Assignment: Equipments Used in Pharmaceutical Industry For Heat and Mass Transfer
Assignment: Equipments Used in Pharmaceutical Industry For Heat and Mass Transfer
Assignment: Equipments Used in Pharmaceutical Industry For Heat and Mass Transfer
Submitted By
Sajid Ahmad
Wasif Naeem
Sajjad Haider
Shahzaib
Zahra Tabeer
MASS AND HEAT TRANSFER EQUIPMENT IN
PHARMACEUTICAL INDUSTRIES
Introduction:
Heat and mass transfer is the core science for many industrial processes as well as technical and
scientific devices. Automotive, aerospace, power generation (both by conventional fossil-based
technologies and also by renewable energies), industrial equipment and rotating machinery, materials
and chemical processing, and many other industries are involving heat and mass transfer processes.
Consequently, both heat transfer and mass transfer are disciplines of the highest significance in
technology and industry and obviously also in research and academia.
Renewable Fuels
Pharmaceuticals
Food Processing
Mining
Agriculture
Distillation is a separation processes involving both Heat and Mass transfer. While there are
many methods for separating chemical compounds, distillation has been proven to be the most
reliable and economical design for many applications.
One single stage of separation is defined as evaporation or more specifically but not commonly termed
“Flash Distillation.” In this process one volatile component is removed in a solution by heating and
consequently boiling the solution. The more volatile component in the solution is vaporized and
removed from the process.
Multiple effect evaporation applies several stages of evaporation in the separation process. In multiple
effect evaporation the process is limited by the sequential process design. Distillation employs the same
multi-stage principle in countercurrent stages to allow for a more efficient process minimizing waste
from the system.
Basics of Distillation
Relative volatility and activity coefficients are key parameters used in the design of a
distillation process. Since most distillation systems contain multiple components the
matrix of equations becomes quite large. Relative volatility is a measure comparing the
vapor pressures of the components in a system. The activity coefficient is a factor used
in the calculations to account for deviation from ideal behavior.
Graphical Method for Continuous Distillation: The McCabe-Thiele
Diagram
Developed in 1925 and still used today, the McCabe-Thiele diagram evaluates the
separation of components in a binary system. This x-y diagram simplifies some
variables to provide a quick, high-level evaluation of a simple distillation based on
established Vapor/Liquid Equilibrium (VLE) data. While useful in providing a visual
representation of the distillation process, this graphical method is limited to analyzing
two variables.
Modern Solutions
For more complicated distillation systems with three or more components,
computerbased simulation software is used in the design process. Two popular brands
of software are Aspen and ChemCad. The software programs allow designers to select
an appropriate VLE model for the mixture and generate accurate predictions and
distillationstage calculations.
The more complex systems also may require pilot testing for final design validation.
Thermal Kinetics can help develop Pilot Testing Equipment unique to a given test
system. These pilot runs provide valuable data for statistical analysis and development
of a more robust simulation model. These customized solutions are invaluable for more
complex systems that can otherwise be difficult to validate.
The use of hand calculation procedures is justified in cases when an engineer is tasked
with: rough system cost analysis, general valuation of operating variables, separations
with coarse purity requirements, designs for ideal and close-to-ideal systems.
• Designing a system that deviates significantly from ideal behavior or the lack of good VLE
data
A small volume tube with a filtering cell which has a certain number of pores has been
placed at one of its ends. A concentrated solution of salt (sodium chloride) has been
introduced inside. The tube is introduced in a vessel with pure solvent (distilled water).
Now, the diffusion starts, and it will be indirectly measured by the conductivity data.
A thermostatic bath allows us to make the experiments at different temperatures.
Materials
Columns
Our graphite columns are adapted to the washing of ultra-corrosive gases as well as the
fractioning or distillation of ultra-corrosive chemicals. They consist in a stack of impervious
graphite cylinders filled with packing material or with distillation trays. Graphite column
internals are used to distribute or collect gaseous and liquid streams at different levels in the
columns.
Quenches
Our graphite quenches are design to instantaneously cool down flue gases and therefore
prevent the formation of harmful chemicals. They consist in a short graphite column section
with a wetting system that ensures an intimate contact between the hot gas and a large
quantity of quenching fluid usually water. The whole piece of equipment is cooled down.
Hydrochloric acid recovery systems
Our hydrochloric acid recovery and dry hydrochloric acid generation systems consist in several
interconnected pieces of equipment that ensures the absorption of hydrochloric acid, its desorb
and its reflux condensation at various temperature to produce dry hydrochloric gas
Vacuum groups
Steam jet ejectors offer a simple, reliable, low-cost way to produce vacuum. For low suction
pressures, jet vacuum pumps shall be combined in series. Between two jet pumps the motive
steam is condensed in order to reduce the energy requirement of the next stage. Our
multistage vacuum generation groups consist in combined graphite steam ejectors and
condensers. Our multi-stage steam jet vacuum pumps can be designed for suction pressures
down to 1 mbar or lower.
Our mass transfer pieces of equipment are modular and can fit with individual process
specification. Their size can be adapted best meet the velocities, pressure drops, process and
heat transfer requirements.
All our graphite mass transfer pieces of equipment are machined after phenolic resin
impregnation thus guarantying a totally free of resin heat transfer surface and ensuring
therefore the highest possible heat transfer rate.
Industrial processes:
• Crop protection
• Fumed silica
• Silicones
• Titanium dioxide
• Fine chemicals
• Active pharmaceutical ingredients
• Epichlorohydrin
• Vinyl chloride monomer
• Fire retardants
• Flavors and fragrances
• Vitamins
• Isocyanates
• Viscose
• Polycarbonate
• Coagulants
• Treatment, purification and concentration of spent acids
• Sulfuric acid dilution
• Vacuum generation
• and many more…
Description
The column is made of Stainless Steel material packed with Borosilicate Glass rasching
rings. An electrically heated reboiler is installed at the bottom of the column. The bottom
product is collected in the tank. The vapours form at the top of column are condensed in
the shell and tube type condenser by circulating cooling water, supplied by laboratory
overhead tank. The condensate is divided into reflux and distillate by automatic reflux
divider and R/D Ratio can be varied. Reflux is fed back to the column and distillate is
received in a receiving tank. The complete column is insulated for minimizing the heat
loss. Instrumentation is provided for pressure & temperature measurement wherever
necessary
Experimentation/Learning Objectives To estimate the batch distillation curves for a
binary system and verify the binary batch distillation equation for a known packed
height. • To operate the column under total reflux condition and estimate the • HETP for
the packing. Utilities Required • Electricity Supply: Single Phase, 220 V AC, 50 Hz, 32
Amp. MCB with earth connection. Earth voltage should be less than 5 volts. •
Water Supply: 2 LPM@1 bar • Floor Drain. • Floor area required: 1.5m x 1.5m •
Required Chemicals. • Refractometer for analysis.
Most of the heat exchangers used in industry are shell and tube, air cooled, or plate and frame.
Typically, plate and frame heat exchangers are used for liquid-liquid exchange at low to medium
pressures. However, gasket-free plate and frame heat exchangers can safely operate at high
temperatures and pressures. Plate and frame heat exchangers offer flexibility because plates
can be either added or compressed for each different situation.
Plate and frame heat exchangers are made of corrugated plates on a frame. This design creates
high turbulence and high wall shear stress, both of which lead to a high heat transfer coefficient
and a high fouling resistance. Fluids travel within the heat exchanger. The two streams flow
counter currently. The hot fluid flows down one plate while the cold fluid flows up the other plate.
Gaskets ensure that the cold fluid and the hot fluid don’t mix. Alternatives to the traditional
gasket seal include brazing and laser welding.
The plates are stacked in an alternating manner to cause the counter current flow. Multiple
plates are clamped together and sealed at the edges. The design allows for the two fluids to
flow in alternate directions and not be mixed. However, heat can be transferred from one
medium to the other through the plates.
Because gasketed plate and frame exchangers are easy to clean, they are especially useful for
food and pharmaceutical processing, where high degrees of sanitation are required.
Advantages and disadvantages of plate and frame heat exchangers
A plate & frame heat exchanger has the following advantages over the widely used shell and
tube heat exchangers:
o High value for overall heat transfer coefficient, for the same two fluids, a flat plate
heat exchanger typically has a U value much higher than either a shell and tube heat
exchanger or a spiral heat exchanger.
o Compact design – The combination of high value for the overall heat transfer
coefficient and the general compact configuration of the flat plate heat exchanger
lead to its ability to have the same thermal capacity as a shell and tube heat
exchanger as much as five times its size
o Easy maintenance and cleaning – The fact that a plate and frame heat exchanger
can be taken apart as discussed in the previous section, allows for easy cleaning and
maintenance. A plate and frame heat exchanger can be designed to allow for easy
addition or removal of plates to expand or reduce its heat transfer capacity.
o Temperature control – A flat plate heat exchanger works well with small temperature
differences between the hot fluid and the cold fluid.
Plate & frame heat exchangers also has some disadvantages in comparison with other types of
heat exchangers as follows:
▪ Potential for leakage – Although plate and frame heat exchangers are designed to
allow the plates and the gaskets between them to be firmly clamped together, there
is still a greater potential for leakage than with either shell and tube or spiral heat
exchangers.
▪ Higher pressure drop – The narrow passageways for fluid flow, which lead to a high
overall heat transfer coefficient, also lead to a higher pressure drop, and thus a
higher cost for pumping, than shell and tube heat exchangers.
▪ Not good for large fluid temperature differences – A flat plate heat exchanger does
not work as well as a shell and tube heat exchanger for cases where there is a large
temperature difference between the two fluids.
▪ Doesn’t work well with very high fluid temperatures – The gaskets may impose
temperature limitations for plate and frame heat exchangers.
Insulating plate and frame heat exchangers
Heat exchangers must be adequately insulated to reduce heat losses. Because inspection and
maintenance of heat exchangers is routine, stay-in-place insulation is not practical. Generally,
heat exchanger experiences touch temperatures that differ from the ambient temperature,
valuable heat is likely radiating away. In the cases of larger heat exchangers or facilities with
multiple units, the amount of energy loss can be substantial.
Insulation coatings are a possible solution however it has to be reapplied each time
maintenance is performed which is costly & labor intensive. Custom fit removable and reusable
insulation is the most economic & efficient way to insulate heat exchangers allowing for easy on
& off application as maintenance is required.
How gasketed plate heat exchangers
WORK?
In a gasketed plate heat exchanger, the plates are fitted with elastomeric gaskets which seal the
channels and direct the fluids into alternate channels. The plate pack is assembled between a
frame plate and a pressure plate, and compressed by tightening bolts fitted between these
plates. The channel plates and the pressure plate are suspended from an upper carrying bar
and located by a lower guiding bar, both of which are fixed to the support column. The physical
design of the gasketed plate heat exchanger allows easy cleaning, and modification of capacity
by the addition or removal of plates. Liquid/Liquid GPHE
Steam heater GPHE
Liquid/Liquid 2-pass GPHE
Liquid/Liquid GPHE
This animation above shows the working principle of an Alfa Laval liquid/liquid 1-pass gasketed
plate-and-frame heat exchanger where the fluids run counter-currently through the heat
exchanger. The hot liquid (illustrated in red) normally enters through one of the upper
connections and leaves through the connection underneath. The cold liquid (illustrated in blue)
enters through one of the lower connections and leaves through the
connection above.
As the fluids pass through the heat exchanger, heat is transferred from the hot media to the cold
media. Counter current flow enables maximum heat recovery possibilities and very close
temperature approach can be achieved. Temperature cross is also possible, meaning that the
hot outlet can reach a lower temperature than the cold outlet. This can only be achieved to a
limited extent with tubular heat exchangers making plate-and-frame heat exchangers more
thermally efficient.
The fluids enter through the connections and portholes of the heat transfer plates. Specially
designed sealing gaskets located between the plates direct the fluids so that the hot and cold
fluids pass counter-currently in alternating channels. When the fluid enters between the plates, it
passes over the distribution area. Alfa Laval offers two types of distribution areas: our patented
CurveFlowTM and the chocolate pattern. The distribution area is one of the most important
features of a plate heat exchanger. Its main purpose is to ensure an even flow of fluid over the entire
plate while maximizing heat transfer efficiency and minimizing maldistribution and fouling. In the
animation you can see that the distribution area helps the fluids to quickly fill up the entire cross
section of the plates.
For very heat sensitive media, co-current flow is used in gasketed plate-and-frame heat
exchangers. The benefit with this design is that the coldest fluid meets the hottest fluid when
entering the heat exchanger, minimizing the risk of overheating or freezing sensitive media. In
the animation you can imagine that the hot fluid is reversed, so that both fluids are entering at
the bottom connections.
The animation shows the working principle of a conventional gasketed plate-and-frame heat
exchanger, but the same working principle is applicable also to specialized ranges such as our
Semi-welded and WideGap plate heat exchangers.
Alfa Laval has an extremely broad range of gasketed plate-and-frame heat exchangers which are used
in all types of industries. The number of sizes, plate and gasket materials and available options
are enormous.
Welded Plate Heat Exchanger
Fully welded plate heat exchanger is a plate heat exchanger made of a series of corrugated
metal plates welded by laser or argon arc welding. The plate group and the plate group are
connected by welding with molding strips. Because there is no gasket seal, it has higher
temperature and pressure resistance. It can be applied to extreme working conditions of high
temperature and high pressure.
Fully welded plate heat exchangers are divided into non-detachable fully welded plate heat
exchangers, 2-sided detachable fully welded plate heat exchangers, 4-sided detachable fully
welded plate heat exchangers (Compbloc) and wide channel fully welded plate heat exchangers
Advantages:
Fully Welded without Gasket
High Temperature /Pressure Resistance
High Heat Exchange Efficiency
Compact Structure:
The Spiral Heat Exchanger
In applications prone to high fouling, consider using a spiral heat exchanger. Its single-channel
design minimizes fouling and erosion and helps ensure high flow velocities even with heavy
process slurries.
A spiral heat exchanger consists of two long flat plates wrapped around a mandrel or center
tube, creating two concentric sprial channels.
Heat exchanger fouling is a major source of maintenance costs and lost production time. It has
been estimated that fouling costs U.S. industry more than $5 billion annually. Over time, as
material builds up on the heat transfer surfaces of a typical heat exchanger, an insulating layer
is formed that reduces the heat transfer rate and increases pressure drop through the
exchanger. Eventually, the heat exchanger must be cleaned to restore the heat transfer rates
and pressure drops required by the process. With many traditional heat exchanger designs,
cleaning is timeconsuming and costly, and it may need to be performed frequently. A spiral heat
exchanger can help processors avoid these problems.
A spiral heat exchanger is a useful alternative to shell and tube designs for many applications
prone to fouling and plugging problems. For more than 60 years, it has been used in difficult
services ranging from PVC slurry coolers to asphalt heaters. Its flow-channel geometry and
single-
channel design induce highly turbulent flow, so the compact exchanger can operate reliably with
low fouling rates even in heavy fouling, fibrous or slurry duties. It can be opened quickly and
easily for inspection, cleaning and maintenance.
In a spiral heat exchanger, the hot fluid flows into the center of the unit and spirals outward
toward the outer plates while at the same time, the cold fluid enters the periphery and spiral
inward, exiting at the center.