Challenges
Incomplete Separation of Close-Boiling Components (ΔBP <25°C)
Single-stage equilibrium insufficient for components with overlapping vapour pressure curves.
Bumping in High-Viscosity or Superheated Still Pot
Localised superheating causes sudden violent vaporisation dangerous still pot disturbance.
Fire and Explosion Risk from Flammable Solvent Vapour
Flammable solvent vapour at still heads and condenser outlet in open systems.
Condenser Breakthrough at High Evaporation Rate
Vapour flow exceeds condenser capacity uncondensed solvent exits condenser outlet.
Residual Solvent in Distillate from Azeotrope Formation
Azeotrope limits achievable distillate purity residual water or impurity remains.
Solutions
- Short Fractional Column (3–5 Theoretical Plates) for Close-Boiling: Packed or tray column above still pot provides extra theoretical plates improves separation.
- Anti-Bumping Stones or Agitator in Still Pot: PTFE boiling stones or slow-speed SS agitator prevents superheating and bumping.
- Fully Enclosed ATEX Zone 1/2 Certified Design + Nâ‚‚ Blanketing: Nitrogen blanketing eliminates air from all vapour spaces no ignition-capable atmosphere.
- Oversized Condenser (1.5× Design Duty) with Cooling Water Control: Excess condensation area prevents breakthrough at maximum evaporation rate.
- Molecular Sieves or Azeotropic Breaking Agent Post-Distillation: Molecular sieve drying or entraining agent breaks residual water azeotrope.
Applications
- Pharmaceutical: IPA, ethanol, acetone, and methanol solvent recovery from API crystallisation.
- Chemical: Toluene, hexane, and chlorinated solvent recovery from reaction and extraction.
- Food & Beverage: Ethanol concentration for food-grade alcohol, aroma compound distillation.
- Cosmetics: Essential oil and fragrance distillate production, alcohol recovery.
- Research & Development: Lab-scale solvent recovery, boiling point determination, purity assessment.
Models & Capacities
11A — Simple Distillation Unit (SD) — 5 L Lab to 10,000 L Large Production — Single Equilibrium Stage — Evap. Rate 0.5–1,500 kg/h — ΔBP > 25°C — Solvent Recovery | |||||||||
Model | Scale | Still Pot Vol [L] | Evap. Rate [kg/h] | Column Plates | Condenser Area [m²] | Op. Temp [°C] | Vacuum [bar abs.] | Motor [kW] | Overall H [mm] |
SD-LAB-5 | Lab | 5 | 0.5 – 2 | 0 (simple) | 0.05 – 0.2 | Amb. – 200 | Atm – 0.1 | 0.12 – 0.37 | 1,200 |
SD-PIL-50 | Pilot | 50 | 2 – 10 | 0 (simple) | 0.2 – 0.8 | Amb. – 200 | Atm – 0.1 | 0.37 – 0.75 | 2,500 |
SD-PIL-200 | Pilot | 200 | 10 – 40 | 0 (simple) | 0.5 – 2.0 | Amb. – 200 | Atm – 0.1 | 0.75 – 1.5 | 3,500 |
SD-PRD-500 | Production | 500 | 30 – 100 | 0 (simple) | 1.5 – 5.0 | Amb. – 200 | Atm – 0.05 | 1.5 – 4.0 | 5,000 |
SD-PRD-2000 | Production | 2,000 | 100 – 400 | 0 (simple) | 5 – 18 | Amb. – 200 | Atm – 0.05 | 5.5 – 15 | 6,500 |
SD-PRD-10000 | Large Prod | 10,000 | 400 – 1,500 | 0 (simple) | 20 – 60 | Amb. – 200 | Atm – 0.05 | 22 – 55 | 9,000 |