Industrial Pharmacy 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.

Equipments used in Mass transfer:

1) Equipments for Mass Transfer:
Distillation Technology and Design:
Distillation is one of the most reliable, cost-effective methods of chemical separation and is a
crucial step or “unit operation” in a wide range of industrial processes. Thermal Kinetics provides
both “Modular” and “Field-erected” Distillation systems that support many industries, including:

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.

Single Stage & Multiple Stage Separation Processes

Before delving into the specifics of the distillation process and design considerations, it is important to
first establish the difference between single and multiple stage separation processes in general.

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

At its most basic definition, distillation is the separation of components in a solution

based on their relative volatility. To accomplish the Distillation process, the liquid and
vapor interact in a counterflow arrangement within a vertical column

Compounds separated by distillation are characterized by their volatility, which is related

to the chemical’s vapor pressure. Chemicals exhibit different boiling temperatures at
different pressures. For example, water boils at 212 °F at atmospheric pressure, or 14.7
psia. At 1.94 psia, it boils at 125 °F. In this example, water has a vapor pressure of 14.7
psia at 212 °F and 1.94 psia at 125 °F. Ethanol, as another example, has a vapor
pressure of 32.5 psia at 212 °F and 4.55 psia at 125 °F. Since the vapor pressure (VP)
of ethanol is higher than water, it is more volatile.

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 Distillation Design Process

Regardless of the specific models used, the overall design process follows a standard
practice. The general steps are as follows:

1. Evaluate the vapor-liquid equilibrium data

2. Calculate the necessary equilibrium stages

3. Determine tray hydraulics

4. Select the appropriate tray or packing efficiencies

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.

Conversely, a rigorous design approach is used for several situations:

• Designing a system that deviates significantly from ideal behavior or the lack of good VLE
data

• High product purity requirements

• Highly precise cost estimate requirement

• Multicomponent distillation with a tight range of component boiling points

Thermal Kinetics will often advise the use of Pilot Testing in a variety of situations,
especially when a design carries a performance risk.

2) LIQUID MASS TRANSFER AND DIFFUSION UNIT:

The QDTL is a teaching unit that allows the students to familiarize with the notions of
mass transfer theory, especially the diffusion in liquid systems, obtaining experimental
data and results which are very useful for an ideal practice understanding of the process
and consequently, for the technical teaching of the students.
General Description:
The experimental determination of the diffusion coefficient D for a binary mixture, can be
performed with a device such as the one AB described below.

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.

3) GRAPHITE MASS TRANSFER EQUIPMENT:

GAB Neumann offers a wide range of
graphite mass transfer equipment for the
most corrosive applications in the
pharmaceutical and the chemical
industries. Our product portfolio includes
absorbers, columns, quenches,
hydrochloric acid recovery units, sulfuric
acid dilution units and well as vacuum jet
pumps.

Materials

• Impervious graphite: GAB GPX1, GPX1T

or GPX2
• Shell, Pressure plates and flanges: carbon
steel or stainless steel
• Tie rods, nuts, bolts, washers, and
springs: stainless steel
• Tanks, containers, and piping: PTFE lined
steel or Fiber Reinforced Plastic
Key features
• Design pressure: -1 barg (full
vacuum) to +10 barg (145 psig)
• Design temperature: -60 to +200°C (-76 to 392°F)
 • Design: according to European PED, ASME code, Chinese Pressure Vessel code and other
national pressure vessel codes on request
Main applications:
• Absorption, washing or quenching of ultra-corrosive gases
• Recovery of spent acids
• Generation of dry hydrochloric acid
• Dilution of sulfuric acid
• Vacuum generation in ultra-corrosive environment
Mass transfer
Mass transfer is the net movement of mass from one stream, phase, fraction or component, to
another. Mass transfer occurs in many processes, such as absorption, evaporation, drying,
precipitation, membrane filtration, and distillation. In industrial processes, mass transfer
operations include separation of chemical components in distillation columns, absorbers such
as scrubbers or stripping, adsorbers such as activated carbon beds, and liquid-liquid extraction.
Mass transfer finds extensive application in chemical engineering problems. It is used in
reaction engineering, separations engineering, heat transfer engineering, and many other sub-
disciplines of chemical engineering.
The driving force for mass transfer is typically a difference in chemical potential. A chemical
species moves from areas of high chemical potential to areas of low chemical potential. Thus,
the maximum theoretical extent of a given mass transfer is typically determined by the point at
which the chemical potential is uniform. For single phase-systems, this usually translates to
uniform concentration throughout the phase, while for multiphase systems chemical species
will often prefer one phase over the others and reach a uniform chemical potential only when
most of the chemical species has been absorbed into the preferred phase, as in liquid-liquid
extraction.
While thermodynamic equilibrium determines the theoretical extent of a given mass transfer
operation, the actual rate of mass transfer will depend on additional factors including the flow
patterns within the system and the diffusivities of the species in each phase. This rate can be
quantified through the calculation and application of mass transfer coefficients for an overall
process.

GAB Neumann’s mass transfer equipment and units

GAB Neumann’s graphite absorbers, columns and quenches are designed to absorb, wash, or
quench ultra-corrosive gases. GAB Neumann’s columns can also be designed to distillate ultra-
corrosive chemicals. GAB Neumann’s hydrochloric acid recovery units enable the absorption
then the desorption of hydrochloric acid to generate highly concentrated hydrochloric acid gas
with a low moisture content (dry HCl). Our sulfuric acid dilution units allow the safe and
progressive dilution of concentrated sulfuric acid. Finally, our vacuum generation groups allow
the generation of deep vacuum in ultra-corrosive environment without using any rotating
pieces of equipment.
All our equipment and units are designed to meet specific process requirements and are
therefore custom made. Safety, reliability, and performance on the long-term are our primary
considerations when we size, design and manufacture our mass transfer equipment and units.
Absorbers
Our graphite annular groove isothermal absorbers are adapted to the absorption of ultra-
corrosive gases such as hydrochloric, bromhydric or hydrofluoric acids. They consist in a stack of
impervious graphite discs with straight flow channels on process side and annular grooves on
service side. Their top sections are equipped with liquid distribution plates and overflow
candles to ensure homogenous liquid distribution.

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

Sulfuric acid dilution units

The dilution of sulfuric acid is uneasy (due to the high viscosity of concentrated sulfuric acid)
and extremely exothermic. Our sulfuric acid dilution units ensure the safe, smooth, and efficient
dilution of sulfuric acid with water as well as the cooling of the diluted acid.

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…

4) Saini PACKED BED DISTILLATION

COLUMN APPARATUS

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.

5) Servo-hydraulic press HV255.45

DESCRIPTION
This model introduces the fourth punch on the horizontal plane, in order to improve the
performance for multi forging stroke and the machine is prepared to 255×255 die
dimensions also, so you will be able to forge a wider range of parts than H205 series, with a
compact furnace for diameters up to 45mm, Neotecman presents a flexible all-in-one forge
system. This approach improves the energy consumption, and provides to this series the
chances to produces slightlest parts with the use of more cilynders to decrease the weight.
Moreover, Neotecman’s design is based in a double structure for press and furnace, that
includes the assembly of a robot to offer a multiple billet positioning in the press, simetric
billets, diferent orientations or multiple billets at the same time.
PUNCHES - 4 horizontal + 1 vertical (option)
PRODUCTION (empty) - From 500 to 4.000 parts/hour
BAR DIAMETER - From 12 to 45 mm (From 0.47 to 1,77 in)
BAR LENGTH - To 4.000 mm (To 2.65 lb)
DIE DIMENSONS - 255 x 255 mm
CHARACTERISTICS
Operation servo-
hydraulic Function
stamping, forging, punching Structure
ram, 4-column, with lifting table, compact
Control
PLC-controlled, fully-automatic Other
characteristics
for production, vertical, for non-ferrous materials, hot, process, for automotive parts,
servodriven, horizontal, short-cycle, high-speed, with manipulator, for industrial applications,
for the automotive industry, ultra-sensitive, with automatic feeder
Opening
Max.: 500 mm (20 in)
500 mm (20 in)
Min.: 100 mm (4 in)
Force
200 ft
 HEAT TRANSFER MACHINES USED IN INDUSTRIES:
Plate and frame heat exchanger
The concept behind a heat exchanger is the use of pipes or other containment vessels to
heat or cool one fluid by transferring heat between it and another fluid. In most cases, the
exchanger consists of a coiled pipe containing one fluid that passes through a chamber
containing another fluid. The walls of the pipe are usually made of metal, or another
substance with a high thermal conductivity, to facilitate the interchange, whereas the outer
casing of the larger chamber is made of a plastic or coated with thermal insulation, to
discourage heat from escaping from the exchanger.

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.