Advanced Reaction Systems for High-Performance Chemical Processing, Process Safety & Operational Excellence

Reactors

We design and manufacture world-class industrial reactors engineered to deliver exceptional process efficiency, superior product quality, optimized reaction kinetics, and maximum operational reliability across the most demanding industrial applications.

Our reactor manufacturing expertise encompasses high-pressure, high-temperature, vacuum, cryogenic, corrosive, hydrogenation, polymerization, catalytic, biochemical, and multiphase reaction systems serving the Chemical, Petrochemical, Refining, Fertilizer, Pharmaceutical, Hydrogen, Renewable Energy, Specialty Chemicals, Food Processing, and Advanced Materials industries.

Combining advanced process engineering, precision fabrication, metallurgical expertise, and stringent quality assurance systems, we provide customized reactor solutions that meet the highest international standards for safety, performance, and lifecycle reliability.

Manufacturing Range

Comprehensive Reactor Systems Portfolio

Chemical Process Reactors

Batch Reactors

Jacketed Batch Reactors
Glass-Lined Batch Reactors
Agitated Batch Reactors
Vacuum Batch Reactors
Pressure Batch Reactors
Multi-Purpose Reactors
Pilot Plant Reactors
Specialty Chemical Reactors
Applications: Fine Chemicals, Pharmaceuticals, Specialty Chemicals, Agrochemicals

Continuous Reactors

Continuous Stirred Tank Reactors (CSTR)
Continuous Flow Reactors
Plug Flow Reactors (PFR)
Tubular Reactors
Pipeline Reactors
Static Mixer Reactors
Applications: Petrochemicals, Large-Scale Chemical Production, Continuous Manufacturing

Petrochemical & Refinery Reactors

Hydrocracker Reactors
Hydrotreating Reactors
Hydrodesulfurization (HDS) Reactors
Hydroprocessing Reactors
Catalytic Reforming Reactors
Isomerization Reactors
Alkylation Reactors
FCC Reactor Vessels
Delayed Coker Reactors
Residue Upgrading Reactors
Applications: Refineries, Petrochemical Complexes, Fuel Processing Facilities

Catalytic Reactors

Fixed Bed Reactors
Moving Bed Reactors
Fluidized Bed Reactors
Trickle Bed Reactors
Packed Bed Reactors
Catalytic Oxidation Reactors
Catalytic Reduction Reactors
Applications: Refining, Hydrogen Production, Emission Control Systems

Hydrogen & Energy Transition Reactors

Hydrogenation Reactors
Green Hydrogen Process Reactors
Methanation Reactors
Ammonia Synthesis Reactors
Carbon Capture Process Reactors
Renewable Fuel Reactors
Sustainable Aviation Fuel (SAF) Reactors
Applications: Hydrogen Economy Projects, Renewable Energy Facilities, Decarbonization Programs

Polymerization Reactors

Polymerization Kettles
Suspension Polymerization Reactors
Emulsion Polymerization Reactors
Bulk Polymerization Reactors
Continuous Polymerization Reactors
Latex Production Reactors
Applications: Polymer Manufacturing, Plastics Production, Synthetic Rubber Processing

Pharmaceutical & Biotech Reactors

GMP Reactors
Sterile Reactors
Bioreactors
Fermentation Reactors
Cell Culture Reactors
API Manufacturing Reactors
High-Purity Process Reactors
Applications: Pharmaceuticals, Biotechnology, Life Sciences

Specialty Reactors

Vacuum Reactors
High Pressure Reactors
Cryogenic Reactors
Autoclaves
Solvent Recovery Reactors
Multi-Phase Reactors
Slurry Reactors
Electrochemical Reactors
Photochemical Reactors
Technical Capabilities

Engineering Standards & Parameters

Design Standards

Reactors designed and manufactured in accordance with:

ASME Section VIII Div. 1
ASME Section VIII Div. 2
ASME Section I
ASME B31.3
API Standards
TEMA Standards
EN 13445
PED Compliance
AD 2000
PD 5500
GMP & FDA Guidelines
IS Standards
Client-Specific International Specifications

Process Engineering Capabilities

Advanced Reactor Engineering

Reaction Kinetics Evaluation
Process Simulation
Heat & Mass Transfer Analysis
Residence Time Distribution Studies
Catalyst Performance Optimization
Scale-Up Engineering
Process Intensification Studies
Mixing & Agitation Analysis
Gas-Liquid-Solid Interaction Analysis
Hydrogen Service Design

Mechanical Engineering

Pressure Vessel Design
Finite Element Analysis (FEA)
Thermal Stress Analysis
Fatigue Analysis
Nozzle Load Analysis
Wind & Seismic Analysis
Dynamic Load Assessment
Lifting & Transportation Analysis

Digital Engineering

3D Modeling
CFD Analysis
Digital Manufacturing Systems
Smart Plant Integration
BIM Compatibility
Laser Scan Verification

Manufacturing Capability Envelope

Internal Diameter
Up to 8,000 mm and above
Equipment Height
Up to 60 meters and above
Shell Thickness
Up to 300 mm+
Design Pressure
Full Vacuum to 700 Bar+
Design Temperature
Cryogenic (-196°C) to High Temperature up to 1,100°C
Single Unit Weight
Up to 1,000 MT+
Agitator Power
Up to 2,500 kW+
Materials of Construction

Comprehensive Material Range

Carbon Steel

ASTM A516 Gr. 60 ASTM A516 Gr. 65 ASTM A516 Gr. 70 ASTM A537 ASTM A36 IS 2062
Applications: General Chemical Service, Petrochemical Processing, Utility Systems

Low Temperature Carbon Steel

ASTM A333 ASTM A350 LF2 ASTM A420
Applications: LNG Applications, Cryogenic Processing

Austenitic Stainless Steel

SS 304 SS 304L SS 316 SS 316L SS 317L SS 321 SS 347
Applications: Pharmaceuticals, Fine Chemicals, Food Processing

Duplex Stainless Steel

Duplex 2205 Duplex 2304
Applications: Corrosive Process Streams, Offshore Processing

Super Duplex Stainless Steel

Super Duplex 2507
Applications: Severe Corrosion Service, High Chloride Environments

Nickel-Based Alloys

Inconel 600 Inconel 625 Inconel 718 Monel 400 Hastelloy C22 Hastelloy C276 Alloy 20 Incoloy 800 Incoloy 825
Applications: Hydrogen Service, Acidic Environments, High Temperature Processing

Titanium & Exotic Alloys

Titanium Grade 2 Titanium Grade 7 Zirconium Tantalum Copper-Nickel Alloys
Applications: Extreme Corrosion Resistance, High Purity Processing

Glass-Lined Reactors

Exceptional Corrosion Resistance High Product Purity Chemical Compatibility
Applications: Pharmaceuticals, Specialty Chemicals

Clad Construction

SS Clad Carbon Steel Duplex Clad Steel Nickel Alloy Clad Steel Explosion Bonded Clad Plates
Benefits: Corrosion Resistance, Cost Optimization, Extended Service Life
Product Configurations

Flexible Design & Build Options

Reactor Orientation

Vertical Reactors

Skirt Supported
Leg Supported
Structural Mounted

Horizontal Reactors

Saddle Mounted
Modular Configurations

Heating & Cooling Systems

Jacketed Reactors

Conventional Jackets
Half-Pipe Coil Jackets
Limpet Coil Jackets
Dimple Jackets
Applications: Precise Temperature Control, Exothermic Reactions

Internal Heat Transfer Systems

Internal Coils
Helical Coils
Plate Coils
Tube Bundle Systems
Applications: High Heat Transfer Duty Processes

Agitation Systems

Mixing Technologies

Anchor Agitators
Paddle Agitators
Turbine Agitators
Propeller Agitators
Helical Ribbon Agitators
Hydrofoil Impellers
Retreat Curve Impellers
Multi-Stage Agitators
Applications: Liquid-Liquid Reactions, Gas-Liquid Reactions, Slurry Processing

Reactor Internals

Baffles
Spargers
Catalyst Support Grids
Distributor Systems
Demister Pads
Cyclone Separators
Heat Transfer Coils
Sampling Systems
Instrumentation Nozzles
Comprehensive Reactor Equipment Portfolio

Complete Reaction System Solutions

Refinery Reactors

Hydrocracker Reactors Hydrotreating Reactors FCC Reactors Catalytic Reforming Reactors Isomerization Reactors

Chemical Reactors

Batch Reactors Continuous Reactors Vacuum Reactors Pressure Reactors Polymerization Reactors

Hydrogen Service Reactors

Hydrogenation Reactors Methanation Reactors Ammonia Synthesis Reactors Renewable Fuel Reactors

Pharmaceutical Reactors

GMP Reactors Sterile Reactors Glass-Lined Reactors High-Purity Process Reactors

Biotechnology Reactors

Bioreactors Fermentation Reactors Cell Culture Reactors Enzyme Processing Reactors

Specialty Reactors

Slurry Reactors Fixed Bed Reactors Fluidized Bed Reactors Trickle Bed Reactors Electrochemical Reactors Photochemical Reactors
Fabrication & Manufacturing Excellence

Precision Manufacturing Technologies

Heavy Fabrication Infrastructure

CNC Plasma Cutting
CNC Laser Cutting
Heavy Plate Rolling
Hydraulic Press Forming
Precision Machining
Automated Assembly Systems

Advanced Welding Technologies

GTAW (TIG)
GMAW (MIG)
SMAW
FCAW
SAW
Narrow Gap Welding
Orbital Welding
Automated Welding Systems
Overlay Cladding
Corrosion Resistant Weld Overlays

Surface Treatment & Finishing

Pickling
Passivation
Electropolishing
Glass Lining
Internal Coatings
Rubber Lining
PTFE Lining
Specialized Corrosion Protection Systems
Quality Assurance & Inspection

Comprehensive Testing & Validation

Non-Destructive Examination (NDE)

Radiographic Testing (RT)
Ultrasonic Testing (UT)
Phased Array Ultrasonic Testing (PAUT)
TOFD
Magnetic Particle Testing (MT)
Liquid Penetrant Testing (PT)
Positive Material Identification (PMI)
Ferrite Testing
Hardness Testing

Pressure & Performance Testing

Hydrostatic Testing
Pneumatic Testing
Vacuum Testing
Helium Leak Testing
Nitrogen Leak Testing
Agitator Performance Testing
Factory Acceptance Testing (FAT)

Documentation & Traceability

Complete Material Traceability
Welding Documentation
Third-Party Inspection Support
Digital Manufacturing Records
Global Certification Packages
Industries Served

Trusted Across Global Sectors

Oil & Gas
Refining
Petrochemicals
Chemicals
Specialty Chemicals
Pharmaceuticals
Fertilizers
Hydrogen & Clean Energy
Renewable Fuels
Food & Beverage
Mining & Metals
Advanced Materials
Environmental Engineering
Why Our Reactors

Engineered for Safe, Efficient & Reliable Process Performance

Advanced Process & Reaction Engineering Expertise
High Pressure, High Temperature & Hydrogen Service Capability
Superior Agitation & Heat Transfer Design
Glass-Lined & Exotic Material Fabrication Expertise
Large Diameter & Heavy-Wall Reactor Manufacturing
GMP, Pharmaceutical & High-Purity Manufacturing Capability
Advanced CFD, FEA & Thermal Analysis Support
Comprehensive Quality Assurance & NDE Programs
Global Code Compliance & International Certifications
Customized Solutions for Critical Process Applications

Flagship Reactor Manufacturing Portfolio

Batch Reactors | Continuous Reactors | Hydrocracker Reactors | Hydrotreating Reactors | Hydrogenation Reactors | Polymerization Reactors | Fixed Bed Reactors | Fluidized Bed Reactors | Trickle Bed Reactors | Bioreactors | Fermentation Reactors | Glass-Lined Reactors | Pressure Reactors | Vacuum Reactors | High-Temperature Process Reactors

"Delivering Advanced Reactor Systems That Maximize Conversion Efficiency, Enhance Product Quality, Improve Process Safety, and Drive Long-Term Operational Excellence Across the World's Most Critical Industrial Manufacturing Facilities."

Ready to discuss your reactor requirements?

Partner with HI-NOVA APEX LLP for custom-engineered reactor systems that maximize conversion efficiency and process safety.

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