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Overhead components integrated with your reactor (or other type of vessel) create a system to efficiently carry out reaction, distillation, and other process functionalities.
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In practice, reaction and distillation processes are frequently executed consecutively. The chemical and pharmaceutical industries have been successfully using a combination of vessels with distillation attachments as a corrosion resistant solution to realize their reaction and distillation / rectification needs, as this dual solution is especially suited for the production of highly refined and high-purity products.
The vessel attachments can be flexibly connected via PTFE bellows directly to or laterally offset from the vapor outlet of the reactor. Vessel attachments are mounted in separate structures next to the vessels. The structure can be adapted individually to the available space conditions, leaving the required free space on the vessel cover for the stirrer unit, filling neck, illumination, sight glass, safety valves, and any other accessories and instrumentation. Since borosilicate glass is transparent, the process can be visually controlled at any time, improving the safety and reliability of the operation.
Vessel attachments are suitable for different processes, including:
The plants are operated at atmospheric pressure or under vacuum mostly in batch but also in continuous mode.
When added to standalone equipment, overheads enhance the performance capabilities of your operation, providing a customized solution specifically tailored to your process requirements. Equipment that often integrates with overheads include:
In practice, reaction and distillation processes are frequently executed consecutively. The chemical and pharmaceutical industries have been successfully using a combination of vessels with distillation attachments as a corrosion resistant solution to realize their reaction and distillation / rectification needs, as this dual solution is especially suited for the production of highly refined and high-purity products.
The vessel attachments can be flexibly connected via PTFE bellows directly to or laterally offset from the vapor outlet of the reactor. Vessel attachments are mounted in separate structures next to the vessels. The structure can be adapted individually to the available space conditions, leaving the required free space on the vessel cover for the stirrer unit, filling neck, illumination, sight glass, safety valves, and any other accessories and instrumentation. Since borosilicate glass is transparent, the process can be visually controlled at any time, improving the safety and reliability of the operation.
This example shows a vessel attachment with uprising condensation means the vapor are moving upwards along the heat exchanger W1 and condensing. The down flowing condensate leaves the condenser W1 at its boiling temperature. Depending on the on/off position of the valve above W2 the condensate is either guided backwards into the reactor or withdrawn.
This example shows a vessel attachment with uprising condensation means the vapor are moving upwards along the heat exchanger W1 and condensing. The down flowing condensate leaves the condenser W1 at its boiling temperature. Depending on the on/off position of the valve above W2 the condensate is either guided backwards into the reactor or withdrawn.
The vessel attachment can be equipped with measuring and control devices according to the process requirements.
The following measuring instruments are generally sufficient:
The same process functionality can be achieved with a shell & tube heat exchanger. They can also be installed in a horizontal position to minimize the required height. The heat transfer rates are higher, and the sizes of shell & tube heat exchanger can be bigger so that they are also suitable for bigger vessels than can be covered with coil type heat exchangers.
The same process functionality can be achieved with a shell & tube heat exchanger. They can also be installed in a horizontal position to minimize the required height. The heat transfer rates are higher, and the sizes of shell & tube heat exchanger can be bigger so that they are also suitable for bigger vessels than can be covered with coil type heat exchangers.
The vessel attachment can be equipped with measuring and control devices according to the process requirements.
The following measuring instrumentation is generally sufficient:
In addition to the apparatus described above, this setup includes a phase separation vessel for the distillate. Such setups are used when the distillate forms two phases as distillates, e.g. for water removal during esterification and heterogenous azeotropes. The phase separator permits the adjustment of the interphase and the separate withdrawal of the light and heavy phase. Either the light phase or the heavy phase can be selectively guided back into the vessel or withdrawn.
In this setup, the vapors enter the condenser W1 and flow downward along the heat exchanger W1. Contrary to an uprising condensation, in descending condensation the condensate runs off with temperatures below its boiling point. This is especially advantageous for vacuum distillations as it reduces the amount of vapors leaving the condenser so that the distillate cooler W2 and the aftercooler W3 operated at a lower temperature than W1 can be smaller if not even skipped. The condensate can either be withdrawn or sent back to the reactor. Boiling under reflux is of course possible but not always advantageous since the reflux is cooled below the boiling point of the distillate and cools down the reactor content. On the other side this can be an advantage if heat of reaction must be taken out from the reaction mixture to control the reaction.
In this setup, the vapors enter the condenser W1 and flow downward along the heat exchanger W1. Contrary to an uprising condensation, in descending condensation the condensate runs off with temperatures below its boiling point. This is especially advantageous for vacuum distillations as it reduces the amount of vapors leaving the condenser so that the distillate cooler W2 and the aftercooler W3 operated at a lower temperature than W1 can be smaller if not even skipped. The condensate can either be withdrawn or sent back to the reactor. Boiling under reflux is of course possible but not always advantageous since the reflux is cooled below the boiling point of the distillate and cools down the reactor content. On the other side this can be an advantage if heat of reaction must be taken out from the reaction mixture to control the reaction.
Additional alternate receivers are integrated, so that the distillate can be taken off during vacuum distillation.
The selected attachment can be equipped with measuring and control devices according to customer’s request and process requirements.
The following measuring instruments are typically included:
Using a packed column C1 with a reflux divider between the condenser W1 and the reactor R1, volatile substances with closer boiling points can be separated by rectification from each other. The column height and the type of column internals are fixed in accordance with the separation problem and the available height. For the advantage of universal corrosion resistance, they are made of borosilicate glass 3.3 or PTFE. We offer a wide range of such internals as:
Depending on the process requirements, other types of random and structured packings in various materials of construction can be used (e.g. metals, plastics [PP, PVDF etc.], ceramics).
The reflux is fed into the column above the packed bed. The withdrawn distillate will be cooled down through the subsequent distillate cooler W2 and finally captured by the receivers. The ratio between the reflux and the distillate take-off required for the rectification is set by means of a magnetically controlled reflux divider in connection with either an electronic timer or a process control system.
Using a packed column C1 with a reflux divider between the condenser W1 and the reactor R1, volatile substances with closer boiling points can be separated by rectification from each other. The column height and the type of column internals are fixed in accordance with the separation problem and the available height. For the advantage of universal corrosion resistance, they are made of borosilicate glass 3.3 or PTFE. We offer a wide range of such internals as:
Depending on the process requirements, other types of random and structured packings in various materials of construction can be used (e.g. metals, plastics [PP, PVDF etc.], ceramics).
The reflux is fed into the column above the packed bed. The withdrawn distillate will be cooled down through the subsequent distillate cooler W2 and finally captured by the receivers. The ratio between the reflux and the distillate take-off required for the rectification is set by means of a magnetically controlled reflux divider in connection with either an electronic timer or a process control system.
Depending on available height and required condensing capacity either tube & shell or coil type heat exchangers are used.
The standard instrumentation covers most applications:
DE DIETRICH PROCESS SYSTEMS is the leading global provider of Process Equipment, Engineered Systems and Process Solutions for the fine chemical, chemical and pharmaceutical industry.
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