of the glass reactor comprises of a main reaction chamber, a circulation chamber for the baffle and an external vacuum jacket. This triple wall design significantly reduces heat loss and provides excellent thermal insulation.

[0010] According to another aspect of the present invention, the helical baffle design provides smooth and unhindered flow of heat transfer fluid in the chamber, efficiently guiding the fluid along a tangential path. This configuration maximizes the heat transfer efficiency by enhancing the contact surface area and fluid dynamics. Further, the manufacturing of the helical baffle glass reactor is simple by eliminating the need to manufacture compartmentalized structures within the jacket.

Brief Description of the Drawings
[0011] Other objects and advantages of the present invention will become apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments, in conjunction with the accompanying drawings, wherein like reference numerals have been used to designate like elements, and wherein:

[0012] Figure 1 illustrates the general view of the triple wall vacuum jacketed helical baffle glass reactor showing the main chamber, circulation chamber, vacuum jacket, and helical baffle.

[0013] Figure 2 illustrates the side two-dimensional view of the main reaction chamber.

[0014] Figure 3 illustrates the schematic view of the helical baffle or circulation coil.

[0015] Figure 4 illustrates the integration of the helical baffle or circulation coil with the main reaction chamber.

[0016] Figure 5 illustrates the schematic view of the circulation chamber.

[0017] Figure 6 illustrates the integration of circulation chamber with the assembly of the main reaction chamber and circulation coil.

[0018] Figure 7 illustrates the schematic view of the vacuum jacket.

[0019] Figure 8 illustrates the two-dimensional and schematic view of the integration of vacuum jacket with the assembly of the main reaction chamber, circulation coil and the circulation chamber.

[0020] Figure 9(a) and 9(b) illustrates the test results of the present invention triple wall vacuum jacketed helical baffle glass reactor against a normal vessel reactor.

Description of the Invention
[0021] It is to be understood that the present disclosure is not limited in its application to the details of composition set forth in the following description. The present disclosure is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0022] The use of "including", "comprising" or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms "first", "second", and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0023] Reference throughout this specification to "one embodiment," or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "one embodiment," and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, different embodiments, or component parts of the same or different illustrated invention.

[0024] Each statement of an embodiment is to be considered independent of any other statement of an embodiment despite any use of similar or identical language characterizing each embodiment.

[0025] The wording "one embodiment," or the like, does not appear at the beginning of every sentence in the specification, but is merely a convenience for the reader's clarity. However, it is the intention of this application to incorporate by reference the phrasing "an embodiment," and the like, at the beginning of every sentence herein where logically possible and appropriate.

[0026] A triple wall vacuum jacketed helical baffle glass reactor that comprises of three main components: the main reaction chamber (101), the helical baffle (102) glass within the internal circulation chamber (103) wherein the helical baffle (102) glass include helical rod and helical strip, and the external vacuum jacket (104). Each of these components are designed to provide increased efficiency and functionality of the glass reactor.

[0027] In accordance with the preferred embodiment the core of the glass reactor is the main reaction chamber (101) wherein all the chemical reaction takes place. This chamber is manufactured using a chemically resistant glass material that allows for clear visibility of the contents of the chamber. The main chamber (101) is cylindrical in shape which provides uniform distribution of heat across the chamber during chemical reactions. Additionally, the main chamber (101) is equipped with multiple ports, such as for the inlet and outlet of reactants and products, as well as for the insertion of monitoring and control instruments, such as temperature probes and pressure gauges.

[0028] In the preferred embodiment, the main chamber (101) is surrounded by the circulation chamber (103) that includes the helical baffle (102). The helical baffle (102) is the key component designed to direct the flow of heat transfer fluid in a helical pattern. The advantage of using the helical baffle (102) is that when the thermal fluid is passed through the helical baffle (102), heat is distributed continuously and uniformly along the main chamber (101). The helical design of the baffle not only maximizes surface area for heat transfer but also minimizes the resistance to thermal fluid flow. This setup is particularly effective in preventing hot spots within the glass reactor and ensuring that the reaction conditions are consistent throughout the process.

[0029] In accordance with the preferred embodiment, the outermost layer of the glass reactor assembly is the vacuum jacket (104) which plays a pivotal role in insulating the glass reactor and minimizing the thermal losses to the environment. The vacuum between the outer jacket and the circulation chamber (103) acts as an excellent thermal barrier. The vacuum jacket (104) is also designed from a robust glass material that complements the overall durability of the reactor while maintaining its chemical inertness.

[0030] In accordance with one of the embodiments all the above-mentioned components are precisely integrated to ensure airtight sealing and structural integrity. The glass reactor is assembled in a modular fashion, allowing each component to be manufactured individually and inspected before assembly. Further, the modularity allows for maintenance and replacement of individual components without the need to dismantle the entire glass reactor.

[0031] Figure 2-8 illustrates the various stages of the manufacturing process from the construction of the main chamber (101) to the final assembly with vacuum jackets (104).

[0032] Figure 2 illustrates the first stage in the manufacturing process of glass reactor, that is, the manufacturing of main reaction chamber (101). The process involves precision moulding and tempering to form the chamber with the necessary durability and resistance properties. The main reaction chamber (101) includes a valve (107) opening at the bottom of the chamber. Additionally, the main reaction chamber (101) can be integrated with multiple inlet or outlet ports for reactants and products and as well as for monitoring instruments.

[0033] Figure 3 illustrates the design and manufacturing of the helical baffle (102) or circulation coil which is the key component of the entire glass reactor. The helical baffle (102) is designed and crafted precisely to fit within the internal circumference of the circulation chamber (103). The manufacturing process involves precision engineering to ensure that the baffle’s curvature aligns with the geometry of the main chamber (101) to facilitate optimal heat transfer.

[0034] Figure 4 depicts the assembly of the main reactor chamber (101) and helical baffle (102). This stage is critical as it involves the integration of the helical baffle (102) or the circulation coil around the main reaction chamber (101). The curvature or the circumference of the helical baffle (102) is precisely manufactured in order to perfectly fit the helical baffle (102) around the main reaction chamber (101), thus ensuring efficient heat transfer from the helical baffle (102) to the main reaction chamber (101). The integration is such that the helical baffle (102) covers the maximum surface area of the main reaction chamber (101).

[0035] Figure 5 focuses on the manufacture of the circulation chamber (103) wall which houses the helical baffle (102). The manufacturing process involves moulding and forming of the circulation chamber (103) wall such that it perfectly encapsulates the helical baffle (102) and fits securely around the main reaction chamber (101). The manufacturing of the circulation chamber (103) should consider the thermal expansion and chemical resistance to maintain structural integrity under operational temperatures and chemical exposure.

[0036] Figure 6 shows the complete assembly of the circulation chamber (103) around the previously installed helical baffle (102) and main reaction chamber (101). This stage of the process includes sealing and securing all components to prevent leaks and ensure robust performance.

[0037] Figure 7 illustrates the manufacturing of the vacuum jacket (104) that will encase the entire assembly to provide vacuum insulation. The main advantage of the vacuum jacket (104) is to offer excellent thermal insulation properties and capable of maintaining a vacuum over prolonged operational periods.

[0038] Figure 8 illustrates the assembly of the vacuum jacket (104) around the entire glass reactor setup. This is the last step in manufacturing of the glass reactor. This critical step involves ensuring that the vacuum jacket (104) is perfectly aligned and securely fastened around the circulation (103) and main reaction chambers (101), providing a final layer of thermal insulation.

[0039] The entire glass reactor assembly also includes “Circulation IN” port (105) through which the thermal fluid enters and “Circulation OUT” (106) port through which the thermal fluid exits. The thermal fluid flows from bottom of the glass reactor to the top of the glass reactor for effective and uniform heat transfer to the main reaction chamber (101). The glass reactor assembly also includes a bottom valve location that holds the bottom valve (107), Additionally, the glass reactor assembly includes a drain port (108) for draining the contents of the reaction chamber.

[0040] Figure 9(a) and 9(b) illustrates the test results comparing the performance of the “Triple Wall Vacuum Jacketed Helical Baffle Glass Reactor” (referred to as Helical Baffle Vessel or SpB) against a “Normal Reactor Vessel” (referred to as Normal Vessel or NV) under controlled cooling and heating conditions. Figure 9(a) illustrates the cooling text results. Both the vessels SpB and NV started at an ambient temperature of 27°C. Over time, the helical baffle vessel of the current invention cooled down significantly faster than the normal vessel. Notable temperature differences were observed at each 10-minute interval, indicating the enhanced cooling capabilities of the helical baffle vessel. At 10 minutes, the SpB was at 0°C while the NV was at 10°C. By 20 minutes, the SpB had already reached -15°C, whereas the NV was at 0°C. The SpB continued to outperform with -25°C at 30 minutes and -30°C at 40 minutes, compared to the NV's -10°C and -20°C respectively. Figure 9(b) illustrates the heating text results. Over time, the heating performance of the helical baffle vessel surpassed that of the normal vessel consistently across the testing period. At 10 minutes, the SpB was at 50°C compared to 45°C for the NV. At 20 and 30-minute intervals, the SpB reached 80°C and 100°C, whereas the NV lagged at 70°C and 85°C respectively. The SpB achieved the target temperature of +150°C at the 60-minute mark, while the NV only managed 125°C. Thus, helical baffle vessel demonstrates superior performance in both rapid cooling and heating, making it particularly suitable for processes requiring stringent temperature controls. These tests confirm the reactor's capability to provide faster thermal response and more stable temperature control.
, Claims:I/We claim:

1. A reactor vessel, comprising:
a. a main reaction chamber (101);
b. an internal circulation chamber (103) surrounding the main reaction chamber (101), wherein the circulation chamber (103) comprises a helical baffle (102) configured to direct a heat transfer fluid;
c. an external vacuum jacket (104) encasing the circulation chamber (103) wherein the external vacuum jacket (104) is designed to provide thermal insulation by minimizing heat exchange with the external environment thus maintaining the desired reaction temperatures.; and
d. a valve (107) system positioned at a base of the main reaction chamber (101) for fluid management; and
e. a drainage port (108) located adjacent to the valve (107) system at the base of the main reaction chamber (101) for fluid management.

2. The reactor vessel as claimed in claim 1, wherein the main reaction chamber (101), circulation chamber (103), helical baffle (102) and the vacuum jacket (104) are all made of glass material, enhancing the chemical resistance and durability within the internal circulation chamber (103).

3. The reactor vessel as claimed in claim 1, wherein the helical baffle (102) is a helically coiled glass pipe, or a helically coiled pipe made up of any other material.

4. The reactor vessel as claimed in claim 1, wherein a heat transfer fluid enters the circulation chamber (103) through an inlet port and exits through an outlet port for efficient heat distribution.

5. A method for manufacturing a reactor vessel, the method comprising:
a. forming a main reaction chamber (101);
b. separately constructing a helical baffle (102) adapted to fit within a circulation chamber (103) of the reactor vessel;
c. integrating the helical baffle (102) within the internal dimensions of circulation chamber (103), ensuring optimal fluid flow and heat transfer;
d. attaching the circulation chamber (103) to the main reaction chamber (101); and
e. enclosing the assembled main reaction chamber (101) and circulation chamber (103) within an external vacuum jacket (104).

6. The method as claimed in claim 5, wherein integrating the helical baffle (102) within the internal dimensions of circulation chamber (103) includes aligning it precisely to maximize the contact area with the circulating heat transfer fluid.