Reactors are at the heart of a chemical process and consequently are a key step to focus upon when considering process intensification (PI). Heat transfer in the reactor can make the difference between a successful process and an out of control process. Heat removal or addition can be especially difficult for a highly exothermic or endothermic reaction. Coupling the reaction and heat transfer allows temperature profiles to be closely controlled, thereby improving the product quality and yield.

Chart Energy & Chemicals manufactures compact heat exchangers and chemical reactors that are used for PI using either aluminium or stainless steel or special metals

Chart has been manufacturing compact brazed aluminium plate-fin heat exchangers for over 50 years, with these being used as chemical reactors as early as 1979. Over the last 15 years a shim-based, diffusion bonded heat exchanger and reactor, known as ShimTecŪ, has been developed and widely applied. ShimTec has options for construction from a wide range of materials depending on temperature, pressure and corrosiveness. Structures are capable of operating under high temperature and pressures.

Manufacturing with other metals, including nickel alloys and high temperature metals, is also done for fuel processing and hydrogen generation fields, which show a lot of activity. In many applications, the processing rate achieved was many times higher than that anticipated.

This paper describes Chart's reactors and includes case studies of their use in the fine chemicals, pharmaceutical and fuel processing fields.