Description:Steady-State Agitation Reactor System with Optimized Design for Manufacturing of Stain Remover
TECHNICAL FIELD
[0001] The present innovation relates to chemical processing reactors, specifically a steady-state agitation reactor system designed for optimized mixing, thermal regulation, and continuous filtration in the manufacturing of high-purity stain remover solutions.

BACKGROUND

[0002] The manufacturing of high-purity stain remover solutions requires precise control over mixing, thermal stability, and filtration to ensure product consistency. However, conventional reactor systems, such as Continuous Stirred Tank Reactors (CSTRs), suffer from several limitations that hinder the efficiency and quality of the final product. One of the primary challenges with existing reactors is inefficient mixing, where standard impellers fail to achieve uniform flow regimes, leading to incomplete reactions, inconsistent product quality, and longer processing times. Additionally, these systems lack precise thermal control, causing temperature fluctuations that negatively impact the stability of chemical formulations.

[0003] To address these issues, users typically rely conventional CSTRs, or semi-continuous processing systems. Conventional Chemical Stirred Tank Reactors (CSTRs) face limitations in ensuring steady-state mixing, thermal stability, and impurity separation without requiring operational pauses. Standard agitators often fail to maintain precise Reynolds and Power number control, leading to inconsistent product quality and batch variability. Additionally, temperature fluctuations in conventional reactors result in localized overheating, uneven reaction rates, and reduced efficiency of active ingredients.

[0004] The Steady-State Agitation Reactor (SSAR) overcomes these challenges by integrating an optimized impeller system, a thermally regulated shell, and a real-time in-line filtration mechanism. The present invention overcomes these challenges by introducing a PBT type agitator with a dynamically adjustable blade pitch angle and rotational speed, allowing real-time control of turbulence and shear forces based on reactant viscosity. The baffle system eliminates vortex formation, while an integrated temperature-regulated jacket shell and in-line filtration system at the flush bottom valve ensure continuous impurity separation without downtime. This steady-state agitation reactor (SSAR) enables precise flow regimes, efficient reactant dispersion, and thermal consistency, making it ideal for manufacturing high-purity stain remover solutions and other chemical formulations.
OBJECTS OF THE INVENTION
[0005] The primary object of the invention is to provide a steady-state agitation reactor (SSAR) that ensures high-purity stain remover production through optimized mixing, thermal regulation, and real-time filtration.

[0006] Another object of the invention is to eliminate inconsistent mixing issues by incorporating an advanced impeller system that maintains optimal Reynolds and Power numbers for steady-state flow regimes.

[0007] Another object of the invention is to enhance thermal stability by integrating a jacketed shell system, ensuring uniform temperature distribution and preventing localized overheating or cooling.

[0008] Another object of the invention is to increase operational efficiency by incorporating an in-line filtration system that continuously removes by-products, preventing process interruptions and downtime.

[0009] Another object of the invention is to improve reaction yield and product quality by enabling precise control over pH, temperature, and shear rates, ensuring homogeneous mixing and stable reaction conditions.

[00010] Another object of the invention is to reduce energy consumption and waste through an efficient heat exchange mechanism that optimizes thermal management while minimizing excess energy usage.

[00011] Another object of the invention is to enhance process scalability, allowing for seamless adaptation to different chemical formulations, viscosities, and batch sizes without compromising performance.

[00012] Another object of the invention is to extend equipment lifespan by utilizing corrosion-resistant SS316 stainless steel with ETFE coating, ensuring durability and compatibility with a wide range of chemical reactions.

[00013] Another object of the invention is to streamline real-time monitoring and automation by integrating temperature sensors, pressure gauges, and vacuum control mechanisms for precise process control.

[00014] Another object of the invention is to offer a cost-effective and high-efficiency reactor system that outperforms conventional CSTRs providing industries with a scalable, continuous, and high-purity production system for stain removers.

SUMMARY OF THE INVENTION

[00015] In accordance with the different aspects of the present invention, a steady-state agitation reactor system with optimized design for manufacturing of stain remover is presented. It is an advanced reactor system designed for the high-purity production of stain removers through optimized mixing, thermal regulation, and continuous filtration. It features a custom impeller system that maintains steady-state flow regimes, ensuring homogeneous mixing and precise reaction control. A jacketed shell system enables uniform temperature distribution, preventing localized thermal fluctuations. An in-line filtration mechanism continuously removes by-products, eliminating downtime and enhancing process efficiency. The SSAR surpasses conventional reactors by integrating real-time monitoring, energy-efficient operation, and improved scalability, making it ideal for high-purity chemical manufacturing.

[00016] Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.

[00017] It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

BRIEF DESCRIPTION OF DRAWINGS
[00018] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

[00019] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

[00020] FIG. 1 is component wise drawing for steady-state agitation reactor system with optimized design for manufacturing of stain remover.

[00021] FIG 2 is working methodology of a steady-state agitation reactor system with optimized design for manufacturing of stain remover.

DETAILED DESCRIPTION

[00022] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.

[00023] The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of steady-state agitation reactor system with optimized design for manufacturing of stain remover and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[00024] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

[00025] The terms “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, or system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.

[00026] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

[00027] The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.

[00028] Referring to Fig. 1, a steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 is disclosed, in accordance with one embodiment of the present invention. It comprises lug support 102, bottom dish 104, main shell 106, top dish 108, body flange 110, body flange bolt 112, temperature sensor 114, jacket shell 116, jacket dish 118, mechanical seal 120, shaft 122, geared motor 124, baffle system 126, PBT type agitator 128, flush bottom valve 130, inlet 132, vent 134, pressure gauge 136, vacuum system 138, spare 140, outlet 142, jacket inlet 144, jacket outlet 146.

[00029] Referring to Fig. 1, the present disclosure provides details of a steady-state agitation reactor system with optimized design for manufacturing of stain remover 100.It is designed for high-purity stain remover production with optimized mixing, thermal regulation, and continuous filtration. It ensures homogeneous mixing through controlled Reynolds and Power numbers, preventing vortex formation and reaction inconsistencies. In one of the embodiments, the steady-state agitation reactor system may be provided with the following key components such as main shell 106, jacket shell 116, and temperature sensor 114, facilitating efficient heat transfer and reaction monitoring. The system incorporates geared motor 124 and PBT type agitator 128 to maintain steady-state flow regimes for enhanced reaction uniformity. It also features flush bottom valve 130 with an in-line filtration system for continuous impurity removal and product purity. Additional components such as baffle system 126 for vortex-free mixing and pressure gauge 136 ensure precise control over reaction conditions and process efficiency.

[00030] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with lug support 102, which serves as a structural reinforcement to ensure stability and secure installation. In different embodiments, the lug support 102 may be manufactured from different materials and may be provided with different dimensions. In one of the embodiments, lug support 102 may be made from IS 2062 to ensure high mechanical strength and durability, and is provided with a dimension of 8 THK. It provides strong mechanical support to the main shell 106. The lug support 102 interacts with the bottom dish 104 to distribute the load evenly and prevent vibrations. It also ensures that all connected components, including the geared motor 124, remain aligned and stable during operation. By maintaining structural integrity, the lug support 102 enhances the reactor's durability and safety.

[00031] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with bottom dish 104, which forms the base of the reactor and ensures a sealed, stable reaction chamber. In different embodiments, the bottom dish 104 may be manufactured from different materials and may be provided with different dimensions. In one of the embodiments, bottom dish 104 may be made from SS316 with ETFE coating to ensure chemical resistance and mechanical integrity, and is provided with a dimension of 200 ID × 4 THK. The bottom dish 104 is securely attached to the main shell 106 and reinforced by the lug support 102. It also works with the flush bottom valve 130 to allow controlled discharge of processed materials. This component plays a critical role in maintaining the reactor’s overall stability and containment.

[00032] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with main shell 106, which serves as the primary containment vessel where mixing, heating, and chemical reactions take place. In different embodiments, the main shell may be manufactured from different materials and may be provided with different dimensions. In one of the embodiments, main shell is made from SS316 with ETFE coating to ensure chemical stability, corrosion resistance, high-purity processing conditions and structural stability, and is provided with a dimension of 200 ID × 4 THK. The main shell 106 integrates temperature sensor and also integrates with the jacket shell 116 to maintain a stable thermal environment. It supports the baffle system 126 to ensure homogeneous mixing and prevents dead zones. Additionally, it houses multiple nozzles, including inlet 132, outlet 142, and vent 134, facilitating reactant input, gas release, and product discharge.

[00033] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with top dish 108, which serves as the upper closure of the reactor, ensuring containment and preventing contamination. In different embodiments, the top dish may be manufactured from different materials and may be provided with different dimensions. In one of the embodiments, top dish 108 is made from SS316 with ETFE coating to ensure sealing integrity and chemical resistance, and is provided with a dimension of 200 ID × 4 THK. The top dish 108 works in conjunction with body flange 110 and body flange bolts 112 to maintain a tight, pressure-resistant connection. It also accommodates vent 134 and pressure gauge 136, allowing controlled gas release and pressure monitoring.

[00034] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with body flange 110, which ensures a secure, leak-proof connection between the top dish 108 and main shell 106. In different embodiments, the body flange 110 is manufactured from different materials and may be provided with different dimensions. In one of the embodiments, body flange is made from SS316 with ETFE coating to ensure a secure and leak-proof connection, and is provided with a dimension of 16 THK. The body flange 110 works in combination with body flange bolts 112, ensuring tight sealing under high pressure. It also facilitates easy disassembly for maintenance, inspection, or modifications.

[00035] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with body flange bolt 112, which secures the body flange 110 to maintain the structural integrity of the reactor. In different embodiments, the body flange bolt maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, body flange bolt 112 is made from SS304 to ensure high tensile strength and corrosion resistance, and is provided with a dimension of M16 × 50 LONG. Constructed from SS304, these bolts are designed for high-strength fastening, ensuring that pressure fluctuations do not compromise the assembly. The body flange bolt 112 works in tandem with the temperature sensor 114 and pressure gauge 136 to prevent leaks and ensure stability.

[00036] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with temperature sensor 114, which continuously monitors thermal conditions inside the reactor. It is integrated into the main shell 106 to provide real-time temperature feedback to the jacket shell 116. This sensor ensures that temperature fluctuations are corrected dynamically, preventing overheating or thermal instability during exothermic reactions. In different embodiments, different temperature sensor 114 may be provided. In one of the embodiments, PT-100 is provided as temperature sensor 114 and is made from SS316 to ensure thermal stability and accurate temperature monitoring. The temperature sensor 114 works closely with jacket shell 116, allowing precise heat regulation and prevent temperature fluctuations that could affect reaction consistency. Additionally, it ensures that the pressure gauge 136 correlates temperature changes with pressure fluctuations for accurate monitoring.

[00037] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with jacket shell 116, which surrounds the main shell 106 and enables temperature control by circulating heating or cooling fluids around the main shell 106. It iss an integrated thermal control system designed to circulate temperature-controlled fluids, ensuring precise heat regulation within the reactor. In one of the embodiments, it is constructed with a 4 mm shell thickness which enables even temperature distribution and efficient heat transfer, preventing localized overheating. In one of the embodiments, the jacket shell 116 supports a thermal range of -20°C to 120°C, making it suitable for high-precision reactions requiring stringent temperature conditions. The advanced thermal management system ensures the reactor can handle exothermic reactions without thermal runaway, maintaining reaction consistency and product purity. In different embodiments, the jacket shell 116 maybe manufactured from different materials and provided with different dimensions. In one of the embodiments, jacket shell 116 may be made from mild steel to ensure high thermal conductivity and structural strength, and is provided with a dimension of 248 ID × 4 THK. It works with jacket inlet 144 and jacket outlet 146 to maintain a steady heat exchange process. The jacket shell 116 also interacts with the temperature sensor 114 for real-time thermal monitoring.

[00038] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with jacket dish 118, which seals the jacket shell 116 and allows controlled fluid circulation for efficient heat transfer. It helps maintain consistent thermal distribution, preventing thermal hotspots or fluctuations in the reaction chamber. The jacket dish 118 is designed to enhance heat transfer efficiency, contributing to the steady-state conditions of the SSAR.In different embodiments, the jacket dish 118 maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, jacket dish 118 is made from mild steel to ensure effective heat transfer and structural integrity, and is provided with a dimension of 248 ID × 4 THK.It is positioned at both the top and bottom of the jacket shell 116, ensuring stable operation. The jacket dish 118 interacts with the pressure gauge 136 and temperature sensor 114 to prevent overheating or cooling imbalances.

[00039] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with mechanical seal 120, which prevents leakage along the shaft 122 and ensures the system remains airtight. In different embodiments, the mechanical seal is manufactured from different materials and may be provided with different dimensions. In one of the embodiments, mechanical seal 120 is made from SS316 to ensure leak-proof operation and high chemical resistance. The mechanical seal 120 interacts with geared motor 124 to maintain rotational stability without compromising containment. It also ensures that the PBT type agitator 128 operates efficiently by preventing fluid escape. Additionally, it works alongside flush bottom valve 130 to maintain sealed conditions during product discharge.

[00040] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with shaft 122, which serves as the connection between geared motor 124 and PBT type agitator 128, transmitting rotational motion for controlled mixing. In different embodiments, the shaft 122 may be manufactured from different materials and may be provided with different dimensions. In one of the embodiments, shaft 122 is made from SS316 with ETFE coating to ensure corrosion resistance and efficient torque transmission, and is provided with a dimension of 25 DIA. The shaft 122 is made of SS316 with ETFE coating, ensuring high chemical resistance. It works in conjunction with mechanical seal 120 to prevent leakage while in operation. The shaft 122 ensures that the PBT type agitator 128 achieves optimal rotation speed for efficient reactant mixing. Additionally, it interacts with baffle system 126 to prevent turbulence and ensure uniform flow.

[00041] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with geared motor 124, which drives the agitator system 128 to maintain uniform mixing. It is connected to shaft 122, ensuring precise rotation at controlled speeds. In different embodiments, the geared motor 124 maybe manufactured from different materials and may be provided with different power rating. In one of the embodiments, a 60 RPM geared motor is provided. It is made from SS316 with ETFE coating to ensure durability and smooth operation, and is provided with a power rating of 360 WATT, 230V AC.The geared motor 124 works in synchronization with PBT type agitator 128 to optimize Reynolds number and prevent sedimentation. It also collaborates with baffle system 126 to maintain vortex-free mixing conditions. Additionally, the motor’s efficiency is enhanced by the stable thermal environment maintained by jacket shell 116.

[00042] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with baffle system 126, which prevents vortex formation and ensures uniform mixing of reactants. It consists of SS316 plates that are installed within main shell 106 to control fluid flow dynamics eliminate vortex formation, and optimize Reynolds number, ensuring uniform shear rates and improved reaction efficiency. In different embodiments, the baffle system 126 maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, baffle system is made from SS316 with ETFE coating to ensure fluid flow stabilization and vortex prevention, and is provided with a dimension of 20 × 4 THK. The baffle system 126 interacts with PBT type agitator 128 to stabilize mixing conditions and optimize shear rates. It also works in coordination with geared motor 124, preventing rotational dead zones. By promoting even reactant distribution, the baffle system 126 enhances overall reaction efficiency.

[00043] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with PBT type agitator 128, which is designed to achieve homogeneous mixing under steady-state conditions. The PBT type agitator 128, acting as the primary impeller, is designed with a 125 mm blade geometry to generate optimal Reynolds and Power numbers, ensuring precise control over flow regimes across varying viscosities. The PBT type agitator 128, driven by a geared motor 124 and connected via a shaft 122, operates at a default speed of 60 RPM to achieve a steady-state turbulent flow regime. The agitator’s blade pitch angle and RPM are dynamically adjustable, allowing it to switch between turbulent and laminar flow based on reactant viscosity. For delicate solutions, the RPM and impeller geometry can be adjusted to maintain laminar flow, reducing shear force and protecting sensitive components. This adjustability ensures compatibility with a wide range of formulations, from high-viscosity solutions requiring intense mixing to delicate compounds that necessitate gentle flow control. High-viscosity reactants are efficiently dispersed using turbulent flow without excess power consumption while Shear-sensitive formulations experience reduced mechanical stress under controlled laminar flow conditions.The agitator’s rotational speed are dynamically adjustable, enabling either turbulent or laminar mixing as needed. This ensures shear-sensitive reactants are protected, while high-viscosity solutions experience optimized dispersion.

[00044] The baffle system 126, constructed from 4 mm thick SS316 plates, works in tandem with the agitator to prevent vortex formation, eliminate stagnation zones, and enhance overall mixing efficiency.In different embodiments, the PBT type agitator 128 maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, PBT type agitator 128 is made from SS316 with ETFE coating to ensure high mixing efficiency and chemical stability, and is provided with a dimension of 125 SWIP DIA. The PBT type agitator 128, integrated with a geared motor 124 and baffle system 126, prevents localized overheating by ensuring uniform reactant distribution and eliminating stagnant zones. Additionally, the temperature sensor (PT-100) 114 provides real-time feedback, allowing dynamic RPM adjustments via the geared motor 124 to stabilize thermal conditions, ensuring controlled heat distribution inside the main shell 106. The PBT type agitator 128 also enhances reaction efficiency by ensuring even distribution of reactants introduced via inlet 132. The agitator’s performance is optimized under controlled thermal conditions maintained by jacket shell 116.

[00045] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with flush bottom valve 130, which facilitates efficient product discharge and continuous by-product removal. It is installed at the bottom of main shell 106, ensuring smooth flow of processed materials. In different embodiments, the flush bottom valve maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, flush bottom valve 130 is made from SS316 with FEP coating to ensure chemical resistance and smooth product discharge, and is provided with a dimension of 25 NB. The flush bottom valve 130 works with in-line filtration system, allowing continuous impurity separation. It also interacts with pressure gauge (N3) 136, ensuring that pressure conditions remain stable during discharge. The valve’s material, SS316 with FEP coating, ensures chemical resistance and prevents clogging.

[00046] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with inlet 132, which serves as the entry point for raw reactants. It is installed on main shell 106 and designed to regulate controlled reactant flow. In different embodiments, the inlet 132 maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, inlet 132 is made from SS316 with ETFE coating to ensure corrosion resistance and controlled reactant flow, and is provided with a dimension of 25 NB SCH40 × 100 mm.The inlet 132 works with PBT type agitator 128 to ensure uniform dispersion of introduced materials. It also interacts with pressure gauge 136, maintaining stable pressure conditions during feeding. The inlet 132 is designed for high-precision chemical dosing, preventing sudden fluctuations in reaction conditions.

[00047] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with vent 134, which facilitates the controlled release of excess gases from the reactor. It is positioned on the main shell 106 to prevent pressure build-up during the reaction process. In different embodiments, the vent 134 maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, vent 134 is made from SS316 with ETFE coating to ensure safe gas release and pressure control, and is provided with a dimension of 25 NB SCH40 × 100 mm.The vent 134 works in conjunction with pressure gauge 136 to maintain safe operational pressure levels. It also interacts with vacuum 138, ensuring that unwanted gases are effectively removed while maintaining the desired reaction conditions. By providing controlled gas release, the vent 134 enhances the stability and safety of the reactor system.

[00048] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with pressure gauge 136, which continuously measures internal pressure within the reactor. It is mounted on main shell 106 and operates within a range from vacuum to 6 kg/cm². In different embodiments, the pressure gauge 136 maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, pressure gauge 136 is made from SS316 with ETFE coating to ensure accurate pressure monitoring and durability, and is provided with a dimension of 25 NB SCH40 × 100 mm. The pressure gauge 136 works in coordination with temperature sensor (PT-100) 114 to monitor pressure variations caused by thermal fluctuations. It also interacts with vacuum system 138, allowing controlled pressure release when necessary. By providing real-time pressure feedback, the gauge ensures safe and efficient operation.

[00049] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with vacuum system 138, which maintains the necessary pressure conditions within the reactor. It is connected to main shell 106 and ensures that excess gases or unwanted air pockets are efficiently removed. In different embodiments, the vacuum system 138 is manufactured from different materials and may be provided with different dimensions. In one of the embodiments, vacuum system 138 is made from SS316 with ETFE coating to ensure efficient removal of unwanted gases, and is provided with a dimension of 25 NB SCH40 × 100 mm.The vacuum system 138 works in coordination with pressure gauge 136 to regulate pressure stability during reaction processes. It also interacts with outlet 142, preventing sudden pressure drops during product discharge. The vacuum system 138 is essential for maintaining steady-state conditions and enhancing reaction efficiency.

[00050] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with spare 140, which is an additional nozzle connection on the main shell 106. It is designed to allow future modifications or integration of auxiliary systems without affecting core functionality. In different embodiments, the spare 140 maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, spare 140 is made from SS316 with ETFE coating to ensure flexibility for additional modifications, and is provided with a dimension of 25 NB SCH40 × 100 mm.The spare 140 can be used for additional temperature sensor 114 or pressure gauge 136, depending on process requirements. It also ensures flexibility in reactor operations, enabling scalability for different chemical formulations.

[00051] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with outlet 142, which facilitates controlled discharge of processed materials. It is positioned at the lower part of main shell 106, ensuring efficient removal of the final product. In different embodiments, the outlet 142 is manufactured from different materials and may be provided with different dimensions. In one of the embodiments, outlet 142 is made from SS316 with ETFE coating to ensure controlled product discharge, and is provided with a dimension of 25 NB SCH40 × 100 mm.The outlet 142 works in conjunction with flush bottom valve 130 to ensure smooth and controlled flow. It also integrates with vacuum system 138, preventing pressure imbalances during discharge. The outlet 142 plays a crucial role in maintaining process efficiency and preventing contamination.

[00052] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with jacket inlet 144, which serves as the entry point for heating or cooling fluids into the jacket shell 116. It ensures controlled temperature regulation by allowing precise thermal fluid circulation. In different embodiments, the jacket inlet 144 maybe manufactured from different materials and may be provided with different dimensions. In one of the embodiments, jacket inlet 144 is made from MS to ensure efficient thermal fluid entry, and is provided with a dimension of 25 NB SCH40 × 100 mm.The jacket inlet 144 works in synchronization with jacket outlet 146 to maintain a steady heat exchange process. It also interacts with temperature sensor 114, providing thermal stability during continuous operation. The efficient design of the jacket inlet 144 enhances reaction control by preventing temperature fluctuations.

[00053] Referring to Fig. 1, steady-state agitation reactor system 100 is provided with jacket outlet 146, which allows the removal of heating or cooling fluids from the jacket shell 116 after temperature regulation. It ensures continuous circulation, preventing thermal stagnation within the system. In different embodiments, the jacket outlet is manufactured from different materials and may be provided with different dimensions. In one of the embodiments, jacket outlet 146 maybe made from MS to ensure effective heat removal, and is provided with a dimension of 25 NB SCH40 × 100 mm.The jacket outlet 146 works in conjunction with jacket inlet 144, enabling efficient heat exchange. It also interacts with temperature sensor (PT-100) 114, ensuring that the system operates within the desired thermal range. By maintaining a controlled thermal environment, the jacket outlet 146 optimizes the performance of the reactor.

[00054] Referring to Fig 2, there is illustrated method 200 for steady-state agitation reactor system with optimized design for manufacturing of stain remover 100. The method comprises:
At step 202, method 200 includes reactants entering the main shell 106 through the inlet 132, allowing precise dosing of raw materials for the preparation of the stain remover solution;
At step 204, method 200 includes the geared motor 124 driving the shaft 122, which in turn rotates the PBT type agitator at 60 RPM, generating steady-state turbulent flow for uniform mixing and efficient reactant dispersion inside the main shell 106;
At step 206, method 200 includes the baffle system 126 stabilizing the fluid motion inside the main shell 106, preventing vortex formation and ensuring uniform mixing;
At step 208, method 200 includes the jacket shell 116 maintaining optimal temperature by circulating heating or cooling fluids through the jacket inlet 144 and jacket outlet 146, ensuring steady-state reaction conditions;
At step 210, method 200 includes the temperature sensor 114 continuously monitoring the reaction temperature inside the main shell 106 and sending feedback for necessary thermal adjustments;
At step 212, method 200 includes the pressure gauge136 measuring and regulating the internal pressure of the reactor, ensuring the system remains within the desired pressure gauge range for stable operation;
At step 214, method 200 includes the vacuum system 138 removing unwanted gases from the main shell 106, maintaining a controlled pressure balance and preventing fluctuations in the reaction environment;
At step 216, method 200 includes the vent 134 allowing controlled gas release from the reactor while ensuring pressure stability and preventing contamination;
At step 218, method 200 includes the reaction progressing under steady-state conditions, facilitated by continuous agitation, controlled thermal regulation, and monitored pressure levels;
At step 220, method 200 includes the in-line filtration system integrated at the flush bottom valve 130 continuously removing by-products and impurities, ensuring a high-purity stain remover solution;
At step 222, method 200 includes the flush bottom valve 130 opening, allowing the final product to flow smoothly from the main shell 106 while preventing clogging and residue buildup;
At step 224, method 200 includes the processed stain remover solution being discharged through the outlet 142, ensuring complete drainage while maintaining product purity;
At step 226, method 200 includes the jacket shell 116 continuing to regulate temperature post-process, ensuring no overheating or thermal instability as the reactor transitions to a standby state;
At step 228, method 200 includes the spare 140 providing additional flexibility for modifications, such as future integrations for auxiliary monitoring systems if needed;
At step 230, method 200 includes the reactor returning to an idle state, where the main shell 106, jacket shell 116, and connected monitoring systems ensure readiness for the next batch operation.
[00055] In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “fixed” “attached” “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.

[00056] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.

[00057] Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
, Claims:WE CLAIM:
1. A steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 comprising of
lug support 102 to provide structural stability and secure installation of the reactor;
bottom dish 104 to form the lower base of the reactor, ensuring containment and support;
main shell 106 to serve as the primary reaction chamber for mixing and processing;
top dish 108 to enclose the reactor from the top, maintaining a sealed reaction environment;
body flange 110 to provide a secure and leak-proof connection between the reactor components;
body flange bolt 112 to fasten the body flange and ensure high-pressure sealing;
temperature sensor114 to continuously monitor and regulate the internal reactor temperature;
jacket shell 116 to circulate heating or cooling fluids for precise thermal control;
jacket dish 118 to enclose the jacket shell, maintaining consistent temperature distribution;
mechanical seal 120 to prevent leakage along the shaft while ensuring smooth operation;
shaft 122 to transfer rotational motion from the geared motor to the agitator;
geared motor 124 to drive the agitator at a controlled speed for steady mixing;
baffle system 126 to prevent vortex formation and stabilize fluid motion inside the reactor;
pbt type agitator 128 to ensure uniform mixing and dispersion of reactants;
flush bottom valve 130 to facilitate controlled discharge of the processed solution;
inlet 132 to allow precise entry of raw materials into the reactor;
vent 134 to release excess gases and maintain pressure stability;
pressure gauge 136 to measure and regulate internal pressure within the reactor;
vacuum system 138 to remove unwanted gases and maintain a controlled pressure environment;
spare 140 to provide flexibility for additional modifications and integrations;
outlet 142 to discharge the final product while ensuring complete drainage;
jacket inlet 144 to introduce heating or cooling fluids for temperature regulation; and
jacket outlet 146 to remove thermal fluids and maintain steady heat exchange.

2. The steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 as claimed in claim 1, wherein main shell 106 is configured to provide a corrosion-resistant, chemically stable reaction chamber, ensuring high-purity processing of stain remover formulations under controlled thermal and pressure conditions.

3. The steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 as claimed in claim 1, wherein PBT type agitator 128, driven by a geared motor 124 and connected via a shaft 122, operates at a default speed of 60 RPM to generate a steady-state turbulent flow for high-viscosity reactants, while allowing rotational speed variations to switch between turbulent and laminar flow regimes based on process requirements.

4. The steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 as claimed in claim 1, wherein PBT type agitator 128 is configured with optimized blade geometry to prevent localized overheating, stabilize reaction conditions in high-temperature processes, and maintain uniform reactant distribution within the main shell 106, ensuring precise heat dissipation during mixing.

5. The steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 as claimed in claim 1, wherein system incorporates a temperature sensor 114 positioned within the main shell 106 and a jacket shell 116 surrounding the main shell 106, configured to circulate heating or cooling fluids through a jacket inlet 144 and a jacket outlet 146, ensuring precise thermal regulation and maintaining steady-state reaction conditions without temperature fluctuations.

6. The steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 as claimed in claim 1, wherein baffle system 126 is configured to stabilize fluid motion, eliminate vortex formation for ensuring homogeneous mixing.

7. The steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 as claimed in claim 1, wherein flush bottom valve 130 with an integrated in-lie filtration system continuously remove by-products and impurities, maintaining product purity and preventing process downtime due to clogging.

8. The steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 as claimed in claim 1, wherein pressure gauge 136 is configured to measure real-time internal pressure variations within the main shell 106, ensuring controlled operation under vacuum or pressurized conditions.

9. The steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 as claimed in claim 1, wherein vent 134 and vacuum system 138 is configured to regulate gas removal and pressure balance, preventing reaction instability and ensuring a controlled processing environment suitable for high-purity chemical formulations.

10. The steady-state agitation reactor system with optimized design for manufacturing of stain remover 100 with optimized design for manufacturing of stain remover 100 as claimed in claim 1, wherein method comprises of
reactants entering the main shell 106 through the inlet 132, allowing precise dosing of raw materials for the preparation of the stain remover solution;
geared motor 124 driving the shaft 122, which in turn rotates the pbt type agitator 128 at 60 RPM, generating steady-state turbulent flow for uniform mixing and efficient reactant dispersion inside the main shell 106.;
baffle system 126 stabilizing the fluid motion inside the main shell 106, preventing vortex formation and ensuring uniform mixing;
jacket shell 116 maintaining optimal temperature by circulating heating or cooling fluids through the jacket inlet 144 and jacket outlet 146, ensuring steady-state reaction conditions;
temperature sensor 114 continuously monitoring the reaction temperature inside the main shell 106 and sending feedback for necessary thermal adjustments;
pressure gauge 136 measuring and regulating the internal pressure of the reactor, ensuring the system remains within the desired pressure range for stable operation;
vacuum system 138 removing unwanted gases from the main shell 106, maintaining a controlled pressure balance and preventing fluctuations in the reaction environment;
vent 134 allowing controlled gas release from the reactor while ensuring pressure stability and preventing contamination;
reaction progressing under steady-state conditions, facilitated by continuous agitation, controlled thermal regulation, and monitored pressure levels;
in-line filtration system integrated at the flush bottom valve 130 continuously removing by-products and impurities, ensuring a high-purity stain remover solution;
flush bottom valve 130 opening, allowing the final product to flow smoothly from the main shell 106 while preventing clogging and residue buildup;
processed stain remover solution being discharged through the outlet 142, ensuring complete drainage while maintaining product purity;
jacket shell 116 continuing to regulate temperature post-process, ensuring no overheating or thermal instability as the reactor transitions to a standby state;
spare 140 providing additional flexibility for modifications, such as future integrations for auxiliary monitoring systems if needed; and
reactor returning to an idle state, where the main shell 106, jacket shell 116, and connected monitoring systems ensure readiness for the next batch operation.