GROUP ID :658942

GUJARAT TECHNOLOGICAL UNIVERSITY

LUKHDHIRJI ENGINEERING COLLEGE MORBI

BATCH REACTOR
SUBJECT: Design Engineering
Semester: 5
Branch: Chemical engineering
Faculty: Prof. M.T. Chauhan
Group members
Group members NAME ENROLLMENT NO
1 MANDANI SHIVAM 220310105014
2 PATEL MEET 220310105016
3 BHANDARI DHRUV 220310105023
4 TANK PARTH 230313105041

5 JOSHI RAJ 230313105048

Guided By: Head of Department:

[Link] [Link]
 CERTIFICATE

This is to certificate that MANDANI SHIVAM (220310105014), PATEL MEET

(220310105016), BHANDARI DHRUV (220310105023), TANK PARTH
(230313105041), JOSHI RAJ (230313105048) of B.E. semester- V
(Chemical engineering) has complete his DESIGN ENGINEERING work for the project
entitled “BATCH REACTOR” satisfactorily in fulfilment for requirement of DESIGN
ENGINEERING course, Gujarat Technological University, Ahmedabad, in the academic
year 2024-2025

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 ACKNOWLEDGEMENT

We have taken many efforts in this project. However, it would not have been possible
without the kind support and help of many individuals and organization. We would like to
extend my sincere thanks to all of them. We are highly indebted to Prof. [Link]
for their guidance and constant supervision as well as for providing regarding the design
engineering project titled “batch reactor and their applications”.

We would like to express my gratitude towards our guide Prof. [Link] & staff
members of chemical engineering department L.E. COLLEGE, MORBI for their kind
cooperation and encouragement which helped us in completion of this project. We even
thank and appreciate to our colleague in developing the project and people who have
willingly helped us out with their abilities.

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 ABSTRACT

Batch reactors play a pivotal role in chemical engineering processes due to their versatility
and adaptability. This abstract provides a concise overview of batch reactors and their
diverse applications.

Batch reactors are characterized by their closed-system operation and flexibility in handling
various reactions. They are employed in industries such as pharmaceuticals, specialty
chemicals, polymers, and food processing, where precise control over reaction parameters
and small-scale production are crucial. Advancements in batch reactor technology,
including automation and process intensification, have enhanced efficiency and product
quality. Furthermore, efforts towards sustainability focus on minimizing waste generation
and optimizing energy consumption.

Keywords:
1. Batch Reactor
2. Reactor design
3. Reaction kinetics
4. Process optimization
5. Closed-system operation
6. Process optimization

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 Table of Contents

Contents

CERTIFICATE ................................................................................................................................................ 2
ACKNOWLEDGEMENT ................................................................................................................................ 3
ABSTRACT ..................................................................................................................................................... 4
LIST OF TABLES ........................................................................................................................................... 5
LIST OF FIGURES .......................................................................................................................................... 5
Chapter 1: Introduction to project ...................................................................................................................... 7
1.1 Brief introduction to Project ........................................................................................................................ 7
1.2 Process of Preparation ................................................................................................................................. 7
1.3 Advantages of Using This Process............................................................................................................... 9
1.4 Disadvantages of Using This Process ........................................................................................................ 10
Chapter 2: Literature Survey ........................................................................................................................... 12
2.1 What are the Features of project? .............................................................................................................. 12
2.2 What is the purpose of this project? ........................................................................................................... 15
2.3 Brief Introduction Of Batch Reactor .......................................................................................................... 15
2.4 Working Principal and Working of Batch Reactor ..................................................................................... 19
2.5 Part Of Batch Reactor ............................................................................................................................... 20
2.6 Titration and Observation table ................................................................................................................. 23
Chapter 3: Working canvas of the project ........................................................................................................ 24
3.1 AEIOU Canvas ......................................................................................................................................... 24
3.2 Empathy Canvas ....................................................................................................................................... 25
3.3 Ideation Canvas......................................................................................................................................... 26
3.4 Production Development Canvas ............................................................................................................... 27
3.5 Mind Mapping Canvas .............................................................................................................................. 28
3.6 Prototype Canvas ...................................................................................................................................... 29
Chapter 4: Summary ....................................................................................................................................... 30
Chapter 5: References ..................................................................................................................................... 31

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 Chapter 1: Introduction to project

1.1 Brief introduction to Project:

Batch reactors are pivotal in chemical engineering, providing a versatile platform for
diverse industrial processes. This project aims to delve into the fundamentals of batch
reactors and explore their extensive applications across various industries.

The project will begin by elucidating the basic principles of batch reactors, emphasizing
their closed-system operation, flexibility in handling reactions, and suitability for small-
scale production and research purposes.

Subsequently, it will explore the wide array of applications where batch reactors excel,
including pharmaceutical manufacturing, specialty chemicals, polymerization
reactions, and food processing industries. The project will highlight the significance of
batch reactors in enabling precise control over reaction parameters and facilitating the
production of high-value products.

Furthermore, the project will investigate recent advancements in batch reactor

technology, such as automation, process intensification, and sustainability initiatives. It
will analyze how these advancements enhance efficiency, safety, and environmental
sustainability in batch reactor operations.

Overall, the project aims to provide a comprehensive overview of batch reactors and
their applications, shedding light on their importance in modern chemical engineering
processes and industrial manufacturing.

1.2 Process of Preparation:

The process of preparing a batch reactor involves several steps, from initial design
considerations to the actual fabrication and installation. Here's a general outline of the
process:

1. Define Requirements:
- Determine the specific requirements of the reaction process, including reaction
kinetics, temperature and pressure conditions, desired product yield, and safety
considerations.
- Identify the type of batch reactor needed based on the reaction characteristics (e.g.,
batch stirred tank reactor, fixed-bed reactor, or plug-flow reactor).

2. Design Phase:
- Develop a detailed design of the batch reactor based on the defined requirements.
- Consider factors such as reactor geometry, material of construction, agitation
mechanisms (if applicable), heating and cooling methods, instrumentation and control
systems, and safety features.
- Perform engineering calculations to ensure the reactor design meets the desired
operating conditions and safety standards.

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 3. Material Selection and Procurement:
- Select appropriate materials of construction for the reactor vessel, agitators, baffles,
and other components based on compatibility with the reactants, operating conditions,
and corrosion resistance requirements.
- Procure the necessary materials from suppliers, ensuring compliance with quality
standards and specifications.

4. Fabrication:
- Fabricate the batch reactor components according to the approved design.
- Weld together the reactor vessel, agitator shaft, baffles, and other structural
elements.
- Install internal components such as heating/cooling coils, thermocouples, sensors,
and safety devices.
- Perform non-destructive testing (NDT) and quality inspections during fabrication
to ensure structural integrity and compliance with design specifications.

5. Assembly and Integration:

- Assemble the fabricated components to construct the complete batch reactor
system.
- Install auxiliary equipment such as pumps, valves, heat exchangers, and control
instruments.
- Integrate the batch reactor with supporting infrastructure such as utility
connections (e.g., steam, cooling water, electricity) and process control systems.

6. Testing and Commissioning:

- Conduct thorough testing of the batch reactor system to verify its performance and
functionality.
- Test individual components, subsystems, and the entire system under various
operating conditions.
- Address any issues or deficiencies identified during testing and make necessary
adjustments or repairs.
- Once testing is successfully completed, commission the batch reactor for
operation.

7. Operation and Maintenance:

- Operate the batch reactor according to standard operating procedures (SOPs) and
safety protocols.
- Monitor process parameters, product quality, and equipment performance during
operation.
- Implement routine maintenance activities such as cleaning, inspection, lubrication,
and replacement of worn-out parts to ensure optimal performance and longevity of the
batch reactor.

By following these steps systematically, the preparation of a batch reactor can be carried
out effectively, ensuring its successful integration into the desired industrial process.

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1.3 Advantages of Using This Process:

The process of preparing a batch reactor offers several advantages, making it a

preferred choice for many chemical engineering applications:

1. Flexibility in Operations: The batch reactor process allows for greater flexibility
in handling a wide range of reactions and products. It accommodates varying
reaction times, temperatures, and feed compositions, making it suitable for
diverse chemical processes.

2. Small-Scale Production: Batch reactors are well-suited for small-scale

production and research activities. They enable the production of limited
quantities of specialty chemicals, pharmaceuticals, and experimental compounds
without the need for continuous operation.

3. Control Over Reaction Parameters: Batch reactors offer precise control over
reaction parameters such as temperature, pressure, agitation speed, and feed rate.
This control allows for optimization of reaction conditions, leading to improved
product quality and yield.

4. Ease of Scale-Up: The batch reactor process is relatively easy to scale up from
laboratory-scale experiments to pilot plant and production-scale operations. This
scalability facilitates process development and optimization, reducing time-to-
market for new products.

5. Safety and Environmental Benefits: Batch reactors minimize the risk of cross-
contamination between different reaction batches, enhancing product purity and
safety. Additionally, they allow for better containment of hazardous materials,
reducing the potential environmental impact of chemical processes.

6. Versatility in Reactor Design: Batch reactors can be designed in various

configurations to suit specific process requirements. Whether it's a stirred tank
reactor, fixed-bed reactor, or plug-flow reactor, the versatility in design allows for
customization according to the desired reaction kinetics and heat transfer
characteristics.

7. Process Intensification Opportunities: The batch reactor process offers

opportunities for process intensification through innovative design features and
operational strategies. This includes the integration of advanced mixing
techniques, multiphase reactions, and in-situ product separation methods to
enhance process efficiency and productivity.

8. Reduced Capital Investment: Compared to continuous-flow reactors, batch

reactors often require lower initial capital investment, making them
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 economically attractive for small-scale or niche production applications.
Additionally, their modular design and ease of installation contribute to cost
savings during plant setup.

9. Adaptability to Market Demand: Batch reactors allow manufacturers to

respond quickly to changes in market demand and product specifications. They
can easily switch between different product formulations or production schedules
without major reconfiguration of equipment, enabling greater agility in meeting
customer requirements.

Overall, the process of preparing a batch reactor offers numerous advantages,

making it a versatile and cost-effective solution for various chemical engineering
applications. Its flexibility, scalability, and control over reaction parameters make
it an indispensable tool for research, development, and production in the chemical
process industries.

1.4 Disadvantages of Using This Process:

While the process of preparing a batch reactor offers several advantages, there are
also some disadvantages associated with this approach:

1. Lower Overall Efficiency: Batch processes typically have lower overall efficiency
compared to continuous processes, as they involve downtime for filling, reaction, and
emptying of the reactor. This results in longer cycle times and lower productivity per
unit time.

2. Limited Production Capacity: Batch reactors are generally less suitable for large-
scale production due to their limited capacity and slower throughput compared to
continuous-flow reactors. This can lead to higher unit costs for large-volume production
runs.

3. Complexity in Process Control: Managing batch processes requires careful

monitoring and control of various parameters such as reaction kinetics, temperature,
pressure, and feed rates. Achieving optimal process control can be challenging,
particularly for complex reactions or sensitive products.

4. Product Variability: Batch-to-batch variability is inherent in batch processes, leading

to inconsistencies in product quality, purity, and yield. Variations in raw materials,
reaction conditions, and operating procedures can contribute to product variability and
require additional quality control measures.

5. Labor Intensive: Batch processes often require more labor-intensive operations,

including manual handling of raw materials, cleaning of equipment between batches,
and monitoring of process parameters. This can increase labor costs and operator
fatigue, especially for repetitive or long-duration batch runs.

6. Higher Energy Consumption: Batch processes may have higher energy

consumption per unit of product compared to continuous processes, particularly for
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 heating and cooling operations during batch cycling. Energy-intensive processes can
contribute to higher operating costs and environmental impact.

7. Difficulty in Process Optimization: Optimizing batch processes for maximum

efficiency and productivity can be complex and time-consuming. Factors such as batch
scheduling, cycle times, and equipment utilization must be carefully balanced to
minimize idle time and maximize resource utilization.

8. Risk of Equipment Failures: Batch reactors are subjected to repeated cycles of filling,
heating, cooling, and emptying, increasing the risk of equipment wear and fatigue.
Mechanical failures, leaks, and process upsets can disrupt production and compromise
safety.

9. Regulatory Compliance Challenges: Compliance with regulatory requirements, such

as safety standards, environmental regulations, and Good Manufacturing Practices
(GMP), can pose challenges for batch processes. Ensuring consistent product quality,
traceability, and documentation may require additional resources and oversight.

Despite these disadvantages, batch reactors remain widely used in chemical engineering
for their versatility, flexibility, and suitability for small-scale production, research, and
specialty applications. By carefully addressing the challenges associated with batch
processes, manufacturers can optimize their operations and maximize the benefits of
batch reactor technology.

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 Chapter 2: Literature Survey

1.1 What are the Features of project?

The features of the project on "Batch Reactors and Their Applications" include:

1. Comprehensive Coverage: The project provides an in-depth exploration of batch

reactors, covering fundamental principles, applications across various industries,
advancements in technology, and sustainability considerations.

2. Interdisciplinary Approach: It integrates knowledge from chemical engineering,

process chemistry, materials science, and environmental engineering to offer a holistic
understanding of batch reactor systems and their role in industrial processes.

3. Practical Applications: The project emphasizes real-world applications of batch

reactors, illustrating their significance in pharmaceutical manufacturing, specialty
chemicals production, polymerization reactions, food processing, and other industries.

4. Current Insights: It incorporates recent advancements and trends in batch reactor

technology, including automation, process intensification, green chemistry initiatives,
and sustainability practices, reflecting the latest developments in the field.

5. Educational Resource: The project serves as an educational resource for students,

researchers, and professionals in chemical engineering and related fields, providing
valuable insights into batch reactor design, operation, and optimization.

6. Problem-Solving Approach: It addresses common challenges and considerations

associated with batch reactor processes, such as process control, scalability, product
variability, energy efficiency, and regulatory compliance, offering practical solutions
and recommendations.

7. Case Studies: The project includes case studies and examples to illustrate the
application of batch reactors in specific industrial contexts, facilitating a deeper
understanding of their operational principles and practical implications.

8. Future Directions: It discusses emerging technologies, research opportunities, and

potential areas for innovation in batch reactor systems, inspiring further exploration and
development in the field.

Overall, the project on "Batch Reactors and Their Applications" is characterized by its
comprehensive coverage, interdisciplinary approach, practical relevance, educational
value, problem-solving orientation, and forward-looking perspective.

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2.1 What is the importance of this project?
The project on "Batch Reactors and Their Applications" holds significant importance
for several reasons:

1. Industrial Relevance: Batch reactors are widely used in various industries such as
pharmaceuticals, specialty chemicals, polymers, and food processing. Understanding
their principles and applications is crucial for professionals working in these sectors to
optimize processes, improve product quality, and ensure safety.

2. Process Optimization: By exploring batch reactor technology and its applications,

the project helps identify opportunities for process optimization, leading to increased
efficiency, reduced production costs, and enhanced competitiveness for industrial
organizations.

3. Innovation and Research: Batch reactors continue to evolve with advancements in

automation, process intensification, and sustainability practices. The project serves as
a foundation for further research and innovation in batch reactor design, operation, and
control, driving advancements in chemical engineering and related fields.

4. Education and Training: The project serves as an educational resource for students,
researchers, and professionals in chemical engineering and related disciplines. It
provides valuable insights into batch reactor systems, fostering a deeper understanding
of their principles, applications, and potential impact on industrial processes.

5. Sustainability and Environmental Impact: Understanding the role of batch reactors

in sustainable manufacturing practices is critical for addressing environmental concerns
and meeting regulatory requirements. The project highlights green chemistry initiatives,
waste minimization strategies, and energy-efficient practices to reduce the
environmental footprint of batch reactor operations.

6. Knowledge Transfer and Collaboration: Sharing knowledge and best practices

related to batch reactors facilitates collaboration among academia, industry, and
regulatory agencies. The project promotes knowledge transfer and exchange of ideas,
leading to synergies and partnerships that drive innovation and continuous improvement
in batch reactor technology.

7. Global Impact: Batch reactors play a vital role in global manufacturing processes,
affecting industries and economies worldwide. By promoting understanding and
adoption of best practices in batch reactor technology, the project contributes to
sustainable development goals and socioeconomic progress on a global scale.

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 Overall, the importance of the project on "Batch Reactors and Their Applications" lies
in its ability to enhance industrial efficiency, drive innovation, foster education and
training, promote sustainability, facilitate collaboration, and make a positive impact on
society and the environment.

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1.2 What is the purpose of this project?
The purpose of a project involving batch reactors depends on the specific context and
industry in which it's being utilized. However, generally speaking, batch reactors are
Vessels used for chemical reactions, where all the reactants are added at the beginning
of the process and allowed to react for a certain period of time. Here are some common
purposes for projects involving batch reactors:

1. Chemical Synthesis: Batch reactors are commonly used in chemical synthesis

processes to produce various compounds or materials. These reactions can range from
small-scale laboratory experiments to large-scale industrial production.

2. Process Development: Batch reactors are often used in the development and
optimization of chemical processes. Engineers and scientists use batch reactors to study
reaction kinetics, determine optimal reaction conditions, and scale up processes for
commercial production.

3. Product Testing: Batch reactors are utilized for testing the feasibility and quality of
new products. This can include testing different formulations, assessing reaction yields,
and evaluating product stability under various conditions.

4. Pharmaceutical Manufacturing: In the pharmaceutical industry, batch reactors are

frequently used for drug synthesis and manufacturing. They enable precise control over
reaction parameters and facilitate the production of pharmaceutical compounds in batch
quantities.

5. Fine Chemicals Production: Batch reactors are employed in the production of fine
chemicals, including specialty chemicals, fragrances, flavors, and dyes. These reactors
allow for the synthesis of complex molecules with high purity and yield.

6. Polymerization Reactions: Batch reactors are essential in polymerization processes

for producing polymers with specific properties. They enable control over reaction
conditions such as temperature, pressure, and feed rates to tailor the properties of the
polymer.

Overall, projects involving batch reactors serve the purpose of conducting controlled
chemical reactions to produce desired products or materials, whether for research,
development, or commercial purposes.

1.3 Brief Introduction Of Batch Reactor

A batch reactor is a closed system in which the time is the only independent variable.
the batch operation can be used for some small production of paracetamol, painkiller
and many more. the drawbacks associated with this type of operation limit its industrial
use:

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  the control of the product
 the productivity is low considering the load, unload, and cleaning times;
 the heat generation rate is high and the control of the reactor temperature is very
difficult because all of the reactant is initially charged into the reactor
 the system suffers from batch-to-batch variations due to irreproducible particle
nucleation that may jeopardize product consistency. in order to avoid this problem,
seeded may be employed.
Batch reactors are commonly used in research laboratories because of its simplicity and
low cost of operation. the composition of the copolymers produced in batch reactors
will be dictated by the reactivity ratios of the comonomers and the ratio of their
concentration in the polymer particles (mayo–Lewis) copolymer composition equation
most of the common monomers employed in emulsion polymerization recipes present
different reactivities, and a consequence of this is the compositional drift (nonconstant
copolymer composition) produced in batch operation. the batch reactor is the generic
term for a type of vessel widely used in the process industries. its name is something
since vessels of this type are used for a variety of process operations such as solids
dissolution, mixing, chemical reactions, batch distillation, crystallization, liquid/liquid
extraction and polymerization. in some cases, they are not referred to as reactors but
have a name which reflects the role they perform (such as crystallizer, or bioreactor).a
typical batch reactor consists of a storage tank with an agitator and integral
heating/cooling system. these vessels may vary in size from less than 1 litre to more
than 15,000 litres. liquids and solids are usually charged via connections in the top cover
of the reactor. vapours and gases also discharge through connections in the top. liquids
are usually discharged out of the bottom. the advantages of the batch reactor lie with
its versatility. a single vessel can carry out a sequence of different operations without
the need to break containment.

Fig.1 : Batch Reactor

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Types Of Reactors

1. Batch Reactor
2. Semi-Batch Reactor
3. Continuous Stirred Tank Reactor (CSTR)
4. Plug Flow Reactor

Fig.2 Batch Reactor

Fig.3 Semi Batch Reactor

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 Fig 4 CSTR

Fig 5 Plug Flow Reactor

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1.4 Working Principal and Working of Batch Reactor
 Working: -
The batch reactor in the laboratory is typically loaded with materials and heated to a
desired temperature. then, after a given time, the reactor is brought to room temperature
and the contents are analyzed. because the vessel is sealed, the mass of the materials in
the vessel cannot change and the volume is constant. since the total mass and volume
are constant in the vessel, the overall density or system density, ρ = m/v, is fixed.
The material, energy, and entropy balances for a batch reactor or constant in the volume.

Fig.6 Study batch reactor

 Principal: -
In the laboratory of batch reactors are pressurized vessels so that the top is sealed by
various types of closures. Batch reactors are used to study the behavior of fluids with
materials under various conditions of temperature and pressure. in a chemical process,
horizontal or vertical vessels are also used to store fluids or to provide a volume so that
a mixture of liquid and vapor can separate into two distinct phases

 Titration: -
In batch reactor we get the sodium acetate as our product, now we have to test the
concentration of our product. it can be measured by two methods,
1) By performing titration with any acid
2) By using material & energy balance calculation

The method of titration is more effective as compare to material & energy balance
calculation. in titration we have required a berate, test tube, bicornes, phenolphthalein,

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 any acid (like Hcl) now fill-up burate with sodium acetate 50ml, now take 1.5m acid in
bicornes, add some drop of phenolphthalein now adds sodium acetate by nozzle of
burate in becor inn which we take acid, now mixing it properly.

After some time, it gets light pink color, note the volume of sodium acetate in burate,
perform this experiment 2-3 time. now we calculate the concentration of sodium acetate
by using following equation.

N1V1=N2V2 ........................................ (1)

Were
N1 = concentration of acid (m)
V1 = volume of acid (ml)
N2 = concentration of sodium acetate (m)
V2 = volume of sodium acetate (ml)

We have the value of N1, V1 & V2 from practical so we can calculate the value of
sodium acetate.

1.5 Part Of Batch Reactor

1. Plastic Container

2. Transparent Plastic Bottle

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 3. PVC Flexible hosepipe

4. Battery

5. Rocker Switch

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 6. Connector

7. DC Motor

8. Plastic Fan (Agitator)

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 9. pen (Baffles, Shaft)

10. m-seal

1.6 Titration and Observation table

1.6.1 OBSERVATION TABLE

Component Titration-1 Titration-2 Titration-3

Sodium Acetate 35.45 ml 34.30 ml 33.80 ml
Acid (HCL) 20 ml 20 ml 20 ml

1.6.2 Calculation;-

Volume of acid (v2) = 20ml

Volume of sodium acetate (v1) =Avg. Of All Titration Reading =34.52 ml
Concentration Of Acid (n1) = 1 m
Concentration Of Sodium Acetate (n2) = ? m
From The Equation N2 = N1V1/V2
= 1*34.52/20
=1.726M
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 Chapter 3: Working canvas of the project

3.1 AEIOU Canvas:

In this canvas we have tried to define which activities we does, how the project affect
to the environment, who is interact with this project, which objects are used in project,
who can use this project.

A - Activities
E - Environment
I - Interaction
O - Objects
U – Users

Figure 7 AEIOU Canvas

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3.2 Empathy Canvas:

Fig. 8 Empathy canvas

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3.3 Ideation Canvas:

Using this canvas, we can tu5n our ideas into opportunities. In this canvas we include
and some activities which users can perform using the system.

Fig. 9 Ideation Canvas

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3.4 Production Development Canvas:

A product canvas is a planning tool designed to help build products that have a great
user experience through a focus on feature development.

Fig.10 Product Development Canvas

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3.5 Mind Mapping Canvas:

A mind map shows the different ideas associated with a particular concept. It is a useful
tool for brainstorming. The concept is usually shown in the middle as a central idea that
branches off in different directions.

Fig.11 Mind Mapping Canvas

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3.6 Prototype Canvas:

The Prototype Canvas helps you test a certain aspect of the product of service you have
in mind.

Our trial is shown below.

Fig 12 Prototype Canvas

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 Chapter 4: Summary

1) We are preparing working model of batch reactor by using vest material

2) We have given each type of reactor a subjective rating based on five parameters. batch
reactors can be used for almost any reaction – their flexibility is excellent. although there
some challenges, the scalability of batch reactors is good and there is a lot of scale-up
experience

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 Chapter 5: References
 [Link] ymer-
science-a- comprehensive-reference
 [Link]
 [Link]
 [Link]
ing+ book&client=firefox-b-
 [Link]
 [Link]
hapters/chapter008/section002/blue/[Link]
 [Link]
glossary/batch-reactor-0
 [Link]
 [Link]
 [Link]
 [Link]
 [Link]
uencing_batch_reactors
 [Link]

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