Our engineering team overhauled a stainless steel batch reactor, combining FEA simulation with smart material blending to achieve superior mechanical performance and cost efficiency.
 
The cylindrical shell and elliptical heads were modelled in SolidWorks and analysed for internal pressure, thermal gradients, and nozzle loads under ASME Section VIII design conditions. The verified safety factors exceeded ASME code minimums by 20 %, ensuring robust compliance and durability.
 
To reduce mass and manage heat expansion, we re-engineered the support legs into a tapered box structure with composite sleeves over 316L stainless steel cores.
Refined fillet radii and gusset slot geometry redirected stress away from weld toes, significantly increasing fatigue life and minimizing maintenance risk.
 
The final engineering package includes fabrication-ready 2D drawings, WPS (Welding Procedure Specifications), and NDT (Non-Destructive Testing) plans, allowing U.S. and international fabricators to proceed directly to production — no design loopbacks or rework required.