Chemical Process Vessels: Core Equipment of India’s Chemical Industry
India’s chemical industry — the world’s sixth largest at over $220 billion — produces dyes, pigments, agrochemicals, specialty chemicals, petrochemicals, polymers and pharmaceutical intermediates. At the centre of every chemical plant are the chemical process vessels: reactors, storage tanks, heat exchangers and mixing vessels that handle reactive, corrosive and high-temperature streams every day. Explore our chemical vessel range.
Types of Chemical Process Vessels
Jacketed Batch Reactors
The jacketed batch reactor is the most versatile chemical vessel — it performs synthesis, extraction, crystallisation and distillation in a single unit. Available in SS 316L (mild chemical service), Hastelloy C-276 (concentrated mineral acids, wet chlorine), glass-lined carbon steel (broad pH compatibility with zero metal contamination) and Titanium (oxidising acids, seawater). Jacket configurations: full jacket (up to 3.5 kg/cm² jacket pressure), half-pipe limpet coil (up to 20 kg/cm²), dimple plate jacket and internal coils. Capacities: 50L to 20,000L.
Glass-Lined Reactors
Glass-lined (enamel-lined) reactors are mandatory in India’s dye, agrochemical and pharmaceutical industries for reactions involving mineral acids and for products requiring zero metal ion contamination. The 2.5–4mm borosilicate glass enamel lining provides chemical resistance across pH 0–14 (except HF and hot concentrated NaOH above 20%). Standard sizes comply with DIN 28136/ISO 4901 and are compatible with Pfaudler, DeDietrich and Thaletec accessories. Every vessel is spark-tested at high voltage before dispatch to verify complete lining integrity.
FRP and PP Vessels
Fibre Reinforced Plastic (FRP) vessels handle mineral acids, alkalis and halogens at 30–50% lower cost than equivalent SS 316L. Used for HCl (all concentrations), dilute H2SO4, NaOH, NaOCl and chlorinated water storage, effluent treatment and scrubber systems. Polypropylene (PP) vessels resist HF, concentrated H2SO4 and oxidising media where FRP resin degrades. ASME RTP-1 certification is available for FRP pressure service applications.
High-Pressure Autoclaves
High-pressure autoclaves (50–350 bar) for catalytic hydrogenation, polymerisation, supercritical fluid extraction and high-pressure synthesis reactions. MOC: SS 316, Hastelloy C-276, Inconel 625 or Titanium Grade 2. Magnetically coupled agitator provides completely leak-free high-pressure stirring. Designed to ASME Section VIII Division 2.
Material of Construction Selection Guide
Correct MOC selection is the most critical decision in chemical vessel procurement. The wrong material leads to rapid corrosion, contamination and safety incidents:
- SS 316L: Dilute organic and mineral acids below 5%, alkalis, solvents, pharmaceutical and food service.
- Hastelloy C-276: Concentrated HCl (all temperatures), wet chlorine, HF (dilute), oxidising acid mixtures — used when SS 316L fails.
- Glass-lined steel: pH 0–14 (except HF and hot concentrated caustic), zero metal contamination for products where purity is critical.
- Titanium Grade 2: Concentrated HNO3 (fuming), H2O2, wet chlorine, seawater service where even Hastelloy is attacked oxidatively.
- FRP (vinyl ester): HCl (all concentrations), dilute H2SO4, NaOH, NaOCl, chlorinated water. 30–50% lower cost than SS 316L for corrosive atmospheric service.
ASME Certification for Export Markets
ASME Section VIII Division 1 (U-stamp) certification opens export markets in the USA, Canada, Middle East and for international engineering companies. Indian ASME U-stamp authorized manufacturers supply fully certified vessels with Manufacturer Data Report (Form U-1). Verify any manufacturer’s ASME authorization at asme.org manufacturer database.
Indian Chemical Industry Applications
Dye and pigment industry (Gujarat, Maharashtra): Glass-lined reactors for diazotisation and coupling; SS storage; FRP acid tanks; Hastelloy for chlorination reactions.
Agrochemical sector: Hastelloy or glass-lined reactors for chlorination and sulfonation; SS formulation vessels; FRP acid storage.
Specialty chemicals: High-pressure autoclaves for hydrogenation; glass-lined vessels for acid condensation; Hastelloy for HCl processes.
Water and effluent treatment: FRP vessels for acid/alkali storage; MS tanks with epoxy lining for bulk service. See also pressure vessel applications.
When should I specify glass-lined reactors instead of SS 316L?
Specify glass-lined when the reaction media is strongly acidic (pH below 2), involves HCl, HNO3 or mixed acids at elevated temperature, or when trace metal contamination from SS would affect product quality, colour or regulatory compliance. SS 316L is adequate for mild acids, alkalis and organic solvents at moderate concentrations and temperatures.
What is Hastelloy and when is it needed?
Hastelloy C-276 is a nickel-chromium-molybdenum superalloy with exceptional corrosion resistance. It resists concentrated HCl at all temperatures, wet chlorine, HF (dilute), oxidising acid mixtures and strongly reducing environments where SS 316L corrodes within days or weeks. Used in dye manufacturing, chlorination reactions, HCl-based synthesis and highly corrosive chemical processing where no cost-effective metallic alternative exists.
What design code applies to chemical vessels in India?
IS 2825 is the primary Indian code for unfired pressure vessels. ASME Section VIII Division 1 (U-stamp) is required by export customers in USA, Canada and Middle East. PED (European Pressure Equipment Directive) with CE marking is mandatory for European export vessels. Most large Indian chemical companies also accept equivalent international codes for specific applications.
Can FRP vessels handle concentrated acids?
FRP with vinyl ester or isophthalic resin handles: HCl at all concentrations, dilute H2SO4 up to 50%, NaOH, NaOCl and most dilute organic acids. NOT suitable for: concentrated H2SO4 above 50%, fuming HNO3 (oxidising attacks resin), HF at any concentration (attacks glass fibre), or most chlorinated organic solvents. Always confirm chemical compatibility with the specific resin type, concentration and temperature before specifying FRP.
What is the maximum pressure for glass-lined reactors?
Standard glass-lined reactors operate from full vacuum (FV) to +6 bar shell pressure and +6 bar jacket pressure. The glass lining is factory-applied by fusing borosilicate enamel at high temperature and every vessel is spark-tested (high-voltage holiday detection at 15,000+ volts) before dispatch to verify 100% glass lining integrity across the entire wetted surface.
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