Loop Reactor
Loop reactors are continuous flow systems in which the reaction medium is recirculated at high velocity around a closed loop — typically comprising a reaction vessel or tube connected by a high-flow recirculation pump or ejector — while fresh feed is continuously added and product is continuously withdrawn at a net rate corresponding to the desired production throughput. The high recirculation ratio (typically 20:1 to 100:1 recirculate-to-feed flow) means the reactor contents behave as a well-mixed CSTR with respect to composition and temperature, while the high-velocity recirculation provides the intense mixing and mass transfer characteristic of tubular flow. Loop reactors are the preferred continuous reactor format for gas–liquid reactions requiring high gas–liquid mass transfer — particularly hydrogenation, oxidation with air or pure oxygen, carbonylation, and chlorination reactions. The gas is introduced at the loop inlet and dispersed into fine bubbles by the high-velocity liquid stream, achieving volumetric gas–liquid mass transfer coefficients (kLa values) of 0.1–1.0 s⁻¹ — substantially higher than conventional stirred tanks (0.01–0.1 s⁻¹). For three-phase (gas–liquid–solid catalyst) systems, the catalyst particles are maintained in suspension by the high recirculation velocity, eliminating the need for mechanical agitation.
Jet loop reactors use a high-velocity liquid jet nozzle to entrain and disperse the gas phase directly into the liquid stream — without any mechanical moving parts — making them particularly suitable for highly exothermic gas–liquid reactions where seal integrity and mechanical reliability are critical. Temperature control in loop reactors is achieved through an external heat exchanger incorporated into the recirculation loop, allowing precise temperature regulation independent of the reaction vessel geometry. For slurry handling, the loop design ensures particles remain suspended continuously, and slurry discharge is achieved through a controlled overflow or withdrawal point without stopping the recirculation.
- Reactor Volume 5 L to 50,000 L (production scale)
- Recirculation Ratio 20:1 to 100:1 (recirculate to fresh feed)
- Gas–Liquid kLa 0.1–1.0 s⁻¹ (jet loop and high-velocity designs)
- Materials of Construction SS 316L, Hastelloy C-276, glass-lined, Ti Gr.2
- Reaction Types Gas–liquid, liquid–liquid, gas–liquid–solid (…
- Recirculation Drive Centrifugal pump, axial pump, or jet ejector …
Key Features
-
Extremely high gas–liquid mass transfer — 10× conventional stirred tank
Extremely high gas–liquid mass transfer — 10× conventional stirred tank
-
Well-mixed CSTR behaviour with tubular-flow heat and mass transfer rates
Well-mixed CSTR behaviour with tubular-flow heat and mass transfer rates
-
Jet loop variants have no moving parts in the reactor loop itself
Jet loop variants have no moving parts in the reactor loop itself
-
Slurry catalyst suspension without mechanical agitation
Slurry catalyst suspension without mechanical agitation
-
External heat exchanger enables precise temperature control
External heat exchanger enables precise temperature control
-
High recirculation ratio moderates concentration spikes from fresh feed
High recirculation ratio moderates concentration spikes from fresh feed
System Components
Modular assemblies engineered for reliable integration, service access, and scale-up from laboratory to pilot plant operation.
Applications
- Continuous catalytic hydrogenation with H₂ under pressure
- Aerobic oxidation with air or enriched O₂ (e.g., toluene oxidation)
- Chlorination reactions with Cl₂ gas in organic media
- Fermentation and enzymatic bioprocesses in continuous mode
- HCl absorption into organic solvents for hydrochlorination
- Carbonylation and CO-gas reactions under moderate pressure
- Oil & gas processing
- Water treatment
Technical Specifications
| Parameter | Specification |
|---|---|
| Reactor Volume | 5 L to 50,000 L (production scale) |
| Recirculation Ratio | 20:1 to 100:1 (recirculate to fresh feed) |
| Gas–Liquid kLa | 0.1–1.0 s⁻¹ (jet loop and high-velocity designs) |
| Materials of Construction | SS 316L, Hastelloy C-276, glass-lined, Ti Gr.2 |
| Reaction Types | Gas–liquid, liquid–liquid, gas–liquid–solid (slurry catalyst) |
| Recirculation Drive | Centrifugal pump, axial pump, or jet ejector (no moving parts) |
| Heat Exchange | External shell-and-tube or plate HX in recirculation loop |
| Pressure Rating | Up to 100 bar (hydrogen service designs) |
| Temperature Range | −20°C to +300°C |
| Residence Time Control | Withdrawal rate controls product RTD independently of recirculation |
| Performance Advantage | The loop reactor achieves gas–liquid mass transfer coefficients of up to 1.0 s⁻¹ — enabling gas-limited reactions (e.g., hydrogenation) to reach full conversion in residence times of 1–5 minutes that would require 1–4 hours in a conventional stirred autoclave. |
Related Products
FAQ
What capacity range is available for Loop Reactors?
We offer project-specific sizing from laboratory benchtop scale through pilot and production volumes. Contact our engineers with your batch size and process requirements for a tailored recommendation.
Can this unit be integrated with existing plant automation?
Yes. All systems support standard instrumentation signals and can interface with DCS, PLC, or standalone controllers. Custom I/O and recipe control packages are available.
What material options are available?
Borosilicate glass, glass-lined steel, stainless steel, and specialty alloys including Hastelloy can be specified based on your process chemistry, temperature, and pressure requirements.
Do you provide installation and commissioning?
Global Lindus provides on-site installation supervision, commissioning, operator training, and optional IQ/OQ documentation for regulated industries.
What is the typical delivery lead time?
Standard configurations ship in 4–8 weeks. Custom skid assemblies and large production units may require 12–16 weeks depending on scope and material availability.