FRP Reactor

An FRP reactor is a process vessel manufactured from fiberglass reinforcement combined with corrosion-resistant resins such as isophthalic, bisphenol, vinyl ester, or epoxy systems. It is used for chemical reactions, mixing, or holding aggressive process media under controlled conditions. Unlike MS reactors, FRP reactors do not corrode in most acid and alkali environments, reducing contamination, wall thinning, and frequent relining or repainting. Compared to glass-lined steel, FRP eliminates risks of glass chipping, thermal shock damage, and expensive repair cycles. Being much lighter than metallic vessels, FRP reactors also reduce structural load requirements. For many non-very-high-pressure and non-very-high-temperature chemical processes in Gujarat, FRP reactors offer an excellent balance of chemical resistance, cost efficiency, and long-term performance.

FRP reactors are best suited for medium-pressure and moderate-temperature processes involving acids, alkalis, brine, etchants, pickling solutions, and many organic or inorganic liquids, subject to resin compatibility. They are widely used for reaction, neutralisation, mixing, and holding operations in chemical manufacturing, pharma intermediates, dyes and pigments, textile auxiliaries, and ETP neutralisation systems. For pickling and surface-treatment duties, FRP reactors safely handle hydrochloric, sulphuric, and mixed acids without the corrosion and leakage problems common in MS equipment. In water treatment and speciality chemical blending, the smooth and inert FRP surface minimises contamination and product build-up. Processes involving extremely high pressures or very high temperatures remain better suited to alloy or glass-lined reactors, but a wide range of ambient-to-moderate services can be reliably handled by FRP.

FRP reactors can be supplied in vertical or horizontal configurations, with flat, dished, or conical bottoms depending on process and drainage requirements. Typical capacities range from a few hundred litres for pilot or small-batch applications to tens of thousands of litres for bulk production. Designs may include manholes, baffles, customised nozzle layouts, sight glasses, and internal linings tailored to specific reaction or mixing duties. Agitation can be provided using top- or side-mounted mixers with appropriate shaft sealing and structural supports. In certain designs, metallic agitator components are combined with FRP-lined wetted zones to balance mechanical strength with chemical resistance. External supports, platforms, ladders, and instrumentation can be integrated into a complete reactor system matched to the plant layout.

FRP reactors are not intended for very high-pressure or very high-temperature services where metallic or glass-lined reactors are required. Design pressure and temperature must be clearly specified so that laminate thickness, resin selection, and safety factors are chosen correctly. Highly oxidising chemicals or certain solvent systems may require specialised resin grades or dual-laminate constructions. Nozzle loads, agitator loads, and thermal cycling effects must be carefully evaluated to ensure proper placement of stiffeners and supports and to avoid local overstress. When these engineering factors are addressed in accordance with recognised standards and experience, FRP reactors can safely replace MS or rubber-lined reactors in many medium-duty chemical applications.

FRP reactors significantly reduce corrosion-related maintenance, leakage risk, and downtime compared to MS or rubber-lined vessels. Their low weight reduces transportation, lifting, and structural steel costs, especially in multi-storey plants and brownfield expansions. Smooth, chemically inert internal surfaces minimise product contamination and simplify cleaning between batches, improving productivity and batch consistency. Over the equipment lifecycle, fewer relining jobs, reduced repainting, and lower unplanned shutdowns result in a lower total cost of ownership. For Gujarat’s chemical clusters such as Ankleshwar, Vapi, Dahej, and surrounding regions, FRP reactors are a reliable and sustainable solution wherever process conditions suit composite construction.