infrastructure - plant equipment

3

GMM Pfaudler has a state of the art factory spread over 20 acres at Karamsad, Gujarat, 450 Kms north of Mumbai. It is easily accessible by two major airports Vadodara and Ahmedabad both having multiple daily flights from Mumbai and other Indian metros.

Our fabrication facility has a covered area of over 38,000 square meters with dedicated bays for Carbon Steel and Alloy Steel fabrication.

GMM Pfaudler currently employs 344 people and has regional Sales & Service offices in Delhi, Ahmedabad, Vadodara, Mumbai, Hyderabad, Vishakhapatnam and Chennai.

INFRASTRUCTURE

4

CONTENTSSECTION I GLASS LINED EQUIPMENT■ GLASS LINED REACTORS

● DIN REACTORS AE 6

● DIN REACTORS BE 9 ● DIN REACTORS CE 13■ NEXT GENERATION MIXING SYSTEMS 16■ AGITATING NOZZLES 19■ GLASS LINED VESSELS ● GLASS LINED STORAGE TANKS 25 ● HEAT EXCHANGERS WK 27■ GLASS STEEL ● WORLDWIDE GLASTEEL ® 9100 28 ● ULTRA GLASTM 6500 39 ● STAINLESS STEEL GLASTEEL ® 4000 42 ● ALKALI GLASS 4300 45 ● PFAUDLER PHARMAGLASS PPG® 48■ ACCESSORIES ● FILLOOK® QUICK OPENING DEVICES 51 ● GLASSLOOK® SIGHT GLASSES 53■ GLASS LINED PIPES & FITTINGS 55■ CONICAL BLENDER DRYERS 60■ KILO LABS & PILOT PLANTS 62

SECTION II FILTRATION & DRYING EQUIPMENT■ MAVAZWAG®AGITATED NUTSCHE FILTERS & FILTER DRYERS 66■ FUNDA® CENTRIFUGAL DISC FILTERS 70■ MAVASPHERE® SPHERICAL DRYERS 71■ MAVAPAD® VACUUM PADDLE DRYERS 72

SECTION III MIXING SYSTEMS■ ECONOMIX® MIXING SYSTEMS 74■ MAVADRIVE® MAGNETIC AGITATORS 77

SECTION IV ENGINEERED SYSTEMS■ WIPED FILM EVAPORATORS 80■ SINGLE FLUID HEATING & COOLING SYSTEMS 85

5

■ GLASS LINED REACTORS

● DIN REACTORS AE 6

● DIN REACTORS BE 9 ● DIN REACTORS CE 13■ NEXT GENERATION MIXING SYSTEMS 16■ AGITATING NOZZLES 19■ GLASS LINED VESSELS ● GLASS LINED STORAGE TANKS 25 ● HEAT EXCHANGERS WK 27■ GLASS STEEL ● WORLDWIDE GLASTEEL ® 9100 28 ● ULTRA GLASTM 6500 39 ● STAINLESS STEEL GLASTEEL ® 4000 42 ● ALKALI GLASS 4300 45 ● PFAUDLER PHARMAGLASS PPG® 48■ ACCESSORIES ● FILLOOK® QUICK OPENING DEVICES 51 ● GLASSLOOK® SIGHT GLASSES 53■ GLASS LINED PIPES & FITTINGS 55■ CONICAL BLENDER DRYERS 60■ KILO LABS & PILOT PLANTS 62

SECTION I

GLASS LINED EQUIPMENT

6

Design Two-piece design that meets the following standards : DIN 28130, part 2 : Assembly of componentsDIN 28136 : Reactors type AEDIN 28157 : Impeller agitatorsDIN 28158 : Anchor agitatorsDIN 28146 : Paddle-type bafflesDIN 28147 : ThermopocketsDIN 28145, part 8 : LegDIN 28145, part 4 : Supporting ringDIN 28151 : Jacket connections Type A1/A2 without circulating nozzles Type B1/B2 with circulating nozzlesDIN 28137, part 2 : Agitator flangeDIN 28006, part 2 : ToleranceGlass Lined as per DIN EN ISO 28721.Design as per ASME Section VIII,Division I.

Operating Conditions Maximum allowable working pressure :

-1/+6 bar(g) in the vessel -1/+6 bar(g) in the jacket

Maximum design temperature : 200°C Minimum design metal temperature :

-28.8°C Custom designs for enhanced pressure and temperatures are also available.

GlassAll our reactors are lined with Pfaudler glass WWG 9100. This glass is extremely resistant to corrosion and mechanical stress. For specific applications, special glasses are also available.

JacketStandard jacket is provided, with the option of Half-pipe coil jacket is also available.

SupportSide brackets are provided, however the support options of pipe legs or support rings are available.

Agitator SystemsStandard: Impeller-type agitator with baffle.Alternate configuration: Anchor-type agitator with thermopocket.

Next Generation MixingA vast range of agitators are available to meet all your mixing requirements resulting in: Reduced batch times Reduced power consumption Reduced costs

Standard AccessoriesManway cover with sight glass DN100. Glass Lined protection ring for manway opening. Opening device for manway cover.

Optional Accessories Quick change seal arrangement -

Faster replacement of the mechanical seal without the need to remove the drive. Agitating Nozzles -

Better heat transfer. Filllook®& Glasslook® -

Easy access for reactor charging & cleaning. - Glass monitoring

DINREACTORS

AE

7

SIDE VIEW: AE 3000, HEAD LAYOUT 2 Glass Lined

instrumentation to measure - - pH, rH - Temperature - Liquid level - Conductivity

GMP ReactorsOur standard GMP reactors include the following SS 304 accessories: Drive hood, lantern, C-clamps, fasteners, split flanges, side brackets, lifting lugs, jacket nozzles and sight/light glass flange.

Spares & ServiceWe know your business demands more than just quality products. GMM Pfaudler’s Spares & Service network is dedicated to keeping your process running smoothly. Our

team of highly trained technicians looks after that and most standard parts are shipped within 48 hours.

Preventive MaintenanceRegular maintenance of your Glass Lined equipment increases it's life and reduces downtime.

GMM Pfaudler offers a comprehensive Annual Maintenance Contract to ensure that your equipment receives maintenance regularly from our committed and highly trained team.

Type AE Total Jacket Heating/ Main Dimensions (mm) Nominal Volume Volume Cooling DN Jacket Anch. Imp. 4) RPM Total Volume Area (ID) dia Motor n Weight (Ltr) (Ltr) (Ltr) (m2) d1 d2 d3 d4 h1 h2 h3 h4 ≈ h5 ≈ h6 e HP (K.W.) Anc/Imp (Kg)1)≈

1 63 95 25 0.53 500 486 600 420 300 400 180 590 80 2370 250 1600 1.5 (1) 48/96 4801 100 130 40 0.85 500 486 600 420 300 600 180 790 80 2590 370 1600 1.5 (1) 48/96 5301 160 215 60 1.23 600 578 700 500 360 700 200 910 80 2710 370 1600 1.5 (1) 48/96 6401 250 335 90 1.66 700 680 800 600 420 800 220 1030 80 2980 400 1830 3 (2.2) 48/96 9001 400 530 125 2.40 800 771 900 700 480 1000 250 1260 90 3154 405 1830 3 (2.2) 48/96 11001 500 2) 730 145 2.56 1000 966 1100 880 600 836 300 1146 90 3100 405 1830 3 (2.2) 48/96 15001 630 850 170 3.10 1000 966 1100 880 600 1000 300 1310 90 3265 405 1830 3 (2.2) 48/96 16502 1000 1465 245 4.56 1200 1163 1300 1060 720 1200 350 1560 90 3580 405 1880 5 (3.7) 48/96 22002 1600 2325 330 6.00 1400 1363 1500 1250 840 1400 400 1810 90 4035 475 1720 7.5 (5.5) 48/96 30002 2000 2) 2615 370 7.10 1400 1363 1500 1250 840 1600 400 2010 90 4235 475 1790 7.5 (5.5) 48/96 33002 2500 3485 435 8.30 1600 1558 1700 1440 960 1600 460 2070 90 4285 485 1820 7.5 (5.5) 48/96 39502 3000 2) 3780 470 9.10 1600 1558 1700 1440 960 1755 460 2225 90 4440 485 1920 7.5 (5.5) 48/96 41002 4000 5420 585 11.70 1800 1756 1900 1630 1100 2000 500 2510 90 4825 630 2000 7.5 (5.5) 36/96 54002 50002) 6745 695 13.10 2000 1950 2100 1810 1100 2000 550 2560 110 5000 640 2030 1 (7.5) 36/96 70002 6300 8235 845 16.20 2000 1950 2100 1810 1100 2500 550 3060 110 5500 640 2050 15 (11) 36/96 7600

Hea

d La

yout

AE

DIN REACTORS AE

8

1) Assembled weight without supporting structure. 2) Not to DIN. 3) Jacket connections to DIN 28151 A1/A2 and B1/B2. Connections N16-N19 are for use with agitating nozzles, the quantity depending on reactor size. 4) Head room required for removal of impeller agitator.

Type AE DN Connections (DN)

Nominal Jacket 3) Reactor Supporting Volume Structure (Ltr)H

ead

Layo

ut

N11 N12 N16 3) Drain N2, N3 N5 N14 N15 N19 K M N1 N9, N10 N4 N7 N6 N8 b

1 63 500 40 … … 80 50 100 40 80 … 80 50 752 1 100 500 40 … … 80 50 100 40 80 … 80 50 752 1 160 600 40 … … 80 50 100 50 80 … 80 80 852 1 250 700 40 … 40 80 80 150 50 80 … 80 80 952 1 400 800 40 … 40 100 80 200 80 80 … 100 80 1056 1 500 2) 1000 50 … 50 100 125 250 100 100 … 150 100 1356 1 630 1000 50 … 50 100 125 250 100 100 … 150 100 1356 2 1000 1200 50 … 50 100 125 350/450 100 … 200 100 … 1560 2 1600 1400 50 50 50 100 150 350/450 100 … 200 100 … 1780 2 2000 2) 1400 50 50 50 100 150 350/450 100 … 200 100 … 1780 2 2500 1600 50 50 50 100 150 350/450 100 … 200 100 … 1980 2 3000 2) 1600 50 50 50 100 150 350/450 100 … 200 100 … 1980 2 4000 1800 50 50 50 100 200 500 150 … 250 150 … 2210 2 5000 2) 2000 80 80 50 150 200 500 150 … 250 150 … 2414 2 6300 2000 80 80 50 150 200 500 150 … 250 150 … 2414

Nozzle N4 and N5 or N7 for thermowell or baffle. Sight glass L = DN 100

NOZZLE ARRANGEMENTS FOR VESSELS FROM 63 LTRS TO 630 LTRS 2

NOZZLE ARRANGEMENTS FOR VESSELS FROM 1000 LTRS TO 6300 LTRS

9

Design One-piece design that meets the following standards: DIN 28130, part 2 : Assembly of componentsDIN 28136 : Reactors type BEDIN 28146 : Paddle-type baffleDIN 29145, part 8 : LegDIN 28145, part 4 : Supporting ringDIN 28151 : Jacket connections Type A1/A2 without circulating nozzles Type B1/B2 with circulating nozzlesDIN 28137, part 2 : Agitator flangeDIN 28006, part 2 : ToleranceGlass Lined as per DIN EN ISO 28721. Design as per ASME Section VIII, Division I.

Operating Conditions Maximum allowable working pressure:

-1/+6 bar(g) in the vessel -1/+6 bar(g) in the jacket Maximum design temperature:

200°C Minimum design metal temperature:

-28.8°CCustom designs for enhanced pressure and temperatures are also available.


JacketStandard jacket is provided, however the option of half-pipe coil jacket construction is also available.

SupportSide brackets are provided, however support options of pipe legs or support rings are available.

Agitator SystemsStandard: Cryo-Lock® agitator with baffle.Cryo-Lock® agitating system utilizes the cryogenic fit between the glass shaft andthe glass impeller hub for a precise fit.

The Cryo-Lock® agitator was designed to offer flexibility and optimized mixing. Impeller changeover is performed

inside the reactor without having to remove the drive, shaft or cover

Large selections of agitators, including multi-flight arrangements of turbines to suit your process

The manhole is the largest opening, reduced gasket length, higher pressure resistance and fewer leakages

Turbines CBT: The ‘Universal’ Curved Blade

Turbine provides high shearing effect and radial flow

TBF: The ‘Efficient’ Turbofoil agitator provides high axial flow with relatively low flow disturbance, and low torque/low power input

FBT: The Flat Blade Turbine provides high shearing force and low radial flow

PBT: The Pitched Blade Turbine provides medium shearing effect, and combined radial/axial flow

DINREACTORS

BE

DIN REACTORS BE

10

RCI: The ‘Classic’ Retreat Curved Impeller in its latest version provides strong radial flow and a relatively high flow disturbance

ANC: The anchor agitator for highly viscous products, provides low shearing forces, tangential flow and high torque


Optional Accessories Quick change seal

arrangement - Faster replacement of the mechanical seal without the need to remove the drive. Agitating Nozzles -

Better heat transfer.

Filllook®& Glasslook® - Easy access for reactor charging & cleaning. Glass Lined

instrumentation to measure - - pH, rH - Temperature - Liquid level - Conductivity - Glass monitoring


Spares & ServiceWe know your business demands more than just quality products. GMM Pfaudler’s Spares & Service network is dedicated to keeping your process running smoothly. Our team of highly trained technicians looks after that and

most standard parts are shipped within 48 hours.


GMM Pfaudler offers a comprehensive Annual Maintenance Contract to ensure that your equipment receives maintenance regularly from our committed and highly trained team.

11

Type BE Total Jacket Heating/ Main Dimensions (mm) 1) Nominal Volume Volume Cooling DN (ID) Jacket * * Total Volume Area dia Motor RPM Weight (Ltr) (Ltr) (Ltr) (m2) d1 d2 h1 h3 h4 h5 ≈ h6 e ≈ HP (K.W.) n (Kg) ≈ 1 630 850 170 3.8 1000 966 1100 1310 1400 90 3548 666 1470 3 (2.2) 96 16002 1000 1470 255 5.2 1200 1163 1300 1560 1650 90 3886 705 1560 5 (3.7) 96 22002 1600 2310 375 7.4 1400 1363 1500 1800 1900 90 4347 733 1775 7.5 (5.5) 96 32002 20002) 2600 415 8.3 1400 1363 1500 2000 2100 90 4547 733 1775 7.5 (5.5) 96 34002 2500 3500 520 9.8 1600 1558 1700 2060 2160 90 4607 775 1775 7.5 (5.5) 96 37002 30002) 3760 550 10.5 1600 1558 1700 2215 2315 90 4762 775 1775 7.5 (5.5) 96 40002 4000 5390 650 13.2 1800 1756 1900 2500 2635 90 5265 990 1960 10 (7.5) 96 52002 50002) 6710 770 14.9 2000 1950 2100 2550 2680 110 5328 1030 1960 10 (7.5) 96 65002 6300 8190 920 18 2000 1950 2100 3050 3180 110 6008 1030 2140 15 (11) 96 70003 8000 9365 900 18 2200 2156 2300 3000 3130 110 5958 1190 2140 20 (15) 96 76003 10000 11770 935 21.1 2400 2360 2500 3180 3315 110 6233 1323 2230 20 (15) 96 100003 12500 14500 1100 25.5 2400 2360 2500 3780 3915 110 6973 1323 2370 25 (18.5) 96 120003 16000 18700 1250 28.5 2800 2750 2900 3705 3840 110 6922 1683 2400 30 (22) 94 153003 20000 22860 1460 34.2 2800 2750 2900 4385 4520 110 7602 1683 2400 30 (22) 94 180003 25000 27720 1675 41.6 2800 2750 2900 5235 5370 110 8452 1683 2400 40 (30) 94 215003 25000 28085 1955 38.4 3000 2920 3100 4755 4890 110 8344 2020 2780 50 (37) 94 230003 32000 36190 2740 47.7 3200 3140 3350 5280 5415 110 8869 2020 2780 50 (37) 80 262003 32000 36820 2790 44.2 3400 3328 3550 4875 5010 110 8464 2020 2780 50 (37) 80 263003 40000 44820 3420 54 3400 3328 3550 5795 5930 110 9384 2020 2780 50 (37) 80 280003 40000 45770 3465 55 3600 3528 3750 5365 5500 110 8954 2185 2780 50 (37) 80 29000

Hea

d La

yout

* Based on density 1100 kg/m3 Viscosity 100 Cps RCI Agitator

SIDE VIEW: BE 4000, HEAD LAYOUT 3

Sweep Diameter (mm)

Capacity DN RCI CBT CBRT TBF PBT FBT ANC

630 1000 720 480 480 480 480 480 4801000 1200 720 480 480 480 480 480 10601600 1400 840 735 735 760 685 685 12502000 1400 840 735 735 760 685 685 12502500 1600 960 735 735 760 685 685 14403000 1600 960 735 735 760 685 685 14404000 1800 960 735 735 760 685 685 16305000 2000 1100 835 835 990 890 890 18106300 2000 1100 835 835 990 890 890 18108000 2200 1100 835 835 990 890 890 195010000 2400 1300 1040 1040 1220 1090 1090 210012500 2400 1300 1040 1040 1220 1090 1090 210016000 2600 1350 1120 1120 1220 1220 1220 230016000 2800 1500 1220 1220 1420 1220 1220 250020000 2800 1500 1220 1220 1420 1220 1220 250025000 2800 1500 1220 1220 1420 1220 1220 250025000 3000 1600 1420 1420 1420 1220 1220 -32000 3200 1600 1420 1420 1420 1220 1220 -32000 3400 1700 1420 1420 1420 1350 1350 -40000 3400 1700 1420 1420 1420 1350 1350 -40000 3600 1700 1420 1420 1420 1350 1350 -

DIN REACTORS BE

12

1) Assembled weight without supporting structure. 2) Not to DIN. 3) Jacket connections to DIN 28151 A1/A2 and B1/B2. Connections N16-N19 are for use with agitating nozzles, the quantity depending on reactor size.

Hea

d La

yout

N11 N12 N16 3) Drain N2 N5 N14 N15 N19 K N1 M N10 N3 N4 N7 N6 N8 N9 b

1 630 2) 1000 50 - 50 100 320/420 125 100 - - 200 100 100 - 13562 1000 2) 1200 50 - 50 100 350/450 125 100 100 - 200 100 - 100 15602 1600 1400 50 50 50 100 350/450 150 100 100 - 200 100 - 100 17802 2000 2) 1400 50 50 50 100 350/450 150 100 100 - 200 100 - 100 17802 2500 1600 50 50 50 100 500 150 100 100 - 200 100 - 100 19802 3000 2) 1600 50 50 50 100 500 150 100 100 - 200 100 - 100 19802 4000 1800 50 50 50 100 500 200 150 150 - 250 150 - 150 22102 5000 2) 2000 50 80 50 150 500 200 150 150 - 250 150 - 150 2414 2 6300 2000 80 80 50 150 500 200 150 150 - 250 150 - 150 24143 8000 2200 80 80 50 150 600 200 150 150 150 300 150 150 150 26143 10000 2400 80 80 50 150 600 250 200 200 300 300 200 200 300 28683 12500 2400 80 80 50 150 600 250 200 200 300 300 200 200 300 28683 16000 2800 80 80 80 150 600 250 200 200 300 400 200 200 300 32003 20000 2800 80 80 80 150 600 250 200 200 300 400 200 200 300 32003 25000 2800 80 80 80 150 600 250 200 200 300 400 200 200 300 3200 3 25000 3000 80 80 80 150 600 250 200 200 300 400 200 200 300 37503 32000 3200 100 100 100 150 600 250/300 200 200 400 400 200 200 400 41003 32000 3400 100 100 100 150 600 250/300 200 200 400 400 200 200 400 43003 40000 3400 100 100 100 150 600 250/300 200 200 400 400 200 200 400 43003 40000 3600 100 100 100 150 600 250/300 200 200 400 400 200 200 400 4500

Type AE DN Connections (DN)

Nominal Jacket Reactor Supporting Volume Structure (Ltr)

Nozzle N4/N9 or N5/N7 for baffle. Sight glass L = DN 100

HEAD LAYOUT

1 2 3

NOZZLE ARRANGEMENT FOR VESSEL 630 LTRS.

NOZZLE ARRANGEMENT FOR VESSEL FROM 1000 LTRS. TO 6300 LTRS.

NOZZLE ARRANGEMENT FOR VESSELFROM 8000 LTRS. TO 40000 LTRS..

13

Design One-piece design that meets the following standard :DIN 28130, part 2 : Assembly of componentsDIN 28136 : Reactors type CEDIN 28157 : Impeller agitatorsDIN 28146 : Paddle-type baffles DIN 29145 : Part 8 legsDIN 28145 : Part 4 supporting ringsDIN 28151 : Jacket connections Type A1/A2 without circulating nozzles Type B1/B2 with circulating nozzlesDIN 28137, part 2 : Agitator flangeDIN 28006, part 2 : ToleranceGlass Lined as per DIN EN ISO 28 721. Design as per ASME Section VIII, Division I.

Operating Conditions Maximum allowable working

pressure : -1/+6 bar(g) in the vessel -1/+6 bar(g) in the jacket Maximum design temperature :

200°C Minimum design metal temperature :

-28.8°CCustom designs for enhanced pressure and temperatures are also available.


JacketStandard jacket is provided, however the option of half-pipe coil jacket construction is also available.

SupportSide brackets are provided, however support options of pipe legs or support rings are available.

Agitator SystemsStandard: Impeller-type agitator with baffle.

Next Generation MixingA vast range of agitators are available to meet all your mixing requirements resulting in: Improvement in mixing performance Reduced batch times Reduced power consumption Reduced costs


Optional Accessories Quick change seal arrangement -

Faster replacement of the mechanical seal without the need to remove the drive. Agitating Nozzles -

Better heat transfer. Filllook®& Glasslook® -

Easy access for reactor charging & cleaning.

DINREACTORS

CE

DIN REACTORS CE

14

Glass Lined instrumentation to measure - - pH, rH - Temperature - Liquid level - Conductivity - Glass monitoring


Spares & Service We know your business demands more than just quality products. GMM Pfaudler’s Spares & Service network is dedicated to keeping your process running smoothly.

Our team of highly trained technicians looks after that and most standard parts are shipped within 48 hours.


GMM Pfaudler offers a comprehensive Annual Maintenance Contract to ensure that your equipment receives maintenance regularly from our committed andhighly trained team.

Type AE Total Jacket Heating/ Main Dimensions (mm) Nominal Volume Volume Cooling Jacket 4) Total Volume Area (DN) ID dia Motor RPM Weight (Ltr) (Ltr) (Ltr) (M2) d1 d2 d4 d6 d7 h1 h3 h4 h5 ≈ h6 e ≈ HP (K.W.) n (kg) ≈

1 1600 2010 335 6.5 1400 1363 1500 840 150 770 1596 1615 90 3975 950 1580 7.5 (5.5) 96 29001 2000 2) 2305 375 7.4 1400 1363 1500 840 150 770 1796 2115 90 4175 950 1590 7.5 (5.5) 96 31001 2500 3055 460 8.6 1600 1558 1700 960 150 770 1845 2175 90 4260 1000 1600 7.5 (5.5) 96 35001 3000 2) 3350 500 9.4 1600 1558 1700 960 150 770 2000 2330 90 4415 1000 1730 7.5 (5.5) 96 37001 4000 4870 600 12.0 1800 1756 1900 1100 150 770 2285 2615 90 4700 1185 1950 7.5 (5.5) 96 50002 4000 4870 600 12.0 1800 1756 1900 1100 150 770 2285 2615 90 4700 1185 1950 7.5 (5.5) 96 50003 5000 2) 6040 715 13.5 2000 1950 2100 1100 200 770 2325 2680 110 4830 1255 2350 10 (7.5) 96 60003 6300 7535 860 16.6 2000 1950 2100 1100 200 770 2825 3180 110 5460 1255 2650 15 (11) 96 70004 8000 9365 895 17.9 2200 2156 2300 1100 200 770 2985 3330 110 5750 1405 2800 20 (15) 96 76004 10000 11875 935 20.9 2400 2360 2500 1300 240 965 3170 3535 110 6045 1550 2950 20 (15) 96 100004 12500 14500 1110 25.4 2400 2360 2500 1300 240 965 3770 4135 110 6715 1550 3450 25 (18.5) 96 120004 16000 18200 1260 29.5 2600 2550 2700 1350 240 965 4080 4435 110 6770 1855 3750 30 (22) 96 138004 16000 18880 1250 28.3 2800 2750 2900 1500 240 1160 3705 4085 110 6590 1940 3400 30 (22) 96 150004 20000 22860 1460 34.2 2800 2750 2900 1500 240 1160 4385 4765 110 7250 1940 3950 30 (22) 96 180004 25000 27720 1675 41.6 2800 2750 2900 1500 240 1160 5235 5615 110 8090 1940 4650 40 (30) 96 215004 25000 28390 1605 39.7 3000 2944 3100 1600 240 1160 4755 5135 110 7610 2275 4200 40 (30) 96 215504 32000 36000 2635 47.3 3200 3410 3350 1600 290 1350 5280 5685 110 8090 2320 4650 50 (38) 96 284504 32000 37050 2965 45.7 3400 3330 3550 1700 290 1350 4875 5285 110 7690 2450 4350 50 (38) 96 284504 40000 45050 3525 55.5 3400 3330 3550 1700 290 1350 5795 6205 110 8610 2450 5100 50 (38) 96 336004 40000 45920 3405 53.5 3600 3520 3750 1800 290 1350 5365 5775 110 8180 2550 4750 50 (38) 96 33600

Hea

d La

yout 1)

SIDE VIEW: CE 8000, HEAD LAYOUT 4

15

HEAD LAYOUT

1 2 3 4

Type CE DN Connections (DN) SUPPORTING NOMINAL JACKET REACTOR STRUCTURE Volume N11, N12 N16 Drain N2 N5 (Ltr) N14, N15 N19 3) K N1 M N10 N3 N4 N7 N6 N8 N9 b

1 1600 1400 50 50 100 350/450 150 … 100 … 200 100 … 100 17801 2000 2) 1400 50 50 100 350/450 150 … 100 … 200 100 … 100 17801 2500 1600 50 50 100 350/450 150 100 100 … 200 100 … 100 19801 3000 2) 1600 50 50 100 350/450 150 100 100 … 200 100 … 100 19801 4000 1800 50 50 100 350/450 150 150 150 … 250 150 … 150 22102 4000 1800 50 50 100 350/450 200 250 150 … 100 100 … 150 22103 5000 2) 2000 50 50 150 500 200 150 150 … 250 150 … 150 24143 6300 2000 80 50 150 500 200 150 150 … 250 150 … 150 24144 8000 2200 80 50 150 500 200 150 150 150 300 150 150 150 26144 10000 2400 80 50 150 500 250 200 200 200/250 300 200 200 200/250 28684 12500 2400 80 50 150 500 250 200 200 200/250 300 200 200 200/250 28684 16000 2600 80 50 150 500 250 200 200 250 300 200 200 250 30004 16000 2800 80 50 150 600 250 200 200 300 400 200 200 300 32304 20000 2800 80 50 150 600 250 200 200 300 400 200 200 300 32304 25000 2800 80 50 150 600 250 200 200 300 400 200 200 300 32304 25000 3000 80 50 150 600 250 200 200 300 400 200 200 300 38504 32000 3200 100 80 150 600 250/300 200 200 400 400 200 200 400 42004 32000 3400 100 80 150 600 250/300 200 200 400 400 200 200 400 44004 40000 3400 100 80 150 600 250/300 200 200 400 400 200 200 400 44004 40000 3600 100 80 150 600 250/300 200 200 400 400 200 200 400 4600

Nozzle N4 or N9 for baffle. Sight glass L = DN 100

1) Assembled weight without supporting structure. 2) Not to DIN. 3) Jacket connections to DIN 28151 A1/A2 and B1/B2. Connections N16-N19 are for use with agitating nozzles, the quantity depending on reactor size. 4) Head room required for removal of impeller agitator.

Hea

d La

yout

DIN REACTORS CE

16

GMM Pfaudler offers glass lined mixing systems for all your process requirements. Our team of highly trained engineers will design an optimal mixing solution for your specific mixing

requirement. Using a fluid mixing design software to simulate the performance of your existing agitator system, we can recommend a Cryo-Lock® agitator design that will optimize your mixing by reducing batch time and power consumption and improving product quality.

The Cryo-Lock® system utilizes the cryogenic fit between the glass shaft and the glass impeller hub for precise interference fit. Impeller changeover is performed inside the reactor without having to remove the

drive, shaft or cover. The Cryo-Lock® family of agitators were designed to offer flexibility along with optimal mixing. The different impeller configurations in the Cryo-Lock® family were designed to meet the needs of different process conditions, Cryo-Lock® impellers may be used in more than one of the five basic unit operations:

Blending/Heat Transfer Suspension Emulsification High Viscosity

Blending Gas Dispersion

NEXT GENERATION

MIXING SYSTEMS

CURVED BLADE TURBINE TURBOFOIL IMPELLER

TYPICAL FLOW PATTERNS

Reduce pRocessing time and save costs with gmm

pfaudleR mixing systems

liquid nitRogen cooling enables the blade to be easily accessed

and Removed quickly. cRyo-lock impelleRs in a be vessel can be changed in less than two houRs

compaRed to two days oR moRe foR standaRd impelleR in a ce

vessel design.

theRe is also no need to Replace a cRyo-lock agitatoR shaft when

only the impelleR has suffeRed damage. this can be changed

inside the cleaned ReactoR without Removing the shaft,

dRive, motoR oR access coveR.Replacement agitatoRs can also

be stoRed economically.foR moRe infoRmation on be

vessels, please contact us.

17

1,0

0,8

0,6

0,4

0,2

0RCI1100

CBT835

PBT890

TBF990

Blade TypeP/V=Constant

2,5

2,0

1,5

1,0

0,5

0RCI1100

CBT835

PBT890

TBF990

Improve Product Quality and YieldReduced Process TimesWith some products, switching to a turbofoil blade from a standard fixed agitator can lead to mixing times being reduced by half while pumping capacity is almost doubled.

REDUCED MIXING TIME

CYRO-LOCK FAMILY OF AGITATORS

INCREASED PUMPING CAPACITY

BLENDING HEAT EMULSION SUSPENSION GAS TRANSFER DISPERSION

1 ANC II Two-piece Anchor √ √ √ 2 PBT Pitched Blade Turbine √ √ √ √ 3 FBT Flat Blade Turbine √ √ √ √4 MFT Multi-Flight Impeller √ √ √ √ 5 RCI Retreat Curve Impeller √ √ √ √ √6 TBF Turbofoil √ √ √ 7 CBT Curved Blade Turbine √ √ √ √

Performance Characteristics

1. ANC II Two-Piece Anchor• low shear

• tangential flow• high torque

• for higher viscosity fluids• can operate at low liquid

levels

2. PBT Pitched Blade Turbine

• moderate shear (higher flow-to-shear ratio)

• combined radial and axial flow

• relatively high drive speed

3. FBT Flat Blade Turbine• high shear load• pure radial flow

6. TBF Turbofoil• low shear forces• high axial flow at

relatively low baffling• low torque

• low power-consumption

Unlimited Impeller OptionsImpeller and baffle configurations can be adapted to serve all basis process operations. In addition, other factors, such as drive speed and baffle arrangement, can be altered to enable most impellers to be used in more than one of the five basic unit operations.

1

2

3

4

5

6

7

7. CBT Curved Blade Turbine

• high shear• radial flow

• wider baffling required with low viscous fluids

5. RCI Retreat Curve Impeller• versatile, general purpose design

• high radial flow• wider baffling required

• insensitive to viscosity variations• suitable for low liquid levels, small batches

4. MFI Multi-Flight Impeller• where single impeller is inadequate

• for high viscosity fluids• lightweight solids in narrow vessels

NEXT GENERATION MIXING SYSTEMS

18

Improve Power and Energy Efficiencies

Minimise Downtime and Maintenance Costs

Increased Energy EfficienciesEffective system design means power input can be reduced by achieving: Optimum heat

transfer Uniform dissipation

of energy Low energy demand

energy saving of up to 35% have been achieved

Power Applications and AdvantagesHomogenisationA high performance agitator Turbofoil (3.2kW) needs 35% less energy compared to an Impeller (5.1kW). On the basis of BE 6300, 1000 kg/m3, 20 mPa.s

Gas DispersionReplacing a Standard Impeller with a CBT agitator can triple the gas absorption rates. On the basis of 1kW/m3, 630 m3 instead of 220 m3/h.

SuspensionFor solid particles distribution needs, the Pitched Blade Turbine (PBT) at 4.2 kW can lead to energy savings of 3.7 kW over the Standard Impeller, representing a considerable cost saving during the year.

CrystallisationReplacing the anchor (ANC) with the double stage Turbofoil can increase output by 30%.

Safety and Environmental ProtectionThe system is corrosive resistant and considerably reduces the risk of leakage caused by replacing gaskets. Cryo-Lock II enables gasket size for BE 6300 vessels to be reduced by 2,500 mm compared to the CE 6300 versions, resulting in a 60% reduced leakage rate at vacuum conditions. Performance EffectivenessFurther cost efficiencies result from Cryo-Lock’s unique one piece design which means the single shaft stays in place so only the blade is changed. GMM Pfaudler’s Glasteel® reactor technology means vessel and agitator life is maximised for mixing corrosive substances. All these factors contribute to minimal downtimes and maintenance costs.

Total FlexibilityGMM Pfaudler mixing technology offers total flexibility. You can respond immediately to changing market conditions by: Reconfiguring your Glasteel reactor Modifying or completely changing the

mixing operation.

19

AGITATINGNOZZLES

Factors Influencing Heat TransferThe value resulting from the thermal conductivity of the materials and the coefficients of thermal conductance at their interfaces may be essentially improved by favorably influencing the heat transfer coefficient on the jacket side. In jackets without agitating nozzles the cooling agent moves nearly axially. The relatively large cross-section provides a low velocity rate. which is especially perceptible with large reactors. Considerable quantities of water are required to obtain only 0.1 m/s. This results in heat transfer coefficients of far below 1000 W/m2·K and correspondingly low heat transfer figures onthe outside. Calculation according to VDI Wärmeatlas (Manual of heat transfer), section Gg 1-6, boundary condition 1. The provisions otherwise commonly used in apparatus construction to provide a controlled flow are unfit to be applied to glass-lined reactors. Guide spirals, for instance, are too expensive and only practicable with larger reactors.

Agitating nozzles enable a considerably improved heat transfer in glasslined reactors since they move the cooling agent faster and more controlled. Our specifications are based on thorough long-term tests with water. The method of calculation may also be used for heat transfer oils and cooling brine, and has been confirmed by practice.

1 Product2 Cooling / heating agent3 Nozzle

DN

AGITATING NOZZLES

FACTORS INFLUENCING HEAT TRANSFER

AGITATING NOZZLES

20

Their principle of Operation:The pressure and volume of the cooling agent are used to produce a rotating movement of the whole jacket contents. The rotating movement has the same direction throughout the jacket space and varies only as to its intensity. They are as efficient as guide spirals; in some cases they even surpass them.

With comparable reactor dimensions and material characteristics, agitatingnozzles reach heat transfer

coefficients on the jacket side of more than 3000 W/m2·K. This results in a 30 to 40 % improvement of the heat transfer as compared to reactors without any additional devices in the jacket. The costs for providing such a favorable heat exchange is relatively low.

Considering the pressure loss which rapidly increases with higher rates, we offer agitating nozzles in 5 sizes. They are designated according to thejacket nozzle diameter they

fit: DN 40, 50, 65, 80 and 100. (The two largestnozzles are only required in special cases.)

The heat transfer coefficient can only be calculated if the mean velocity rate on the surface to be cooled is known. To this end we have carried out extensive measurements in our standard vessels. The results obtained arecompiled in the following diagrams.

The Solution: Agitating Nozzles

w [m

3 /h]

18

17

16

15

14

13

12

11

10

9

8

0 500 1000 1500 2000 2500 3000

d1 [mm]

Nozzle sp

acing =

1400 m

1200

1000

800

600

400

m

1

w [m

3 /h]

12

11

10

9

8

7

6

50 500 1000 1500 2000 2500 3000

d1 [mm]

14001200

1000800

600

1

Nozzle spacing = 400 mm

NOZZLE DN40 NOZZLE DN50

w required cooling water quantity per nozzle to obtain a mean flow velocity of 1 m/s in the jacketd1 outside diameter of inner vesselh vertical nozzle spacing in jacket

21

The recommended flow velocity of 1 m/s in the jacket has proved suitableand economic. A higher flow velocity improves the heat transfer to a negligible extent only. In extreme cases, however, it is advisable to use theoptimum heat transfer fully. The mean flow velocity

required in this case and the cooling agent quantity to be supplied accordingly are in proportion. The curves are only valid for reactors of 1000 mm diameter and more. With smaller reactors one nozzle fitted in the vessel center would be sufficient, provided that the distance

between the inner vessel and the jacket allows the installation of a nozzle at all. Another diagram shows the proportionalincrease in pressure loss with the rising quantity for all 5 nozzles.

Water quantity w [m3/h] Pressure loss p[bar]

w [m

3 /h]

70

60

50

40

30

20

10

00 .5 1.01 .5 2.02 .5 3.03 .5

DN100

DN80

DN65

DN50

DN40

p[bar]

w1 [m

3 /h]

26

24

22

20

18

16

14

12

100 500 1000 1500 2000 2000 2500

d1 [mm]

Nozzle spacing 1400 mm

1200

1000

800

600

400

NOZZLE DN65

WATER QUANTITY AND PRESSURE LOSS

w1 [m

3 /h]

24

22

20

18

16

14

12

100 500 1000 1500 2000 2500 3000

d1 [mm]

Nozzle spacing 1400 mm

1200

1000

800

600

400

NOZZLE DN80

w required cooling water quantity per nozzle to obtain a mean flow velocity of 1 m/s in the jacket

d1 outside diameter of inner vesselh vertical nozzle spacing in jacket

AGITATING NOZZLES

22

Practical ApplicationOur diagrams indicate the functional relationship between all the factorsinfluencing cooling agent requirements per nozzle. But how many nozzlesare suitable and how should they be arranged ?

ArrangementThe mean flow velocity is not changed by staggering

the nozzles. Therefore, it is advisable to place them vertically one above the other in order to alsosimplify the design of piping.

Nominal DiameterSmaller nozzles require less water to obtain the same mean flow velocity.However, the pressure loss as well as nozzle wear

are increased. For this reason, we recommend not to exceed the following water quantities per nozzle. When selecting nozzle diameters the prevailing operating conditions, i.e. the available water quantities and the admissible pressure loss, should be taken into due consideration

Number and DistanceSuch considerations also determine the number of nozzles. Fewer nozzlesinstalled at larger distances require less cooling agent but they are subject to

an increased pressure loss in comparison to nozzles at smaller distances.Identical distances between the nozzles result in identical efficiency ranges.The lowest nozzle should be installed as low as

possible in the cylindricalpart of the jacket shell to allow the cooling agent to also rotate in the bottomsection.

Outside diameter of inner vessel d1 - 2800 mm Distance H - 1350 mm Available cooling water quantity - 62 m3/h Allowable pressure loss - 1 bar

Practical Application and Example

SIZE DN 40 50 65 80 100

FLOW RATE m1/h 9 17 35 43 60 l/s 2.5 4.7 9.7 12.0 16.7

WATER QUANTITIES

Practical Example

SELECTION OF NOZZLES FOR BE 20000

NUMBER OF NOZZLES n 3 4 5NOZZLE SPACING H [mm] 1060 705 525

Nozzle DN50 w[m3/h] 14.2 12.4 11.5 p[bar] 1.00 0.76 0.68



23

Recommendation 4 nozzles DN50, 2 nozzles outlet (top and bottom) Actual pressure loss

∆p = 0.7 bar Required water quantity

per nozzle w = 12.4 m3/h Total demand WG = 4 x

12.4 = 49.6 m3/h

DN40 is not to be taken into consideration as water quantity exceed > 9 m3/h

H = Distance between the two farthest nozzle.

In case H < 400, one nozzle is sufficient to move the jacket content.

~~ 500

H

AGITATING NOZZLES FOR FACTORY STANDARD APPARATUS

REACTOR SERIES NOMINAL DIAMETER OF H* VOLUME INNER VESSEL [I] D1 [mm] [mm]

BE 630 1000 -

BE 800 1000 -

BE 1000 1400 -

BE 1000 1200 -

E 1200 1200 150

E 2000 1400 295

E 3000 1600 220

E 4000 1800 470

E 6000 2000 1455

E 8000 2000 1455

E 12500 2400 1475

E 16000 2600 1725

E 20000 2700 2115

DG 100 600 -

DG 250 800 -

DG 500 1000 -

DG 800 1000 -

DG 1200 1200 75

DG 2000 1400 210

DG 3000 1600 270

DG 4000 1800 370

DG 6000 2000 700

DG 8000 2000 1350

P 8000 2000 1475

P 14000 2500 1715

P 20000 2700 2115

P 25000 2800 2770

P 32000 3100 2805

Agitating Nozzle Overview

AGITATING NOZZLES

24

AGITATING NOZZLES FOR FACTORY STANDARD APPARATUS

REACTOR SERIES NOMINAL DIAMETER OF H* VOLUME INNER VESSEL [I] D1 [mm] [mm]

P 40000 3100 3805

T 100 600 -

T 200 800 -

T 300 800 -

T 500 1000 -

T 800 1000 -

AGITATING NOZZLES FOR DIN APPARATUS

REACTOR SERIES NOMINAL DIAMETER OF H* NOZZLE VOLUME INNER VESSEL ARRANGEMENT [I] D1 [mm] [mm] TO DIN 28151,B1

AE 63 508 - 1 X DN40

AE 100 508 - 1 X DN40

AE 160 600 - 1 X DN40

AE 250 700 - 1 X DN40

AE 400 800 - 1 X DN40

AE 630 1000 - 1 X DN50

AE 1000 1200 - 1 X DN50

BE / CE 1600 1400 - 1 X DN50

BE / CE 2500 1600 - 1 X DN50

BE / CE 4000 1800 350 2 X DN50

BE / CE 6300 2000 700 3 X DN50

BE / CE 8000 200 700 3 X DN50

BE / CE 8000 2200 600 3 X DN50

BE / CE 10000 2400 600 3 X DN50

BE / CE 12500 2400 700 3 X DN50

BE / CE 16000 2600 1200 4 X DN50

BE / CE 16000 2800 900 4 X DN50

BE / CE 20000 2800 1350 4 X DN50

BE / CE 25000 2800 2250 4 X DN50

BE / CE 25000 3000 1650 4 X DN50

BE / CE 32000 3200 1800 3 X DN80

BE / CE 32000 3400 1400 3 X DN80

BE / CE 40000 3400 1500 3 X DN80

BE / CE 40000 3600 1200 3 X DN80

* H = Distance between the two farthest nozzles. In case H < 400, one nozzle is sufficient to move the jacket contents

25

Main Dimensions

Nozzles on manhole cover DN

Nominal* Capacity

(Ltrs)10001600200025003000400050006300800010000125001600020000250003200040000

Total Capacity

(Ltrs)12501750230028003350440062907100904511050132501675022500261003487544150

Nominal Size

DN1000100012001200140016001800180020002000220022002400260028003200

d1

96696611631163136315581756175619501950215621562360255027503140

l1

1800250023302800250025252870320033304000404050005600560064006300

l1

1000170014001900180014001650195020502700240033503800380043004000

h2

70070080080090010501150115012501250135013501450155016501900

h4

1530153017301730193021802380238026202620282028203020322034203870

A8080808080808080100100100100100100100100

B+C 50 50 50 50 50 50 50 50 80 80 80 80 80 80 80 80

Discharge

DNK

80808080

100100100100100100100150150150150150

Weight without Support

~ (kg)83011901340154017402150289030403930453048306130923099801358015380

* Maximum permitted filling level 95% of the total capacity.

HORIZONTAL STORAGE TANKS

HORIZONTAL STORAGE TANKS

Design GMM Pfaudler’s glass linedcylindrical storage tanksmeet the following standards:DIN 28018 : DimensionDIN 28105 : DimensionDIN 28005 : ToleranceGlass Lined as per DIN EN ISO 28721. Design as per ASME Section VIII,Division I.

Operating Conditions Operating Pressure :

-1 / +3 bar Operating Temperature :

-10 / 500CCustom designs for enhanced pressure and temperatures are also available.

Glass All our Storage Tanks are lined with Pfaudler glass WWG 9100. This glass is extremely resistant to corrosion and mechanical stress. For specific applications, special glasses are also available.

When required, non standard sizes with higher temperature and pressure rating can also be supplied.

Horizontal StorageTanks Circular manhole is supplied at the top of the cylindrical part, Ø 500/600mm.

Support : Saddle brackets

Vertical Storage TanksCircular manhole is supplied in the upper spherically dished end, Ø 500/600mm.

Support : Pipe legs or support ring.

GLASS LINED STORAGE TANKS

GLASS LINED STORAGE TANKS

26

VERTICAL STORAGE TANKS

Main DimensionsNozzles on manhole cover DN

Nominal*Capacity

(Ltrs)10001600200025003000400050006300800010000125001600020000250003200040000

TotalCapacity

(Ltrs)12501750230028003350440062907100904511050132501675022500261003487544150

Nominal Size

DN1000100012001200140016001800180020002000220022002400260028003200

d1

96696611631163136315581756175619501950215621562360255027503140

l1

1800250023302800250025252870320033304000404050005600560064006300

h2

460460460460460460460460600600600600600600600600

h4

2670337032003670337033953740407044055075511560756675667574757375

A8080808080808080

100100100100100100100100

B+C50505050505050808080808080808080

Discharge

DN K

80

808080

100100100100100100100150150150150150

Weight without Support

~ (kg) 830 1190 1340 1540 1740 2150 2890 3040 3930 4530 4830 6130 9230 9980 13580 15380

* Maximum permitted filling level 95% of the total capacity.

VERTICAL STORAGE TANKS

27

Design The inner vessel is glassed outside and the outer vessel is glassed inside. The equipment is provided with a jacket.

Operating Conditions Operating Pressure : -1 / +6 bar Operating Temperature : -25 / 2000C

Custom designs for enhanced pressure and temperatures are also available.

GlassAll parts in contact with product are glass lined with Pfaudler glass WWG 9100. This glass is extremely resistant to corrosion and mechanical stress. For specific applications, special glasses are also available.

NozzlesAll Condenser nozzles are supplied with loose split backing flanges drilled ANSI 150 as standard.

Note: Installation of agitating nozzles increases heat transfer Subject to change

Cooling Area Type Main Dimensions (mm) Weight

(m2) d1 d2 d3 e h1 h5 h6 S2 T K ~ (Kg)

WK 2 420 488 320 200 1120 1250 1420 4 × 25 100 50 450

WK 4 600 690 500 220 1600 1765 1965 4 × 32 100 80 950

WK 6 700 800 600 220 1900 2070 2305 4 × 40 100 80 1200

WK 8 850 950 750 300 2000 2210 2455 4 × 50 200 80 2150

WK 10 1000 1100 900 300 2200 2420 2675 4 × 50 200 80 2450

WK 12 1000 1100 900 300 2500 2720 2975 4 × 50 200 80 2750

WK 16 1000 1100 900 300 3000 3245 3500 4 × 50 200 150 3850

HEAT EXCHANGERS

WK

HEAT EXCHANGERS WK

HEAT EXCHANGERS WK

28

Why Glasteel?The benefits of Pfaudler glass lined equipment are well known : Glasteel is resistant

to most corrosive substances even under extreme thermal conditions

Glasteel is essentially inert, so it cannot adversely affect product purity or flavor

Glasteel resists the buildup of viscous or sticky products, which means better heat transfer, less frequent cleaning and higher productivity

Glasteel is strong fusing glass to steel produces a high strength, corrosive resistant composite

Now, A Glass for the WorldIn recent years, because of the expansion of the chemical process in pharmaceutical industries worldwide and increased concerns for safety and quality control, Pfaudler began investigating new approaches in glass development that would lead to a glass composition that could be made available to all users of glass lined equipment. Together with the chemical process industry and with the cooperation of Pfaudler divisions around the world, Pfaudler established the criteria for a new composition:

A non-crystalline structure Increased resistance

to acid and alkali corrosion High resistance to

impact High resistance to

thermally induced stresses A formulation that

could be easily produced by all Pfaudler manufacturing plants

The result is Glasteel 9100, Pfaudler’s first “international glass”, offering an unmatched combination of corrosion resistance, impact strength, thermal shock resistance, non-adherence and heat transfer efficiency. Now Pfaudler customers, regardless of where their processing operations are located, can purchase a single glass system and be assured of getting the same high quality worldwide. With Glasteel 9100, Pfaudler

sets a standard the world can depend on. Technical Data on Glasteel 9100The remainder of this brochure provides technical data for Glasteel 9100. In addition to presenting chemical and physical characteristics, this material describes performance under various conditions, identifies testing procedures used by Pfaudler researchers and provides a variety of other information derived from Pfaudler research and experience in the field, all of which is intended to help the user.

PFAUDLERWORLDWIDE GLASTEEL®

9100

Molten glass is poured into a sparger during the frit manufacturing operation.

29

The resistance of Glasteel 9100 to acids, water, alkalis and other chemical solutions is presented in Figure 1. Based on the isocorrosion curve (0.1 mm/year) of a number of hydrous acids and alkalis, it describes in general the resistance of Glasteel 9100 to these substances. Isocorrosion curves for specific acid and alkali solutions are included in the sections that follow.

AcidsOutstanding acid resistance under extreme process conditions is a primary characteristic of Glasteel 9100. In the charts that follow, we present isocorrosion curves for acids most commonly used in the chemical industry: hydrochloric, sulfuric, nitric, phosphoric and acetic. These curves are the result of a test procedure that includes a parameter especially pertinent to glass lined equipment in service, i.e. the ratio between liquid volume and the glass surface area. The test Conditions according to DIN151174 (see Test Conditions section on page 8) meets this requirement.1DIN: Deutsche INDustrIe Norm.

Corrosion Resistance

Figure 1: Characteristic resistance curves for acid and alkaline solutions (isocorrosion curve 0.1 mm/year and 0.2 mm/year.)

CHARACTERISTIC RESISTANCE CURVES

ISOCORROSION CURVES FOR ACIDS

220

180

140

100

20 40 60 80 100

H3PO4

Phosphoric Acid

C

0.01 mm/year200ppm SiO2

0.5 mm/yr

0.2 mm/yr

0.1 mm/yrFully Resistant

SiO2 Inhibition

%H3 PO4 BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O)=20

20 40 60 80 100

CH3COOHAcetic Acid

C

0.08 mm/year100ppm SiO 2

0.5 mm/yr

0.2 mm/yr0.1 mm/yrFully Resistant

220

200

180

160SiO2 Inhibition

%CH3 COOH BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O)=20

200

180

160

140

120

100 10 20 30

HCl

Hydrochloric Acid

C


SiO2 Inhibition

0.5 mm/yr

0.2 mm/yr


%HCL BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O)=20

220

180

140

10020 40 60 80 100

H2SO4

Sulfuric Acid

C


SiO 2 Inhibition

0.5 mm/yr

0.2 mm/yr


%H2 SO4 BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O)=20

200

180

160

140

120

10020 40 60

HNO3

Nitric Acid

C

0.02 mm/year250ppm SiO 2

SiO2 Inhibition

0.5 mm/yr

0.2 mm/yr


%HNO3 BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O)=20

300

200

100

001 23 45 67 89 10 11 12 13 14

Characteristic Resistance Curves

Not Resistant

Fully Resistant

Resistant Within Limits

Not Resistant

enilaklAdicA

HydrousBase

HydrouspH Acid (H 2O)

Acids

PFAUDLER WORLDWIDE GLASTEEL® 9100

30

Isocorrosion Curves for AcidRegent-grade acids were used in the laboratory tests that produced these curves. In a practical operation, these acids are usually of a lower grade and are mixed with other chemical species. Other factors such as velocity, phase type, (e.g. liquid, vapor, condensing vapor, splash zone, hardness and size distribution of a particulate phase) can also affect the corrosion rate. Depending on a variety of complex interacting factors, increases (catalysis) or decreases (inhibition) in corrosive reactivity over the pure chemical rates should be expected. It is for this reason that statistically oriented testing using the identical recipes and operational parameters to the actual process is strongly recommended.

Chemical InhibitionThere are variety of chemical species that will inhibit the corrosion rate of glass. However, these are very recipe sensitive and general statements cannot usually be made. An exception to this are chemistries that involve the element silicon (Si), especially when ionized, e.g. Si4+, SiO4.

4. As shown in both Figure 2 andon the isocorrosion curves, relatively small amounts of dissolved SiO2 can be highly effective in reducing the corrosion rate of the Glasteel 9100 system, thereby greatly extending its usable range. It has also been shown that colloidal silica additions to recipescontaining the highly corrosive fluorine ion (F) can drastically reduce the corrosive rate.

WaterPure WaterPure water in the liquid phase is not very aggressive. Its behavior resembles highly diluted acid and corrodes only the surface layer of the glass (“ion exchange process”). At 170°C, a corrosion rate of 0.1 mm/year can be expected.

But because this water is an unbuffered, pH-unstable system, even a slight alkalization can change the situation. If there is a shift toward higher pH values, the isocorrosion curves for diluted alkaline solutions have to be consulted for orientation purposes.

Glasteel 9100 is highly resistant to condensing water vapor. However, to counter the possible danger of the condensate shifting to an alkaline pH, it is recommended that the vessel contents be slightly acidified with a volatile acid, e.g. hydrochloric or acetic acid. It is also highly recommended that the unjacketed top head be insulated or head traced to reduce condensation formation.

Aqueous Neutral pH MediaWith these type media, e.g. tap water, salt solutions, corrosion rate depends greatly on the type and quantity of the dissolved substance. Carbonates and phosphates usually increase the rate while alcohols and some Ionic species, e.g. AI3+ Zn2+ Ca2+, may reduce it.

Figure 2. SiO2 effect on glass corrosion using 20% HCl at 160 C.Note: We present this test data as a guideline only. Extrapolation or

interpolation to actual conditions is next to impossible.

SiO2 Effect on Glass Corrosion

V L = mm/year liquidphase corrosionrate

ppm = parts/million

ppm SiO2

0.6

0.4

0.2

50 100

VLmm/year

31

AlkalisAs alkali concentration rises, corrosion rate increases. Also, the temperature gradient for alkaline glass corrosion is steeper. The result is that concentrated alkalis require more definite setting of the temperature limits.

The corrosion rate of concentrated alkaline solutions cannot be expressed by the pH value alone. For aqueous solutions of alkaline materials with a pH value of 14, the particular concentration must also be considered to establish appropriate operating temperatures. Other factors affecting alkaline corrosion are the specific reaction and the dissolving ability of the chemical, the influence of the nature and amount of other dissolved substances and agitation.

Isocorrosion curves are presented on page 5 for sodium hydroxide, potassium hydroxide, sodium carbonate and ammonia. They take into account technically relevant parameters influencing the rate of corrosion; for example, the volume/surface area ratio, inhibition effects by calcium ions, alkaline concentration and temperature.

The information in the graphs is based on pure alkaline solutions.

Under actual operating conditions, even very slight contamination (tap water

in sodium hydroxide, for example) can cause major changes in the rate of corrosion. Other factors, such as product velocity and splash zone, can affect the corrosion rate as well. Due to these interactive complexities, meaningful testing is strongly advised.

To eliminate the influence of the testing equipment on the rate of corrosion, procedures were carried out in polypropylene bottles. For solutions above the boiling point, autoclaves with PTFE insert were used. By comparing the results with control experiments, it was proven that the testing equipment did not have an inhibiting effect.

Other ChemicalsTable 1 provides general information on the resistance of Glasteel 9100 to some other chemical substances. The data based on practical experience and laboratory tests.

NOTE: Pfaudler provides this information without obligation, and we do not claim it is complete. We strongly recommend testings for any exposure not listed in Table 1, especially for combinations of chemicals. Pfaudler also recommends performing corrosion tests or contacting Pfaudler even for those conditions listed, as details of individualized processes may accelerate or inhibit corrosion.

ISOCORROSION CURVES FOR ALKALIS


32

Corrosion Testing

Standard ProceduresAlthough the older test equipment and associated procedures do not completely eliminate inhibition type effects caused by a reduced volume to surface area ratio, they still can provide, by way of a detailed standard testing format, valuable comparative type data.

AcidsThis procedure is suitable for all acids up to the boiling point. It gives quantitative data for the condensing vapor phase. For above the boiling point conditions, Pfaudler has developed a pressurized autoclave along with the associated procedure. This has been standardized in DIN1 51174 and is discussed more fully under Test Conditions.

Salt Melts and Highly Viscous LiquidsTesting dishes must be covered by glass and heated in a dryer, oil or sand bath. Qualitative data is obtained.

AlkalisThis procedure can be used for all alkalis to provide quantitative data for the liquid phase.

WaterThis procedure is used at the boiling point to yield quantitative data for the condensing vapor phase.

The cutaway view of this glass lined demonstration vessel shows a fin baffle and Cyro-Lock® agitator in

position, Some of the other available Cyro-Lock® impeller configurations

are displayed at the foot of the reactor.

Practical Scale Corrosion TestingFor safety reasons, we need to know the maximum possible attack of a pure acid on glass coatings. Inhibiting influences, therefore, must be excluded. In the last few years, however, when glass lined vessels were increasingly used at the limits of their ranges, Pfaudler tracked down a phenomenon that is also of major importance in connection with corrosion in the vessel: the ratio between liquid volume and glass surface area. The graph in Figure 3 shows how this ratio changes with the size of the vessel. This new understanding required a new set of test conditions for practical corrosion testing.

Test Conditions (DIN1 51174) Under the new test conditions, very small dumbbell shaped immersion samples, completely coated with glass so as toprecisely determine the weight loss, are exposed to reagent-grade acids for 24 hours. These samples have a glass lined surface area of 11 or 25 cm2, depending on the type of dumbbell used. They are immersed in large acid volumes (500 ml) in autoclaves with a tantalum lining to prevent any SiO2 inhibition.

The isocorrosion curves shown for hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid and acetic acid, were obtained under these severe conditions.

In addition to the glass coating, other component of the system, e.g. repairs or seals, must be carefully evaluated for suitability as they may have lower resistivities.

Figure 3. Liquid volume/glass surface area ratio (V/O) with vessel filled

Acids

Samples(Test Plates)

Test Unit

According to DIN-ISO 2723

According to DIN-ISO 2733, Sheet 2

According to DIN-ISO 2743, Sheet 1Procedure

WaterAccording to DIN-ISO 2744Procedure


Test Unit


According to DIN-ISO 2733, Sheet 2

AlkalisAccording to DIN-ISO 2745Procedure


Test Unit



Liquid Volume/Glass SurfaceArea Ratio with Vessel Filled

60

40

20

51 01 52 0

)PRODUCT VOLUME V (M

VOLU

ME/

SURF

ACE

AREA

(m

l/cm

2)

33

acetic acid - - sp3acrylic acid 0 150 1aluminum acetate melt 200 1aluminum chlorate w 110 1aluminum chloride 10%w bp 1aluminum potassium sulfate 50%w 120 1aminoethanol 0 170 1m-aminophenol 0 150 1aminophenol sulfonic acid 0 130 1ammonia - sp5ammonium-carbonate w bp 1ammonium chloride 10%w 150 1ammonium nitrate w bp 1ammonium phosphate w bp 1ammonium sulfate w bp 1ammonium sulfate w 320 3ammonium sulfide melt 80 1ammonium sulfide w 140 3aniline 100 184 1antimony (III) chloride w 220 1antimony (V) chloride 100 150 1aqua regia 100 150 1 barium hydroxide w bp 2barium sulfate w 150 1benzaldehyde 100 150 1benzene - - 2benzoic acid 0 150 1benzyl chloride 100 130 1boric acid w 150 1boron trifluoride ether complex - - 2bromine w 100 1butanol 100 140 1 calcium chloride (free of CaO) w 150 1carbon dioxide w 150 1carbon dioxide w 250 1carbon disulfide 100 200 1carbon tetrachloride 100 200 1chloride bleaching agent w 150 1chlorinated paraffin 0 180 1chlorine vapor 200 1chlorine water w 180 1chlorosulfonic acid 100 150 1chlorpropionic acid w 175 1chromic acid 30%w 100 1chromic acid w 150 1

chromic sulfuric acid w 200 1citric acid 10%w bp 1cupric chloride 5%w 150 1cupric nitrate 50%w 100 1cupric sulfate w 150 1cyano acetic acid w 100 1cyanoacetamide 0 100 1 dm-dichlorobenzene 100 220 1dichloro-acetic acid w 150 1dichloro-propionic acid 100 175 1diethylamine 100 100 1diethylamino-propanol 100 150 1diethyl ether 100 100 1dimethylamino-propanol 100 150 1dimethyl sulfate 100 150 1 ethyl acetate 100 200 1ethyl alcohol 100 200 1ethylene diamine 98%w 80 1 fatty acid diethanolamide 0 105 1fatty acids 0 150 1ferric chloride 10%w bp 1ferric (II) chloride w 150 1ferric (III) chloride w 150 1fluoride in aqu. acid sol. - - 2formaldehyde 100 150 1formic acid 98%w 180 1fumaric acid 0 150 1 gallic acid 0 100 1glutamic acid 0 40 1glycerine 100 100 1glycol 100 150 1glycolic acid 57%w 150 1 heptane - - 2hexane - - 2hydrazine hydrate 80%w 90 1hydrazine hydrate 40%w 90 1hydrazine sulfate 10%w 50 1hydrochloric acid - - sp2hydrogen peroxide 30%w 70 1hydrogen sulfide w 150 1hydroiodic acid 20%w 160 1hydroiodic acid 60%w 130 1

AGENT CONC. ºC RESISTANCE AGENT CONC. ºC RESISTANCE

THIS DATA IS PROVIDED AS A READY REFERENCE FOR THOSE IN THE CHEMICAL AND PHARMACEUTICAL INDUSTRIES.RESISTANCE OF WORLDWIDE GLASTEEL 9100 TO CHEMICAL SUBSTANCES

1. Good resistance 2. Contact Pfaudler 3. Not resistant 0. All concentrations up to saturation in an inert solventw. All concentrations up to saturation in water, unless otherwise noted bp. boiling point sp. See page (of this brochure)


34

AGENT CONC. ºC RESISTANCE AGENT CONC. ºC RESISTANCE

iodine 0 200 1iron sulfate w 150 1isoamyl alcohol 100 150 1isopropyl alcohol 100 150 1 lactic acid 95%w bp 1lead acetate w 300 1lithium chloride 4%w 80 2lithium chloride 30%w bp 2lithium hydroxide conc. w 80 3 magnesium carbonate w 100 1magnesium chloride 30%w 110 1magnesium sulfate w 150 1maleic acid w 180 1methanol 100 200 1methyl ester of o-hydroxy-benzoic acid 0 150 1monochloracetic acid w bp 1 naphthalene melt 215 1naphthalene sulfonic acid w 180 1nitrogen oxides w 200 1nitrobenzene 100 150 1nitric acid - - sp2 octanol 100 140 1o-hydroxy-benzoic acid w 150 1oleum (10%SO3) 170 1ortho chlor-benzoic acid w 250 1oxalic acid 50%w 150 1 palmitic acid 0 110 1perchloric acid 70%w bp 1perfluoro cyclic ether, anhydrous - - 2phenol 100 200 1phenolphthalein 0 100 1phosphoric acid - - sp3phosphoric ethyl ester 100 90 1phosphorous acid (F-free) w 80 1phosphorous acid (F-free) w 100 2phosphorous oxychloride (F-free) w 110 1phosphorous trichloride (F-free) 100 100 1phthalic anhydride 0 260 1picric acid 0 150 1poly phosphoric acid w 140 1potassium bisulfate melt 200 1potassium bromide w bp 1potassium chloride w bp 1potassium hydroxide - - sp5

pyridine 100 bp 1pyridine chloride 0 150 1pyridine hydrochloride 0 150 1pyrogallic acid 5%w bp 1pyrrolidine 100 90 1 sodium bicarbonate w bp 2sodium bicarbonate, 1N w 95 1sodium biphosphate 50%w bp 1sodium bisulfate W 300 1sodium bisulfite 2%w 150 1sodium carbonate - - sp5sodium chlorate w 80 1sodium chloride w bp 1sodium ethylate 0 bp 1sodium fluoride - - 2sodium glutamate w 150 1sodium hydroxide - - sp5sodium hypochloride w 70 1sodium methylate 0 90 1sodium nitrate w 320 1sodium sulfide 4%w 50 2stearic acid 0 160 1succinic acid w 200 2sulfur 0 150 1sulfur dioxide w 200 1sulfuric acid - - sp2 tannic acid w 150 1tartaric acid w 140 1tetrachloroethylene 100 150 1tin chloride w 250 1toluene - - 2trichloro-acetic acid w 150 1triethanolamine w 250 1triethylamine 30%w 80 1triethylamine w 130 3trifluoracetic acid, anhydrous - - 2trimethyl-amine 30%w 80 1trisodium phosphate 50%w 80 1trisodium phosphate 5%w bp 2 urea 0 150 1 water - - sp2 o, m, p xylenes - - 2

zinc bromide w bp 1zinc chloride melt 330 1zinc chloride w 140 1

1. Good resistance 2. Contact Pfaudler 3. Not resistant 0. All concentrations up to saturation in an inert solventw. All concentrations up to saturation in water, unless otherwise noted bp. boiling point sp. See page (of this brochure)

35

Physical Properties

Temperature LimitsAlthough Pfaudler glasses are modified to make them adhere to steel, and the firing process incorporates helpful compressive stresses in the glass layer, they are prone to excessive thermal stresses. There are definite limits beyond which damage can occur.

“Safe” operating temperatures vary with conditions. Because so many variable are involved, temperature ranges are given only as a guide for standard vessels,including those with half-pipe jackets. Operation below the maximum temperature and above the minimum is strongly recommended.Only two conditions must be considered when determining the temperature limits of a Glasteel vessel:

A. Introduction of reactants into a vessel. B. Introduction of media into a jacket.

The limits for condition A are determined from Chart A; those for condition B from Chart B. In both cases, the safe operating range lies within the polygons as outlined on the charges. Wall temperature is plotted on the horizontal axes of both charts.

Reactant Temperature (Chart A) and Jacket Temperature (Chart B) on the vertical axes.

With Chart B, it is also necessary to know the heat transfer film coefficient of the jacket media. Three curves are shown : one for steam (8500 W/m2K) andtwo for typical heating oils (1500 and 1000 W/m2K).

Operating Temperature: Practical ExampleExample 1.Determine the maximum and minimum allowable wall temperature of a vessel when introducing reactants at 100°C into the vessel.Procedure: Since the reactants are being introduced into the vessel, Chart A applies: Find the temperature of 1000°C on the reactant temperature axis. If you follow this constant temperature along the wall temperature axis, you will see it intersects the polygon at wall temperature, of -30°C (ASME vessel) and -60°C (DIN vessel) at thelower temperature end and at 210°C at the upper temperature end.Answer: Reactants at 1000C can be introduced safely into a vessel whose wall temperature is between- 30°C ASME/ -60°C DIN and 210°C.

Example 2.A vessel with a wall temperature of 100°C is to be heated using hot oil with a heat transfer film coefficient of 1500 W/m2K. What is the maximum temperature oil that can be used?Procedure: Since the media is being introduced into the jacket, Chart B applies. Find the wall temperature of 100°C along the wall temperature axis. If you follow this line along the jacket temperature axis,

CHART (A)


36

it intersects the oil (1500 W/m2K) polygon at a jacket temperature of 257°C.Answer: The maximum allowable temperature of a 1500 W/m2K oil introduced into the jacket of a 100°C vessel is 257°C.

Example 3.A batch has just been completed and the wall temperature of the vessel is 150°C. What are the upper and lower temperature limits of reactants that canbe introduced in the vessel for the next batch?Procedure: Chart A applies. Find the temperature of 150°C. on the wall temperature axis. This line intersects the polygon at reactant temperatures of 0° and 232°C.Answer: The maximum and minimum temperatures of reactants that can be introduced into a vessel with a wall temperature of 150°C are 232°C and 0°C respectively.

Example 4.Steam is being used to

heat reactants in a vessel. The vessel content are at 125°C. Can steam at 250°C be introduced into the jacket?Procedure: Chart B applies. The intersection of a wall temperature of 125°C and a jacket temperature of 250°C is outside the steam polygon on the Chart.Answer: Steam at 250°C cannot be introduced safely into a vessel whose contents are at 125°C.

Caution: While pressure loads

are included in the Charts, other

mechanical stressing effects,

(e.g. nozzle loadings) are not.

Since most of these stress type

loads are additive, a combined

lading analysis must be done

and the appropriate safety

factors incorporated. Contact

Pfaudler for further information.

Thermal ConductivitySteel allows the glasslining to be kept relatively thin compared to self supporting glass equipment. Thus, the low thermal conductivity of the glass is counterbalanced by the high heat transfer

coefficient of the steel. Due to the chemical bond between glass and steel, no interface heat transfer resistance needs to be taken into account.

Table 2 compares the overall heat transfer coefficients for pure stainless steel and

glassed steel reactors under four typical process conditions. Note, contrary to popular belief, that the thinner stainless reactor in three of the four process conditions does not show the usually assumed significant heat transfer advantage over the glassed steel

reactor. In actual operation, the usefulness of Glasteel is further enhanced due to its inherent resistance to heat robbing, process side fouling.

Table 3 gives pertinent material properties for both the glass and low carbon steel substrate.

CHART (B)

37

TABLE 2 HEAT TRANSFER COEFFICIENTS

OverallHeatTransferCoefficients(ServiceU)* W/m2K**

Material of Construction Heating Water Heating Water Cooling Cooling Viscous (Barrier Material) with Steam with Heat Organic Liquid Organic Liquid Transfer Oil with Water with Water Stainless Reactor 512 353 199 95 0.656 in. (16.7 mm) wall†

Glasteel Reactor 437 316 185 94 0.05 in (1.3 mm) glass 0.688 in (17.5mm) steel†

Combined Film Conductance, 1703 778 284 114 hi ho / hi+ho

* Fouling factors typical to process fluids and materials of construction are included.** Divide by 5,678 for conversion to BTU/hr ft – E

† Thickness based on 1,000-gallon reactors for service at same pressures.

Property Glass Low Carbon SteelAdhesion (Glass on Steel) >100 N/mm2

(14.5 × 103 lb/in2) -Compressive strength 800 – 1000 N/mm2 -240 N/mm2

(11.6 – 14.5 × 104 lb/in2) (-34.5 × 103 lb/in2)Density 2.5g /cm3 7.8g / cm3

(0.09 lb/in3) (0.28 lb/in3)Dielectric strength 20 – 30 kv / mm (508 – 762 v / mil) Elongation 0.1% 15-35%Glass thickness 1 – 2 mm (0.039 – 0.079 in) -Hardness 600 Vickers 100 Vickers (5.5 Mohs scale) (62 HRB)Linear coefficient of expansion 200 – 4000C 88 × 102/C 136 × 102/C (49 × 102 /F) (76 × 102 /F)Modulus of elasticity 75,000 N/mm2 210,000 N/mm2

(10.9 × 104 lb/in2) (30.5 × 104 lb/in2)Softening temperature 5700C (10580F) -Specific electrical resistance (R.T.) 1012 – 1014 ohm-cm 12 × 100 ohm-cmSpecific heat 835J/kg K 460J/kg K (0.2 BTU/lb0F) (0.11 BTU/lb0F)Surface resistance 5 × 104 ohms -(R.T., 60% RH) Surface roughness 0.08 – 0.18 micrometers (3.1 – 7.1 microinches) -Tensile strength 70 – 90 N/mm2 380 – 515 N/mm2

(10.2 – 13.1 × 103 lb/in2) (55 – 75 × 103 lb/in2)Thermal conductivity 1.2W/mK 52W/mK (6.9 BTU – in/hr ft2 *F) (360 BTU – in/hr ft2 *F)

TABLE 3 MATERIAL PROPERTIES FOR GLASS AND LAW CARBON STEEL


38

CavitationThe introduction of steam into liquids of lower temperature can result in the rapid collapse of the bubble through condensation. This collapse, termed cavitation, can result in considerable energy release. If this release occurs near or at the surface of the glass, an impact type damage may result. Cavitation type problems may also occur due to the exothermic volatilization of a low boiling reactant with bubble collapse affected by condensation, pressure buildup or kinetic reaction. The partial vacuum created on the backside of a agitator blade can also cause formation of low boiling vapor bubbles that may collapse as they move the higher pressure regions. Consult Pfaudler for further information.

Electrostatic DischargeLiquid organic media usually do not pose chemical resistivity problems for Glasteel. However, materials that possess low specific conductivities, e.g. hexane, the xylenes, toluene, benzene, heptane, either alone or in combination with other liquids, solids and /or vapor phases, may lead to an electrostatic discharge within the liquid, between the liquid and vapor, or between the liquid/ vapor and the vessel walls or accessories. Note that this discharge can occur even in a grounded metal vessel. Addition of static sensitive powders through a nozzle may also present a problem.

The electrostatic discharge could ignite a flammable vapor in a poorly inserted atmosphere, harm instrumentation or

produce a pinhole type dielectric breakdown of the protective Glasteel glass coating. If these type of problems are existent or anticipated, professionals in the area of electrostatics should be consulted.

Abrasion ResistanceGlasteel coating are sufficiently hard (600 Vickers) to provide excellent resistance to abrasive wear.

The abrasion resistance of the glasslining by particulates is dependent on the hardness, shape, size distribution and concentration of the particles, as well as the characteristics of the liquid medium, e.g. polarity. Testing must be done under actual conditions to ensure serviceability.Glasteel 9100 offers the best combination of abrasion corrosion

resistance available to the chemical precession industry today. Abrasion resistance has been measured using both the ASTM abrasion test C448 and the DIN test 51152. The results were: ASTM = 3.9 ± 0.3 mg/cm2-hr; DIN = 2.5 mg/cm2-hr.

Pfaudler Makes a Glass for Your ApplicationIn addition to Worldwide Glasteel 9100, Pfaudler offers a wide variety of unique glasses to meet special requirements such as these: Elevated Operating

Temperatures Glass Coatings for

Austenitic Stainless Steels

Higher Alkali Resistance

Increased Resistance to Thermal Stress

Reduced Polymer Adherence

Other Information

The Numbering System for Pfaudler GlassesMany of the people reading this brochure have had or will have an opportunity to order glass lined equipment from Pfaudler. To assist you in that process and help you better understand how our glass identification system works, the following decoding information is offered.

Pfaudler glasses are identified by a four-digit number also used for ordering purposes. The first two digits represent the glass system. For example, 91 indicates the 9100 series of glasses. However, you cannot simply order 9100; you must also specify the third and fourth digits. The third digits represents color instrumentation or produce a pinhole type dielectric breakdown of

the protective Glasteel glass coating. If these type of problems are existent or anticipated, professionals in the area of electrostatics should be consulted.1 = Dark Blue

2 = White

3 = Green

4 = Light Blue

9 = All Other

The fourth digit represents factory DC test voltage permutations:1 = Visual, no test voltage

2 = 5,000 Volts

3 = 7,000 Volts

4 = 12,000 Volts

5 = 15,000 Volts

9 = Any non-standard test

condition

For example, an order for Pfaudler 9115 glass indicates our 9100 series glass in Dark Blue with a test rating of 15,000 volts. Your Pfaudler representative will assist you in identifying the proper specification number for your particular order.

39

Certain chemical reactions require high temperatures. These reactions, as well as many others operating at lower temperatures, would benefit from faster heating and cooling rates for enhanced productivity and/or a high margin of thermal safety to minimize the danger of process upsets or operator error.

To meet these needs, Pfaudler has achieved another Pfaudler first, Ultra-Glas 6500, a glass specially developed to be rated to 343 degrees C (650 degrees F). This represents a large (200

degree F) improvement over Pfaudler’s internationally respected standard glass. Furthermore, this expanded heat tolerance is accomplished in Ultra-Glas 6500 without sacrificing abrasion, impact, or corrosion resistance, nor is there any increase in product adherence. The features of Pfaudler Ultra-Glas 6500 are the result of changes in glass composition and material preparation, altered applications and firing procedures, as well as changes in equipment design and materials of construction. These changes permit trouble-free application of the required high-stress coating (see Fig.1) and provide the highly corrosive-resistant

glass lined surface for which Pfaudler has been respected for years. Technical details of corrosion rates in common chemicals and thermal operation limits follow herein.

ULTRA GLASTM

6500

KEY FEATURES: PFAUDLER ULTRA-GLAS 6500

1. Extends the range of Glasteel® applications.

2. Allows safe and easy handling of high temperature processes never before approved for Glasteel equipment.

3. Provides potential for reduced cycle time compared to conventional vessel glass.

4. Provides extended thermal shock protection for faster heating and cooling.

5. Provides increased operating safety margin through its enhanced thermal protection.

6. Is ideal for the higher temperatures required by today’s chemical process applications.

Temperature LimitsAlthough Ultra-Glas 6500 has a high degree of helpful compressive stress in the glass layer, there are definite limits to the level of thermal stress which the glass can

withstand without incurring damage.

Only two thermal conditions must be considered when determining the temperature limits:A. Introduction of media into a vessel. The limits are determined from Chart A (located on next page).B. Introduction of media into a jacket. The limits are determined from Chart B (located on next page).

In both cases the safe operating range lies within the polygons as outlined on the charts. The left and right sides on the polygons represent, respectively the minimum wall temperatures allowed. The bottom and top on the polygons represent,

respectively the minimum and maximum product temperatures allowed (Chart A, see next page) and the minimum and maximum jacket temperatures allowed (Chart B, see next page).

With Chart B, it is also necessary to know the heat transfer film coefficient of the jacket media. Three curves are shown: one for steam (8500 W/m2k) and two for typical heating oils (1500 and 1000 W/m2k).

CAUTION: “Safe” operating

temperatures vary with conditions.

Because so many variables are

involved, temperature ranges are

given only as a guide. When practical,

operation below the maximum and

above the minimum is recommended.

Contact Pfaudler for details.

FIG.1. GLASS STRESS vs TEMPERATURE

KEY Standard glass

Ultra-GlasTM 6500

ULTRA GLASTM 6500

40

Operating Temperature – Example Exercises

Exercise No. 1.Determine the maximum and minimum allowable wall temperatures of a vessel when introducing a product at 100°C into the vessel.Procedure: Since the media is being introduced into the vessel, Chart A applies. Find the product temperature of 100°C on the product temperature axis (ordinate). If you follow this constant temperature along the wall temperature axis (abscissa), you will see it intersects the polygon at wall temperatures of -30°C at the lower temperature end and at 232°C at the upper temperature end.Answer: Product at 100°C can safely be introduced into a vessel whose wall temperature is between -30 and 232°C. Exercise No. 2A vessel with a wall temperature of 1000C is to be heated using hot oil with a heat transfer film coefficient of 1000 W/m2K. What is the maximum temperature oil that can be used?Procedure: Since the media is being introduced into the jacket, Chart B applies. Find the wall temperature of 100°C along the wall temperature axis (abscissa). If you follow this line along the jacket temperature axis

(ordinate), it intersects the oil (1000 W/m2K) polygon at a jacket temperature of 343°C.Answer: The maximum allowable temperature of a 1000 W/m2K oil introduced into the jacket of a 100°C vessel is 343°C.

Exercise No. 3A batch has just been completed, and the wall temperature of the vessel is 150°C. What are the upper and lower temperature limits of the product that can be introduced in the vessel for the next batch? Procedure: Chart A applies. Find the temperature of 150°C on the wall temperature axis. This line intersects the polygon at product temperatures of -30 and 280°C.Answer: A product’s maximum and minimum temperatures of that can be introduced into a vessel with a wall temperature of 150°C are 280°C and -30°C respectively.

Exercise No. 4Steam is being used to heat a product in a vessel. The vessel contents are at 50°C. Can 250°C steam be introduced into the jacket?Procedure: Chart B applies. The intersection of a wall temperature of 50°C and a jacket temperature of 250°C is outside the steam polygon on the chart.

Answer: Steam at 250°C cannot safely be introduced into a vessel whose contents are at 50°C.

Corrosion ResistanceIn the charts that follow, we present the isocorrosion curves for Ultra-Glas 6500. The curves are for pure acids and bases most commonly used in the chemical industry and take into account technically relevant parameters influencing the rate of corrosion. For example, the volume/surface area ratio, inhibition effects, concentration and temperature. In practical operation these materials are always encountered with liquid additives, dissolved substances, or gases which may have

positive or negative effects on resistance. Therefore we recommend performing corrosion tests or contacting a Pfaudler consultant to assure material suitability for individual processes.

HOT PRODUCT COLD PRODUCT

HEATING COOLINGHOT OIL (1500 W/M 2 K) HOT OIL (1000 W/M 2 K) STEAM

VESSEL SIDE (CHART A)

JACKET SIDE (CHART B)

41

Volume to Surface Area Ratio (V/O) applicable to all charts = 20

The information contained in this bulletin are believed to be reliable general guidelines for consideration of the products and services described herein. The information is general in nature and should not be considered applicable to any specific process or application.

The Pfaudler Companies, Inc. expressly disclaim any warranty, express or implied, of fitness for any specific purpose in connection with the information contained herein.

POTASSIUM HYDROXIDE SODIUM CARBONATE

AMMONIA

HYDROCHLORIC ACID NITRIC ACID SULFURIC ACID

PHOSPHORIC ACID ACETIC ACID SODIUM HYDROXIDE

ULTRA GLASTM 6500

42

CAUTION: “Safe” operating temperatures vary with conditions. Because so many variables are involved temperature ranges are given only as a guide. When practical, operation below the maximum and above the minimum is recommended. Contact GMM Pfaudler for details.

Glassing BreakthroughScore another first for Pfaudler research, which has pioneered most of the major developments in glassed-steel equipment. For the 70-some years that stainless steel has been available as a material of construction, it has rejected all efforts to bond glass reliably to it –until now. After decades of effort, Pfaudler researchers have developed a new glass formulation, along with special application and firing techniques. It’s called Glasteel 4000 and it is the first high-voltage test glass that can be applied and tested to guarantee a reliable glasslining of uniform thickness and

quality on stainless steel. No thin spots, no bare metal, no exposed base coat – all of which can occur with other glasses on stainless steel.

Glasteel 4000 glass made possible the invention of the revolutionary Pfaudler Stainless Steel Pharmaceutical Glasteel Reactors. This series fulfilled a long-felt need for pharmaceutical manufacturers concerned with meeting FDA Good Manufacturing Practices.

The highly polished exteriors of conventional all-stainless reactors are easy to clean and sanitize, which largely accounts for their widespread use. But the bare stainless interiors can interact with powerful corrosives inthe process solutions,

and this can both contaminate the product and shorten equipment life.

The Stainless Steel Glasteel reactor provides the same smoothly polished, easy-to-maintain exterior, but the interior has a lining of virtually inert glass that resists corrosion, abrasion, thermal shock, and product adherence. The inert glass will not contaminate the product and functions to protect the product purity, color, and quality. In addition, the stainless steel substrates and Glasteel 4000 linings of the Stainless Steel reactors also make them valuable for other applications, such as cryogenic processes and pure products for electronics.

Glasteel 4000 is not only used in the Stainless Steel reactor, it has already been used in other series and, in fact, could be used in any standard Pfaudler glass lined reactor capable of being fabricated from stainless steel. In addition, it has been used to cover special agitators and other accessories made of stainless steel.

Pfaudler Glasteel 4000 is the first high-voltage test glass ever developed for reliable bonding to stainless steel. It opens new possibilities for pharmaceutical, ultra-clean, cryogenic and other applications.

STAINLESS STEEL

GLASTEEL® 4000

43

JACKET SIDE (CHART B)VESSEL SIDE (CHART A)

Temperature LimitsAlthough Glasteel 4000 has a high degree of helpful compressive stress in the glass layer, there are definite limits to the level of thermal stress that the glass can withstand without incurring damage. Only two conditions must be considered when determining the temperature limits:1. Introducing media into a vessel. The limits are determined from Chart A

2. Introducing media into a jacket. The limits are determined from Chart B In both cases, the safe operating range lies within the polygons as outlined in the charts. The left and right sides of the polygons represent, respectively, the minimum and maximum wall temperatures allowed. The bottom and top of the polygons represent, respectively, the minimum and maximum reactant temperatures allowed

(Chart A), and the minimum and maximum jacket temperatures allowed (Chart B).

With Chart B, it is also necessary to know the heat transfer film coefficient of the jacket medium. Three curves are shown: one for heating steam and cooling water (8500 W/m2k) and two for typical heating/ cooling oils (1500 and 1000 W/m2K).

Corrosion ResistanceThe graphs that followthe present isocorrosion curves for Glasteel 4000 glass. These curves are for pure acids and bases most commonly used in the chemical industry. They take into account, technically relevant parameters which may

include, volume tosurface area ratio, inhibition effects, concentration, and temperature.

In practical operation, these corrosives are nearly always encountered with liquid additives, dissolved substances, or gases, any of which may

have positive or negative effects on resistance. Therefore GMM Pfaudler recommends performing corrosion tests or contacting a GMM Pfaudler specialist to assure material suitability for specific processes.

STAINLESS STEEL GLASTEEL® 4000

44

NITRIC ACID

HYDROCHLORIC ACID

AMMONIA POTTASSIUM HYDROXIDE SODIUM HYDROXIDE

SULPHURIC ACID SODIUM CARBONATE

PHOSPHORIC ACID ACETIC ACID

0.5mm/year 0.2mm/year 0.1mm/yearFullyresistant

% HNO3 BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O) = 20

% HCI BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O) = 20

% NH3 BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O) = 20

% KOH BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O) = 20

% NAOH BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O) = 20

% H2SO4 BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O) = 20

% NA3CO2 BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O) = 20

% H3 PO4 BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O) = 20

% CH3 COOH BY WEIGHTVOLUME TO SURFACE AREA RATIO (V/O) = 20

C

200

180

160

140

120

180

20 40 60 80

20 40 60 80 100

C

220

220

180

160

140

120

100

80 20 40 60 80 100

C

220

200

180

160

140

10 20 30

C

200

180

160

140

120

100

80

C

20 40 60 80 100

240

220

200

180

160

140

120

100

80

45

Chemical glasses and glass coatings for chemical apparatus characteristically have superior acid resistance. This is due to their acidic components and structure. For this reason, acid resistance is their major field of application. Alkali resistance is usually the inherent advantage of metallic and polymeric vessel materials and defines their principal application range. However, decades of Pfaudler research and development have finallybroken down these boundaries. Pfaudler Standard Glass CoatingsPfaudler’s standard glass coatings already have relatively high alkaliresistance without compromising their extremely high acid resistance. They are ideal for conventional glass coating applications and

are preferred for highacid operations with occasional neutralization and intermediate alkaline operations.

Pfaudler Type 4300 Glass CoatingsType 4300 glass coatings represent a new aspect of this tradition and are designed to bridge a perceived gap in the application range. Pfaudler Type 4300 glass is still an acidic type of glass, but its primary application is based on improved alkali resistance. Pfaudler Type 4300 glass coatings are advisable wherever alkaline conditions prevail during the cycle, or as a result of concentration and temperature, or where concentration and/or temperature conditions exceed permissible limits for conventional glass.

In addition, Type 4300 glass coatings are advisable where any of the following conditions exist : Protection of alkaline

products against metal contamination

Danger of discoloration of alkaline products due to incorporation of metals

Stabilization of high-molecular alkalis sensitive to metal contact

Inadequate redox stability of the vessel material in the alkaline range

Compared to our world renowned standard glass, Type 4300 has three times better alkali resistance. This means that higher process temperatures can be used, or that, under otherwise equal conditions, these glass coatings will have three times the life expectations. The Type 4300 glass does make a slight concession in the area of acid resistance. Although it is adequate for mild service, it is not recommended for aggressive acid conditions. The isocosion curves and thermal limit diagrams for Type 4300 glass appear in the next section.

Temperature LimitsAlthough Type 4300 glass has a high degree of helpful compressivestress in the glass layer, there are definite limits to the level of thermalstress which the glass can withstand without incurring damage.

Only two conditions must be considered when determining thetemperature limits:A. Introduction of media into a vessel. The limits are determined from Chart A (located on next page).B. Introduction of media into a jacket. The limits

are determined from Chart B (located on next page).

In both cases the safe operating range lies within the polygons asoutlined on the charts. The left and right sides on the polygons represent,

respectively, the minimum and maximum wall temperatures allowed. The bottom and top on the polygons represent, respectively, the minimum and maximum product temperatures allowed (Chart A) and the minimum and maximum

ALKALI GLASS 4300

ALKALI GLASS 4300

46

Operating Temperature – Example Exercises

Exercise No. 1.Determine the maximum and minimum allowable wall temperatures of avessel when introducing a product at 100°C into the vessel.Procedure: Since the media is being introduced into the vessel, Chart Aapplies. Find the product temperature of 100°C on the product temperature axis (ordinate). If you follow this constant temperature along the wall temperature axis (abscissa), you will see it intersects the polygonat wall temperatures of -30°C at the lower temperature end and at 232°C at the upper temperature end.Answer: Product at 100°C can safely be introduced into a vessel whosewall temperature is between -30 and 232°C.

Exercise No. 2A vessel with a wall temperature of 100°C is to be heated using hot oilwith a heat transfer film coefficient of 1500 W/m2K. What is themaximum temperature oil

that can be used?Procedure: Since the media is being introduced into the jacket, Chart Bapplies. Find the wall temperature of 100°C along the wall temperature axis (abscissa). If you follow this line along the jacket temperature axis (ordinate), it intersects the oil (1500 W/m2K) polygon at a jackettemperature of 257°C.Answer: The maximum allowable temperature of a 1500 W/m2K oilintroduced into the jacket of a 100°C vessel is 257°C.

Exercise No. 3A batch has just been completed, and the wall temperature of the vesselis 150°C. What are the upper and lower temperature limits of the product that can be introduced in the vessel for the next batch?Procedure: Chart A applies. Find the temperature of 150°C on the wall temperature axis. This line intersects the polygon at producttemperatures of -5 and 232°C.Answer: The maximum and minimum

temperatures of a product that can be introduced into a vessel with a wall temperature of 150°C are 232and -5°C respectively.

Exercise No. 4Steam is being used to heat a product in a vessel. The vessel contents are at 125°C. Can 250°C steam be introduced into the jacket?Procedure: Chart B applies. The intersection of a wall temperature of125°C and a jacket temperature of 250°C is outside the steam polygon on the chart.Answer: Steam at 250°C cannot be introduced safely into a vesselwhose contents are at 125°C.

Corrosion ResistanceIn the charts that

follow, we present the isocorrosion curves for 4300 glass. The curves are for pure acids and bases most commonly used in the chemical industry and take into account technically relevant parameters influencing the rate of corrosion (for example, the volume/surface area into, inhibition effects, concentration, andtemperature).

In practical operation these materials are always encountered with liquid additives, dissolved substances or gases which may have positive or negative effects on resistance. We therefore recommend performingcorrosion tests or contacting a Pfaudler consultant to assure material suitability for individual processes.

HOT PRODUCT COLD PRODUCT

HEATING COOLINGHOT OIL (1500 W/M 2 K) HOT OIL (1000 W/M 2 K) STEAM

VESSEL SIDE (CHART A)

JACKET SIDE (CHART B)

jacket temperatures allowed (Chart B).With Chart B, it is also necessary to know the heat transfer filmcoefficient of the jacket media. Three curves are shown : one for steam(8500 Wm2K) and two for typical heating oils (1500 and 1000 Wm2K).

CAUTION : “Safe” operating

temperatures vary with

conditions. Because so

many variables are involved,

temperature ranges are

given only as a guide. When

practical, operation below the

maximum and above the

minimum is recommended.

Contact Pfaudler for details.

47

Volume to Surface Area Ratio (V/O) applicable to all charts = 20

The information contained in this bulletin is believed to be reliable general guidelines for consideration of the products and services described herein. The information is general in nature and should not be considered applicable to any specific process or application.

The Pfaudler Companies, Inc. expressly disclaim any warranty, express or implied, of fitness for any specific purpose in connection with the information contained herein.

SODIUM HYDROXIDE

SODIUM CARBONATE

NITRIC ACID

ACETIC ACID

PHOSPHORIC ACID

AMMONIA

POTASSIUM HYDROXIDE HYDROCHLORIC ACID

ALKALI GLASS 4300

SULFURIC ACID

48

Glasslining for GMP and FDA Requirements

When the requirements of the Bulk Drug industry were recently studied in context of the stringent requirements of GMP and FDA, the need for a different glass was evident. Two of the requirements of the pharmaceutical industry are increased purity in order to comply with the FDA and GMP requirements and alternating alkali/acid operation. The process equipment of the chemical and pharmaceutical industries have so far been characterized by great similarity-especially in terms of glass lined reactors and components. In light of the survey, Pfaudler’s response was a novel glass tailored to tile needs of manufacturing pharmaceutical products, vitamins and fine chemicals.

Pfaudler Pharma Glass PPGThe PharmaGlass PPG was developed free of heavy metals, light blue color, with a smoother surface finish compared to the conventional glass and improved alkali resistance.

PU RITY OF PRODUCTMetal Free GlassDuring corrosive chemical reactions glasslining corrodes at

a rate depending on the chemicals present & the temperatures. Ask for GMM Pfaudler WWG 9100 catalog for isocorrosion curves. The debris of corrosion including heavy metals reduces the purity of the Active Ingredient (AI).

Pfaudler PharmaGlass is practically freefrom heavy metals i.e. no heavy metals can be dissolved. The proportionate heavy metal content is below the analytical detection limits preserving the purity of the AI.

CLEAN IN PLACESmooth SurfaceWhen Pfaudler PharmaGlass PPG was developed, one primary challenge was the surface quality. The smoother the surface, fewer the incrustations is to be expected.

Pfaudler PharmaGlass PPG surface is three times smoother than the conventional glass surface.

PFAUDLER PHARMAGLASS PPG®

Smoother, Cleaner, More Resistant

Pfaudler PharmaGlass PPG compared to CrNi. Surface structure, magnified 200 times

CrNi

PPG

ADK α20-400 10-7 [K-1] 97-100

IMPACT 20-24 NM RESISTANCE

DIELECTRIC > 20 KV/MM STRENGTH

SPECIFIC > 109 ΩCM ELECTRICAL RESISTANCE*

ADHESIVE > 100 N/ STRENGTH MM2

WEAR < 6 MG CM-2 H-2

The properties of this new product contribute significantly to an improved safety and efficiency of

production processes.

*at room temperature

PROPERTY PROFILE OF PFAUDLER PHARMAGLASS PPG

PHARMA SOLUTIONS

DESI

GN

PPG

PROC

ESS

49

DIN ISO 719* DIN ISO 720*Sb < 0.01 < 0.01As < 0.02 < 0.02Ba < 0.001 < 0.001Pb < 0.01 < 0.01Cd < 0.002 < 0.002Cr < 0.01 < 0.01Co 0.001 0.005Cu 0.012 0.075Ni < 0.005 < 0.005Sr < 0.001 <0.001Zn < 0.01 < 0.01Sn < 0.05 < 0.05

Analytical detection limits according to applicable DIN standards The analysis was carried out on glass grains sized

0.3 < 0.425 mm DIN 7190.3 < 0.500 mm DIN 720

Resistance of PPG to water

Corrosion curve of Pfaudler PharmaGlass PPG

pH value measured at room temperature max. 0.1 mm/a max. 0.2 mm/a

40°C-2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

60°C

80°C

100°C

120°C

140°C

160°C

180°C

200°C

This product incrustation is efficiently avoided, further more; the time required for cleaning is reduced significantly. The benefits are obvious: Shorter and fewer downtimes, the systems are more productive.

The extremely high surface quality is preserved even after prolonged service times. Corrosion tests have shown that its roughness after an acid or alkali attack is much lower than with commercially available glass types. The surface of Pfaudler PPG is much smoother even after a corrosive attack - than that of healthy, electro-polished stainless steel surfaces.

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

before before beforeafter after after

R a C

rNi (

μm)

R a P

PG (μ

m)

HCI H2O NaOH

CHANGE IN ROUGHNESS OF PPG DURING CORROSION TESTS COMPARED TO ELECTROPOLISHED STAINLESS STEEL

PFAUDLER PHARMAGLASS PPG THE SOLUTION FOR ADDED PERFORMANCE

Improved Optical MonitoringPfaudler PharmaGlass PPG has a light-blue color, thus increasing contrast with dark blue, white or colored products. The light-blue color also improves the lighting of the reactor inside. Improved

monitoring of the production process and safe verification of the cleaning result are now possible.

Alkali WashWith the PharmaGlass PPG it is possible to wash

the reactor with dilute alkali (1.5%-5%) at temperatures below 70°C. The neutralization of any remaining acidic mass will help in cleaning and validation.

PFAUDLER PHARMAGLASS PPG®

50

We will be pleased to give you detailed answers to your questions on the new Pfaudler PharmaGlass PPG. Our engineer can visit you for a detailed presentation on the new glass. As a specialist for Reactor Systems, we will assist you with all projects, from engineering and production through installation and maintenance up to retrofits. This service is

offered for glass lined equipment and turnkey projects alike.

Right From the Beginning…Getting us involved in your planning at an early stage could mean benefiting from the practical experience of Pfaudler companies worldwide. The use of glass may add significantly to the efficiency of your production – we will

be pleased to provide you with supporting documentation for your decision-making process.

… Up the Operative SystemImplementation, operation and maintenance are our issues. Our specialists and their know-how ensure the safe, efficient and continuous operation of apparatuses and entire systems.

RATE OF CORROSION 0.1 MM/A 0.2 MM/A

IN PH -1 125˚C CA. 144W˚C

IN PH 7 150-160˚C CA. 170˚C

FROM PH 13 75˚C CA. 82˚C

Higher Resistance to Aggressive SubstancesOne of the properties characteristic of glass is its resistance to aggressive substances, even at high temperatures.Compared to other materials, glass is extremely resistant to acid media. The new Pfaudler PharmaGlass PPG for the first time combined this property with a significantly improved resistance to alkali substances. In the alkali range PharmaGlass PPG is 2.5 times better than chemical glass while it matches the acid resistance of WWG 9100.

Greater Application RangeEquipment lined with Pfaudler PharmaGlass PPG can withstand varying loads, thus offering a greater application range. Changing between stainless steel and glassed apparatuses is practically no longer necessary. You will save real money in terms of investment and in your day-to-day operations.

IMPROVED CHEMICAL RESISTANCE TO ALKALI

DEVELOPING THE OPTIMUM SOLUTION

51

Fillook® Simply a Clean SolutionThree functions in one – that’s what you get with the Fillook® filing hole and handhole covers from Pfaudler.

The fused - in Glasslook® sight glass ensures clear insight while offering increased safety.

Easy filling/easy removal of product is guaranteed by the quick-action closing system comprising four tommy screws made of stainless steel which do not require any additional tools. Funnel tubes facilitate filling of the reactor. And last but not least, Pfaudler also supplies manhole covers with an integrated filling hole cover and a lamp – three functions on one reactor nozzle. Of special interest is Fillook® for the food processing and

pharmaceutical industries, e.g. for quickly inspecting the inside of a reactor before and after cleaning processes. The added benefits of the Fillook® family:

Easy to clean outside and inside, no contaminated spots at the sight glass, clearance-free

No gaskets at the sight glass

CIP and GMP- approved

Optimized for pharmaceutical applications

Leakage-free with high safety margins

Fracture-proof, no total failure of the sight glass

Adjustable opening angle

Closing system with 3 tommy screws made of stainless steel: Quick-action

closing system of the filling hole cover

Easy handling Can be opened and

closed without tools Suitable for

pharmaceutical usage

Easy to clean

Filling cover on manhole cover with second sight glass and lamp: Lamp sight glass is

easily accessible, easy to clean

One reactor nozzle remains free for additional purposes

Fillook® Makes Everything EasierThe different Fillook®

design options have

positive effects on many aspects of reactor works. Cleaning is easier. There are fewer screws and fastening elements.

The number of gaskets is reduced. The total number of parts required is lower and besides, the process becomes more safer. In order to meet all demands, the Pfaudler Fillook® filling hole covers are available in different designs:

Fillook® 1 is fastened to the nozzle with a split flange.

Fillook® 2 for handholes on reactor types AE, DG and T is fastened with profiled ring.

FILLOOK® QUICK OPENING

DEVICES

FILLOOK® 1

FILLOOK® QUICK OPENING DEVICES

52

OPTIONS50W lamp cleaning devices for flange connections funnel tube in stainless steel No. 225 680

TOTALLY OPEN: THE DIFFERENT OPTIONS

Technical data:Pressure: -1/+6 barTemperature: -25/+2000C

Materials:Sight glass: Soda-lime glass DIN 8902Pressure-bearing steel parts: P275 NHOther components: stainless steelSurface protection: electroplated coating Fe/Zn8C to DIN 50961Glasslining: Pfaudler-WWG, blue or whiteO-Ring: FEP-sheathed Viton*

Chemical resistance:Only limited by glass and glasslining; refer to publication SB95-910-3GMM-01/02

Approval:Type approval by TUV, No. TUV.Db210/2 or TUV.Db.210/3

* Other materials available optionally, including with FDA approval.

DESCRIPTION SIZES PART NUMBERFillook® 1 DN100 FD-000for stand-alone nozzle; DN110 FE-000fastened with split flange DN150 FD-100 DN200 FD-200 DN250 FD-300 DN300 FD-400 Fillook® 2 DN100 FE-000for handholes at AE, DG and T; DN150 FD-100profiled ring fastening DN200 FD-200 DN250 FD-300 Fillook® 3 DN320/420 FD-600Manhole cover with DN350/450 FD-700integrated filling hole cover DN500 FD-800 DN600 FD-900 Fillook® 4 DN320/420 FD-620Manhole cover with integrated DN350/450 FD-720filling hole cover and additional DN500 FD-820Glasslook® sight glass DN600 FD-920 Fillook® 5 DN320/420 FD-630Manhole cover with integrated DN350/450 FD-730filling hole cover and additional DN500 FD-830Glasslook® sight glass with 20W lamp DN600 FD-930

FILLOOK® 3

FILLOOK® 5

*The actual design may slightly differ from the one shown in all the diagrams

Fillook® 5 is additionally equipped with a lamp unit at the second sight glass. Non-dazzling insight, non-dazzling illumination;

direction of light = viewing direction No shading-off by agitator shaft

Fillook® 3 is a filling hole cover mounted on a manhole cover.

Fillook® 4 is similar to Fillook® 3, but has an additional Glasslook® sight glass.

FILLOOK® 4

FILLOOK® 5

53

GLASSLOOK® - All You Face is SafetySafety has top priority in the operation of chemical plants.Pfaudler now offers added safety in the field of sight glasses in vessels and pipelines for optical monitoring of the process.Our enhanced sight glass type Glasslook® features a sight fused into a glass lined steel mount. The glass and the glass lining are thus joined into a single compound.

With the combination of glasteel and soda-lime glass we achieve an extremely homogeneous stress distribution over the entire temperature range and the glass itself.

Insight according to choice - Glasslook® sight glasses from Pfaudler are available in various designs: as sight in a glass

lined steel mount for installation in the manhole cover

or nozzle one or two sight

glasses directly fused into the manhole cover. The option with two sight glasses is also available with a lamp

Universal application range - The product only gets in contact with glass and the glasslining, with an equal chemical resistance of both materials.

The product is not contaminated.

In comparison to other metal-fused sight glasses (Hastelloy, Inconell), the Pfaudler combination offers a broader application range with higher chemical resistance. In contrast to customary tempered sight glass panes, the Glasslook® sight glasses yield clear benefits.

Advantages of Glasslook®: Resistance to

thermal shock due to homogeneous stress distribution within the glasteel compound

Leakage-free, higher resistance to pressure with high safety margins

Fracture-proof, no total failure, the sight glass remains tight even in the event of cracks

Always clear sight, higher scratch resistance, generally less sensitive to mechanical impacts

New clear insights into the process with additional handling advantages and increased safety are now available from Pfaudler with its range of fused-in sight glasses of the Glasslook family. To meet different application demands, the glasses are even available in four different designs.

GLASSLOOK® 1*

*The actual design may slightly differ from the one shown

GLASSLOOK® SIGHT GLASSES

FILLOOK® 2

GLASSLOOK® SIGHT

GLASSES

More Functions Few ComponentsThe appropriate Glasslook® for each applicationGlasslook® 1 is designed to replace conventional sight glass fittings. The sight glass only has to be fastened to the nozzle with a split flange to provide immediately more safety and more insight.

Advantages of Glasslook® 1: Safe installation: distortion and damages of the

glass when tightening the flange bolts are excluded Fewer contaminated spots, only one gasket at

the nozzle GMP - approved

54

Glasslook® 3 and Glasslook® 4 feature one or two sight glasses fused right into a complete manhole cover. These compact units offer convincing advantages: The glasses, just like the manhole cover, are slightly inclined, permitting condensate to run off easily. The view into the inside of the reactor is thus never obstructed. Cleaning is equally simple: the glass or glasses are easily accessible once the cover has been opened.

Advantages of Glasslook® 3 and 4: Sight glasses are easy to clean Condensate runs off quickly due to inclined position Fewer gaskets, more safety Additional glass protects against impacts from outside Longer life, more safety, absolutely maintenance-free

after installation

ø97

79ø79ø

ø97

79ø79ø

GLASSLOOK® 3*

GLASSLOOK® 4*

ø97

ø97

GLASSLOOK® 5*

GLASS-CLEAR : SELECTION OF OPTIONSTechnical Data:Pressure/Temperature:Glasslook® 1:Pressure: -1/+16barTemperature: -25/+2000C

Glasslook® 3/4/5:Pressure: -1/+6barTemperature: -25/+2000C

Materials:Sight glass: Soda-lime glass to DIN 8902Steel parts: TAStE 285 for Glasslook® 1 P 275 NH for Glasslook® 3/4/5Glasslining: Pfaudler-WWG, blue or white

Surface Protection:Glasslook® 1: Electroplated coating Fe/Zn8C to DIN 50691Glasslook® 3/4/5: Aluchrome or paint according to customer specification*

Chemical Resistance:Only limited by glass and glasslining: refer to publication SB95-910-3GMM-01/02Approval: Type approval by TUV, No. TUV.Db.210/1 or TUV.Db.210/2* electRoplated coating optionally available

Description Sizes Part NumberGlasslook® 1Sight glass in glass lined steel mount for DN50 225 639installation on manhole cover nozzle DN80 225 638or stand-alone nozzle, fastened with DN100 225 403split flange idem, with protective sleeve DN100 225 498

Glasslook® 3Manhole cover with a DN320/420 225 622fused-in sight glass DN350/450 225 623 DN500 225 624 DN600 225 625

Glasslook® 4Manhole cover with two DN320/420 225 626fused-in-sight glasses DN350/450 225 627 DN500 225 628 DN600 225 629

Glasslook® 5Manhole cover with two DN320/420 225 630fused-in sight glasses DN350/450 225 631and one 20W lamp DN500 225 632 DN600 225 633

Options 50W lamp

Glasslook® 5 with additional lamp.In contrast to lamps mounted on a nozzle, Glasslook®

5 offers not only a larger lighting angle of the light source, but also a more favourable position of the light cone. The processes inside the reactor are thus much easier to monitor. Advantages of Glasslook® 5: Three-in-one: manhole cover, sight glass unit,

and lighting One reactor nozzle remains free and can be used

for other purposes Non-dazzling insight/non-dazzling illumination No shading-off by agitator shaft Lamp sight glass is easily accessible and easy

to clean

55

Operating Conditions As per ASME Code Admissible operating pressure in the Pipes and Fittings -1/6 bar Admissible operation temperature -25°/+250°C Dimensions according to DIN 2873

Flange connection dimensions according to DIN 2501. Pipes and flanges for higher pressure on request.

GLASS LINEDPIPESAND

FITTINGS

DN mm 25 40 50 80 100 125 150 200 250

PN (bar) Standard flanges 6-20 6-20 6-16 6 I = each (mm) Length available to 1000 1500 2000 3000

ELBOW 45°

ELBOW 90°

DN mm 25 40 50 80 100 125 150 200 250d = Ø of Glassed mm 68 88 102 138 158 188 212 268 320 area Weight ≈kg 1.4 2.3 5.1 5.9 5.7 8.4 10.4 16.4 24

DN mm 25 40 50 80 100 125 150 200 250

e mm 90 105 115 135 155 175 195 260 315

Weight ≈mm 2.8 4.4 5.5 11.3 13.4 19 23 36 54.4

e

e

DN

e

DN

GLASS LINED PIPES AND FITTINGS

56

REDUCERS

DN 1

DN2

I

b2

b1

SPACERDN

d

s

DN mm 25 40 50 80 100 125 150 200 250d mm 68 88 102 138 158 185 210 265 320

Weight ≈kg 10 0.25 0.37 0.45 0.75 0.9 1.1 1.3 1.7 2.3

15 0.35 0.55 0.7 1.15 1.3 1.6 1.9 2.6 3.4

20 0.5 0.75 0.9 1.5 1.8 2.2 2.5 3.4 4.6

25 0.6 0.0 1.1 2.2 2.7 2.7 3.2 4.4 5.8

30 0.75 1.1 1.4 2.3 2.7 3.3 3.8 5.2 6.9

40 1.0 1.4 1.8 3.0 3.6 4.4 5.0 6.9 9.3

DN1 b1b2 DN2 25 40 50 80 100 125 150 200▼ ≈ ►

l (mm)= 140

(kg) 3,0 ← Weight (kg)

40 31 140

3.2

50 32 140 140

3.6 4.3

160 160

80 35 7.2 7.5

100 37 175 175 175

8.5 8.7 10.9

125 37 200 200 200

11.5 13.9 14.6

150 37 225 225 225

16.5 17.1 19.3

200 39 250 250 250 250

21.1 22.1 24 25.4

250 41 300 300 300 300

29.7 32.6 33.9 36.2

TEE

TEE

DN MM 25 40 50 80 100 125 150 200 250

L MM 180 210 230 270 310 350 390 520 630

WEIGHT ≈MM 4.2 6.9 9.4 16.9 21.7 30.8 39.2 63.2 93.1

DN MM 25 40 50 80 100 125 150 200 250

L MM 180 210 230 270 310 350 390 520 630

WEIGHT ≈KG 6.2 9.7 12 24.7 29.2 40.4 49.1 76.7 114

e

DN

e

DN

57

Size NB A B C Nxd L H T

mm mm mm mm holes mm mm mm

25 115 80 65 4-16 127 105 16

40 140 98 85 4-16 159 140 16

50 165 121 100 4-18 191 150 18

75 200 153 135 4-18 254 205 20

100 230 190 165 8-18 305 270 22

150 280 241 212 8-22 406 357 24

DN1 DN2 25 40 50 80 100 125 150 200▼ ► 40 l (mm)= 35 A Weight (kg) 3.9 50 A 35 35 4.8 4.6

80 B 35 35 35 35 7.1 6.8 6.7

100 45 45 45 45 10.9 10.5 10.3 9.5 125 45 45 45 45 13.8 13.6 12.4 11.7 150 45 45 45 45 18 17 16 15 200 45 45 45 45 45 B 26 24 23 22 21 250 45 45 45 45 34 32 30 25

DIAPHRAGM VALVES

DIN 2873

Operating pressure: 6 bars; up to DN1 150 ALSO 16 bars.

REDUCING FLANGES

DESIGN A (THREADED BORE)

DESIGN B (FLUSH BORE)

FITTING DIMENSIONS: DIN 2501

DN 1

DN 2

LT

N

NB C B A

H

d

BLIND FLANGEd

DN mm 25 40 50 80 100 125 150 200 250d = Ø of Glassed mm 68 88 102 138 158 188 212 268 320 area Weight ≈kg 1.4 2.3 5.1 5.9 5.7 8.4 10.4 16.4 24


58

FLANGED MANIFOLDS

L

L1L2

L4 L5 L5 L5 L4

DNNB

DN2

NB2

DN1

NB1

L3

- Larger dimensions upon request

DN NB DN1 NB1 DN2 NB2 L L1 L2 L3 L4 L5

50 2” 50 2” 50 2” 770 115 115 115 115 180

80 3” 50 2” 80 3” 810 130 135 135 135 180

100 4” 50 2” 100 4” 850 140 155 155 155 180

150 6” 100 4” 125 5” 1150 170 185 185 185 260

FLANGED 900 ELBOWS WITH JACKET

DN NB L INSIDE JACKET DN1 NB1 a f G ELBOW ELBOW

40 1-1/2” 105 48.3 dia. X 5.08 t. 73 dia. X 4 t. 20 3/4” 110 70 6.5 50 2” 115 60.3 dai. X 5.54 t. 90 dai. X 4 t. 25 1” 115 70 8.0

80 3” 135 88.9 dia. X 7.63 t. 115 dai. X 4 t. 25 1” 135 90 12.0

100 4” 155 114.3 dai. X 8.56 t. 140 dia. X 4 t. 40 1-1/2” 150 100 16.0

- G = approx. weight in kg. (incl. split flange) - Larger dimensions upon request

f

a

a

N11

FLANGED 450 ELBOWS WITH JACKET

DN NB L INSIDE JACKET DN1 NB1 a G ELBOW ELBOW

40 1-1/2” 70 48.3 dai. X 5.08 t. 73 dai. X 4 t. 20 3/4” 110 6.5

50 2” 80 60.3 dai. X 5.54 t. 90 dai. X 4 t. 25 1” 115 8.0

80 3” 95 88.9 dia. X 7.62 t. 115 dai. X 4 t. 25 1” 135 12.0

100 4” 105 114.3 dai. X 8.56 t. 140 dai. X 4 t. 40 1-1/2” 150 16.0

DN NB

L

L

DN1NB1

a a


OBSERVATION CROSS

L

DN mm 25 40 50 80 100 125 150 200 250l mm 180 210 230 270 310 350 390 520 630Weight ≈kg 7.1 10.9 13.3 25.2 30.9 41.6 51.3 77.4 116.2

59

FLANGED CONCENTRIC REDUCER WITH JACKET


DN NB DN1 NB1 DN2 NB2 L a f

50 1” 25 1” 25 1” 140 125 70

50 1” 40 1.5” 25 1” 140 125 70

80 3” 40 1.5” 25 1” 160 135 80

80 3” 50 1” 25 1” 160 135 80

80 3” 65 2.5” 25 1” 160 135 80

100 4” 40 1.5” 40 1.5” 175 135 90

100 4” 50 1” 40 1.5” 175 135 90

100 4” 65 2.5” 40 1.5” 175 150 90

100 4” 80 3” 40 1.5” 175 160 90

125 5” 50 1” 40 1.5” 200 135 100

125 5” 65 2.5” 40 1.5” 200 135 100

125 5” 80 3” 40 1.5” 200 150 100

125 5” 100 4” 40 1.5” 200 160 100

150 6” 65 2.5” 40 1.5” 225 135 110

150 6” 80 3” 40 1.5” 225 150 110

150 6” 100 4” 40 1.5” 225 160 110

150 6” 125 5” 40 1.5” 225 185 110

- SPLIT FLANGE DRILLING AS

DN2NB2

DN1

NB1

DN2NB2

L

aa

f

DN NB

FLANGED T PIECES WITH JACKET

DN NB L H INSIDE PIPE JACKET PIPE DN1 NB1 A F G40 1-1/2” 210 105 48.3 dia. X 5.08 t. 73 dai. X 4.78 t. 20 3/4” 110 105 10.0

50 2” 230 115 60.3 dia. X 5.54 t. 88.9 dia. X 4.78 t. 25 1” 115 115 14.0

80 3” 270 135 88.9 dai. X 7.62 t. 114.3 dia. X 4.78 t. 25 1” 135 135 18.5

100 4” 310 155 114.3 dia. X 8.56 t. 141.3 dia. X 6.65 t. 40 1-1/2” 150 155 23.5


DNNB

DN NB

f

H

L

TREE (G.L ANGULAR NOZZLE)


DN NB DN1 NB1 DN2 NB2 L A B C D E F

100 4” 50 2” 25 1” 511 109 200 105 200 150 150

150 6” 50 2” 25 1” 511 158 200 105 200 175 175

BB

C

C


60

GeneralDesigned for drying and blending, in one operation, aggressive or metal-sensitive substances, also suitable for impregnating and concentrating, for pharmaceutical products, synthetic resins and other plastics, dye-stuff and pigments, metal soaps and catalyzers. Compared with conventional methods, this process cuts time and costs of most applications considerably.

OperationAs the unit revolves, the top layers of the product roll down, constantly exposing new surface areas for faster drying. The gentle tumbling action intensifies the drying process while handling the product carefully, assuring an intimate mixture. The double cone shape balances the forces caused by the rotating product, prevent a substantial transfer of the gravity centre, protecting the aggregate from periodic impact stresses. The suitable speed of rotation is largely dependent from product properties and vessel size. Standard values are contained in the table overleaf. Operation under vacuum increase the drying speed respectively enables lower temperatures, which furthermore preserve the product. Drying results of 0.1% final moisture and less, have been obtained in a few hours. The optimum operating conditions should be determined by tests

which may be carried out with your product in our research centre.

SizesStandardized from 400 to 6300 litres total volume. Specially designed units up to 8000 litres. Best performance has been achieved with charges amounting to 50 - 60% of total volume. With solid or viscous products, the working volume should be reduced accordingly.

GlassConical Dryer-Blender components in contact with the product are lined with Pfaudler glass WWG 9100. This glass is extremely resistant to corrosion and mechanical stress. For specific applications, special glasses are also available.

DesignBase frame for all sizes upon request. Self-aligning roller bearings for supporting stands. Concrete base also possible. Heating medium is circulated via the trunnion at the drive end. Suction (vacuum) pipe and thermometer well led through the opposite bearing. If no temperature measurement is requested, the thermometer well can be used as an inlet pipe. Pressure gauge in the distribution compartment of suction pipe upon request.

The stationary vacuum pipe extends up and out of the path of the product movementto prevent clogging.

For fine drying goods, we deliver a PTFE filter with cap, if desired. A glass lined dust precipitator (cyclone) may be additionally connected to the suction line. Material of suction pipe: Hastelloy C. Other materials on request.

DriveInfinitely variable speed gear with explosion-proof motor. Speed indicator upon request. For determination of driving power we require details on product density and angle of repose.

CONICAL BLENDER DRYERS

61

Operating Pressure: All types listed below – internal 6 kg/cm2 (bar)/full vacuum

Type d1 d2 d3 d4 e h1 h2 h3 l1 l×b ≈ ≈

MT 400 1000 1100 430 200 900 1110 295 1625 2410 2200 × 1000

MT 1000 1350 1450 430 200 1200 1565 365 2155 2870 2800 × 1200

MT 1600 1550 1650 430 200 1300 1790 350 2370 3325 3000 × 1300

MT 2500 1800 1950 430 200 1500 2155 370 2750 3620 3600 × 1500

MT 4000 2100 2250 430 200 1900 2485 605 3315 3900 4000 × 1900

MT 6300 2450 2600 430 200 2300 2810 850 3780 4000 4500 × 1900

DIMENSIONS IN MM

Type

MT 400

MT 1000

MT 1600

MT 2500

MT 4000

MT 6300

Working

Volume

(I)

250

600

960

1500

2500

4000

Total

Volume

(I)

450

1115

1620

2615

4090

6350

Jacket

Volume

(I)

110

190

205

410

440

900

Heat./cool.

Area

(m2)

2.7

5.1

6.8

9.4

13.4

17.2

N

(motor)

(HP)

1.5

3

4

7.5

11.2

15

n

(vessel)

(rpm)

2 – 12.3

1.6 – 10

1.6 – 8.4

1.2 – 6.4

1.9 4.7

1.6 3.5

Weight

≈

(kg)

1250

2000

2900

4400

7100

9000

CONICAL BLENDER DRYERS

62

Kilo Lab Units or Pilot Plants are used to carry out process

development or process simulation in the laboratory.

They can also be used for low volume production of active pharmaceutical ingredients.

Complete reaction & distillation systems can be tailor-made to

suit a particular purpose or designed as a multi-purpose

system using a combination of corrosion resistant materials –

glass lined, borosilicate glass 3.3 and PTFE.

KILO LABS & PILOT PLANTS

63

Glass Lined Reactor Vessel Light blue Pfaudler

PharmaGlass PPG® Different agitator

designs including Curve Blade Residual Turbine for low level mixing, gas dispersion impellers and other configurations for better mixing

cGMP design CIP provision Double insulation with

polished stainless steel jacket cladding

Reactor Top Cover Standard version –

Glass top cover Glass Lined, SS,

Hastelloy for pressure reactions (standard up to 6 bar, special design up to 20 bar)

Stirrer SystemInverter duty ex-proof motor (ATEX optional), suitable gear reducer, optional Variable Frequency Drive.

Bottom Outlet ValveFlush with zero dead volume: Glass/PTFE

Reactor Bottom Pan-Raising / Lowering Device Manual or motorized Also removable after

lowering Safety Devices Glass/PTFE Pressure

Relief Value Rupture Disc Translucent coating of

glass components

Glass Overhead AssemblyThe standard overhead glass assembly is designed to contact reactions under reflux, followed by distillation. The following process equipment are standard:

Cylindrical graduated feed vessel for controlled addition of liquid reactants

Vapour pipe Primary condensor Vent condensor Distillate cooler Phase Separator for

azeotropic distillation with re-cycle of any phase. The design of the phase separator permits the adjustment of interface layer height externally without disturbing any process pipeline

Twin distillate receivers

Interconnecting glass process pipeline with high quality valves

Comprehensive and rational pressure equalization process pipeline for hydraulic integrity of the complete system. Single point application of vacuum for the complete system

Optionsa. Two liquid feed vesselsb. Vacuum manifoldc. System without phase separatord. Fractional distillation with infinitely variable

reflux

Support Structure Complete SS construction Special designs for low headrooms Suitable for installation in walk-in fume hoods Skid mounted mobile units also possible

Flanges Special design high strength re-enforced plastic

as standard SS also available as option SS nut bolts with compression springs as

standard PTFE coated as option Online SamplingContinuous on-line liquid sampling from the reactor.

Heating/Cooling SystemsSingle fluid with precise temperature control.

Solid Handling Systems Jet Mill Micronizer, Double Cone Vacuum

Dryer, Tray Dryer, Vibro-Sifters, Cream ointment & Planetary Mixer, Triple Roll Mill/Ball Mill, Colloid Mill, Multimill.

KILO LABS & PILOT PLANTS

64

NOTES

65

SECTION II

FILTRATION & DRYING

EQUIPMENT

■ MAVAZWAG®AGITATED NUTSCHE FILTERS & FILTER DRYERS 66■ FUNDA® CENTRIFUGAL DISC FILTERS 70■ MAVASPHERE® SPHERICAL DRYERS 71■ MAVAPAD® VACUUM PADDLE DRYERS 72

66

GMM Pfaudler's Mavazwag® Agitated Nutsche Filters and Filter Dryers (ANF and ANFD) are designed and manufactured with state-of-the-art technology from Mavag AG, Switzerland. Mavazwag® ANF and ANFDs are versatile and maintenance free, performing most effectively in Pharmaceutical and Chemical industries where solid washing and solid-liquid separation is required.

All operations of an ANF and ANFDs are performed in an enclosed system, ensuring product quality, product consistency and operational safety.

Our ANF and ANFDs are also available in GMP/Sterile designs, which adhere to CIP/SIP requirements.

GMM Pfaudler’s Mavazwag® ANF and ANFDs are available in Stainless Steel, Hastelloy and Special Alloys.

For extremely corrosive applications, GMM Pfaudler can offer ANF and ANFDs in Glass Lined construction.GMM Pfaudler offers Pilot ANFD for on-site test work, enabling the user to gain valuable experience and gather reliable process data at the same time. Our engineers welcome the opportunity to assist you in selecting the right ANF or ANFD and then optimizing it for your process conditions.

MAVAZWAG® AGITATED NUTSCHE FILTERS & FILTER

DRYERS

67

KEY FEATURES

Boltless Design Designed to ensure

boltless construction No bolts, no dead zones

and hence no product accumulation

Eliminates chance of contamination

Quicker process validation during product changeover

Agitator Hollow agitators made

from heavy sections making them suitable for both solids and liquids

Blade design improves mixing, heat transfer and facilitates uniform temperature distribution

Low angle blade profile ensures cake smoothening

Agitators available in both 2 blade and 3 blade design, 3 blade agitators can reduce the drying time by upto 30%

Shaft Seals and Bellows Stuffing box Single/Double

Mechanical Seal Bellows Scraper

Multipurpose Design Unique filter plate design

allows interchangeability of filter media without changing the base

Flexibility for multiple products and campaigns in the same equipment

Filter BaseBayonet type design available as an alternative to C clamp design.

Main VesselDesigned and manufactured according to ASME Sec. VIII Div. I.

Side Discharge Valve Hydraulically operated

valve with metal to elastomer sealing allows for a pressure tight shut-off after each product discharge

Fully automated, sealing surfaces do not require cleaning after each discharge

Specially designed metal to metal sealing is available as an option with self-locking arrangement to prevent loss of batch in case of hydraulic failure

Side Discharge PortFor contained discharge of the product a side discharge port can be provided which can be integrated with an isolator.

Online SamplingThe Online sampling valve is provided to take samples under vacuum, without stopping the agitator/process.

Material of Construction Stainless steel Hastelloy and other

exotic materials Glass Lined construction

upto 5m2

Control Panel and AutomationHydraulic power pack with electrically operated flame proof solenoid valves.Local control panel with electrical and hydraulic safety features. Control panel with PLC is available as an option.

Boltless Bellow & Blade

Bayonet Design

Sintered Filter Media

Interior of Main Vessel with CIP Washring

3 Blade Agitator

MAVAZWAG® AGITATED NUTSCHE FILTERS & FILTER DRYERS

68

SPECIAL DESIGN FOR STERILE PRODUCTS AND MOBILE UNIT FOR CONSTRAINED AREAS

Process Advantages

Processing of concentrated suspensions

Cake filtration

Cake washing and cake purification

Extraction of active agents from organic solids

Filtration plants with product and solids processing

Filter-dryer plants with solvent recovery unit

Filter systems for sterile applications with integrated CIP-system

Integrated plants with reaction, filtration and final drying stages

Pre-assembled, PLC-controlled systems in modular design

Environmentally safe, totally enclosed systems

Reliable, proven filter design and construction

Construction materials for a wide application range

Optimized filter media selection to meet specific product and process requirements

69

Features

High Pharma finish confirming to cGMP norm specially designed double mechanical seal with metal bellows

Tri clover connections instead of flanged nozzles CIP and SIP designs available

Size Working Max. cake Diameter Height Stroke volume volume D H S ltrs. ltrs. mm mm mm

0.15 60 30 450 2900 2000.25 140 50 600 3100 2000.5 400 150 800 3350 3000.6 500 180 900 3550 3000.8 700 320 1000 3700 4001 900 400 1200 3900 4001.6 1400 640 1500 4100 4002 1800 800 1600 4300 4002.5 2200 1000 1800 4350 4003 2700 1200 2000 4600 4003.6 3300 1440 2200 4950 4004 3600 1600 2400 5050 4005 5500 2000 2600 5050 5006 6600 3000 2800 5100 5008 9600 4000 3200 5100 50010 12000 5000 3600 5300 50012 14000 6000 4000 5300 50016 19000 8000 4500 5500 500

H

S

D

MAVAZWAG® AGITATED NUTSCHE FILTERS & FILTER DRYERS

70

The Funda®Centrifugal Disc Filter is used for the separation of solid particles from a liquid with the help of porous layers that allow the liquid to pass through but retain the solid matter. The Funda®Filter can be operated automatically and can be integrated with other process equipment such as pre-coat vessels, pumps, valves and instrumentation.

Material of ConstructionStainless Steel, Hastelloy and Special Alloys.

Shaft Sealing DesignDouble wet mechanical seal or dry mechanical seal to eliminate product contamination.

Key features and advantages: Completely enclosed vessel,

ensuring product quality, product consistency and operational safety

Rotating filter assembly discharges the cake in dry/slurry form

Self-cleaning system Suitable for both batch

and continuous processes Pre-coating, filtration,

heel filtration, cake washing, cake drying and discharge are all done in one closed system

FUNDA® CENTRIFUGAL DISC FILTERS

71

The Mavasphere®Spherical Dryer is a multi purpose dryer used in the drying of Active Pharmaceutical Ingredients (API’s) and Fine Chemicals in compliance with cGMP and FDA guidelines. The Mavasphere®provides excellent drying performance over a wide range of filling capacities with a good turn down ratio.


Shaft Sealing DesignsGas lubricated double mechanical seal installed outside of the product zone.

AgitatorHollow heated rotating 3-blade agitator with minimal clearance between agitator blade and vessel wall.

Bottom DischargeSpherical disc valve for quick opening and discharge of dried product with no dead volume.

Standard AccessoriesLump Breaker, Dust Filter and Sampling System.

Optional AccessoriesBayonet type quick closing design for body flange, Condenser and Vacuum Pump.

Key features and advantages: Minimal clearance

between the vessel wall and agitator for efficient and uniform drying

Entire vessel covered by jacket for better heat transfer

Wide range of filling capacities with a good turndown ratio

Minimal product hold-up for easy cleaning and validation

Eccentrically top mounted agitator for uniform mixing and gentle drying of product

Discharge at lowest point for complete product discharge

Compact system with lower footprint

MAVASPHERE®

SPHERICAL DRYERS

Model Working Vol. L1 B1 H1 H2 H3 фD Empty Heat Transfer Agitator Agitator Chopper Chopper

Weight Area Power Speed Power Speed litrs. mm mm mm mm mm mm kg m2 KW 1/min KW 1/min

TYP100 100 1000 1000 900 1800 900 700 1500 1.5 11 3.5-40 3 1000

TYP400 400 1300 1400 900 2050 1400 1050 3000 3.5 25 3.5-30 5.5 1000

TYP1000 1000 1800 1800 1400 2800 2100 1400 8000 6.4 45 2.5-18 7.5 1000

TYP2000 2000 2400 2200 1700 3500 2600 1700 12000 9.4 55 2.5-18 12 1000

TYP4000 4000 2900 2600 1700 4000 3200 2100 17000 16.5 75 2.5-15 15 1000

TECHNICAL DATA

MAVASPHERE® SPHERICAL DRYERS

72

The Mavapad®Vacuum Paddle Dryer is a versatile energy efficient system used for the drying of Active Pharmaceutical Ingredients (API’s) in compliance with cGMP and FDA guidelines. The Mavapad®can be designed for use in sterile/clean room areas by providing a stainless steel partition wall that separates the drive unit from the process area.

Our engineers can assist in sizing and optimizing the Mavapad®to meet your process requirements.


Shaft Sealing DesignDouble wet mechanical seal or dry mechanical seal to eliminate product contamination.

AgitatorHollow rotating agitator with improved paddle design for better heat transfer.

Bottom DischargeTwist Close Valve/Segmented Ball Valve for quick opening and discharge of dried product with no dead volume.

Standard AccessoriesDust Filter.

Optional AccessoriesLump breaker, Sampling system, Condenser, Receiver and Vacuum Pump.

Key features and advantages: Large heat transfer area

(vessel body and agitator) for faster drying

Flat ends instead of dished ends for lower heel volumes and better emptying characteristics

Full door opening for easy cleaning and validation

Lower operating and maintenance cost compared to other dryers

MAVAPAD®

VACUUM PADDLE DRYERS

Model Total Vol. Usable Vol. Diameter - A Shell Length - B Total Length - C Base Width - D Overall Height - E ltrs. ltrs. mm mm mm mm mm

RXPD 100RXPD 200RXPD 300RXPD 500RXPD 800RXPD 1000RXPD 1500RXPD 2000RXPD 2500RXPD 3000RXPD 3500RXPD 4000

1402103505108201130160021202640320038504300

105140250360570800112014801850255027003000

52565075085010501175130015001550167517501850

6506258009009501050120012001400145016001600

190022002700290034003600390043004500490052005300

7009001050120015001650180022002350260027502900

200021502500270035004300490055006000640068007400

TECHNICAL DATA

73

SECTION III

MIXING SYSTEMS

■ ECONOMIX® MIXING SYSTEMS 74

■ MAVADRIVE® MAGNETIC AGITATORS 77

74

GMM Pfaudler offers Economix® Mixing Systems for Stainless and Alloy Steel Reactors. Our team of highly trained engineers will design an optimal mixing solution for your specific mixing requirement. Using a fluid mixing design software to simulate the performance of your existing agitator system, we can recommend a superior agitator design that will optimize your mixing by reducing batch time and power consumption and improving product quality.

Under the brand name of Economix®, GMM Pfaudler supplies a wide range of mixing systems to the Pharmaceutical, Agrochemical, Specialty Chemicals, Biotech, Paints, Paper & Pulp industries. We design and manufacture mixing systems for various applications: Blending/Heat Transfer Suspension Emulsification High Viscosity Blending Gas Dispersion

Advantages: Reduction in Power Consumption without

compromising the mixing requirement Improvement in mixing performance like

Heat Transfer and Mass Transfer Transfer, Blending or Solid

Suspension, Blend time Small and Compact systems Easy Maintenance

The agitators offered by us are guaranteed for the stated mixing performance. If the specified performance is not achieved the agitator will be modified or replaced at our cost.

ECONOMIX®

MIXING SYSTEMS

75

High Efficiency Impeller An established industry

standard for axial flow impellers

Extremely efficient creates greater fluid motion with less energy

Ideal for blending, heat transfer and solids suspension

Transition Flow Turbine Excellent performer

in abrasive solids suspension, liquid-solid-gas and boiling applications

High-solidity blade design translates into higher gas rates and viscosity values over other high efficiency designs

Gas Dispersion Turbine Advanced design Highest gas dispersing

capability at nearly six times the D-6 (Rushton) turbine

Reduced unloading Relatively insensitive to

viscosity

Pitched Blade Turbine Axial flow design suitable

for wide changes in process viscosity

Good for blending and solids suspension where elevated shear is needed

Able to handle higher gas rates over high efficiency designs

Propeller Marine style energy

efficient design Ideal for small batches Handles higher viscosities

than hydrofoil designs

Straight Blade Turbine Close clearance design

for operation near the tank bottom

Excellent for low-liquid-level solids suspension applications

Designed for use in laminar regime (Reynolds number < 50) applications

Cowl Disc Customize levels of shear to

suit your process Proper fluid turnover

minimizes the need for auxiliary pumping impellers

Small particles possible: 2 microns achieved in processes such as micro-encapsulation

Traditional dispersion blades can also be used in high shear applications

Double Helical Ribbon Proven the best high viscosity,

laminar flow impeller Highly effective in heat

transfer Efficiently incorporates

surface liquids and solids For viscosities over 30,000

Mpa

Anchor Most economical

laminar flow impeller available

Horizontal flow well suited for low-liquid-level geometries

Solve heat transfer fouling problems with optional wall scrapers

Screw Ideal for shear

sensitive, uniform blending applications (polymers)

Excellent top-to-bottom turnover flow characteristics

Use in mildly pseudoplastic applications with power law indexes as low as 0.5

Advanced Impeller Technology

ECONOMIX® MIXING SYSTEMS

76

IMPELLER NAME AND DESCRIPTION APPLICATIONS

High Efficiency Impeller l Blending l Turbulent heat transfer l Solid suspension

Pitched Blade Turbine l Blending l Dispersion l Solid suspension

Straight Blade Turbine l Local liquid motion for blending dispersion l Keeping outlets clear from solids

Transition Flow Impeller l Blending, Np and Nq vary with tip angle wide-blade, l Transitional flow number of blades l Simultaneous gas dispersion and solid suspension (like mining)

Cowl Disc l Liquid - liquid dispersion l Solid - liquid dispersion l Local shear

Gas Dispersion Turbine l Gas dispersion l Intermediate and high gas flows

Helical Ribbon l Blending and heat transfer in viscous media

Anchor l Heat transfer in viscous media

Impeller Section Guide

77

The patented Mavag double acting impeller is designed to reduce wear & tear of the bearings. Other features include: No contamination, no

emission and no sealing problems

No maintenance required, trouble-free operation for longer periods of time

Multiple stage impellers are available for cell culture and microbial fermentation

Easy to clean and sterilize (CIP/SIP)

CleanabilityProcess wetted components are designed in a way to eliminate deposits during the process phase and that

for cleaning cycles besides flooding other CIP concepts can be used: Oscillating movement

of the agitator head by patented counter acting blades

Largest gap between containment shell and agitator head for best possible cleanability

Inclined surfaces and accessibility of all wetted areas

Dead zone free construction in combination with slots and holes

Adjustment of the operating parameters and of the cleaning cycles during selection of process parameters

MAVADRIVE® BOTTOM AND TOP ENTRY

MAGNETIC AGITATORS

PRINCIPAL SKETCH OF MDB WITH DOUBLE IMPELLER

CERAMIC�BEARINGS

O-RING�SEALS

MAGNETICCOUPLING

GAP

SPEED�CONTROL�SENSOR

FIXINGSCREW

IMPELLERHEAD

COUNTERACTING BLADE�

MAVADRIVE® BOTTOM AND TOP ENTRY MAGNETIC AGITATORS

78

NOTES

79

SECTION IV

ENGINEERED SYSTEMS

■ WIPED FILM EVAPORATORS 80■ SINGLE FLUID HEATING & COOLING SYSTEMS 85

80

Proven by IndustryThe evaporator technology and systems produced by GMM Pfaudler can be found in the wide range of industries worldwide including: Pharmaceuticals Chemicals

Polymers and Resins Foods Fats and Oils Waste Solvents Biodiesel Lube Oil Refining Herbal Products

Proven by ApplicationCompanies within these industry sectors apply the technology for a variety of purposes: Deodorization Distilling Concentration Reboiling Solvent Recovery Stripping

GMM Pfaudler produces the widest range of evaporator systems to ensure we can meet specific market and customer needs. These ranges are based on thin film evaporators and tubular systems. GMM Pfaudler can advise on the best evaporator system for a given application. For example, a stratavap thin film evaporator is often used in conjunction with tubular evaporators

to concentrate solutions to near dryness.

Commitment to Adding Value Design, manufacture

and installation of complete systems

Our highly experienced and creative project engineers will work closely with you to meet your specific process requirements and ensure effective systems performance. To enable the evaporators to perform their optimum capability, we can also help with the proper selection and installation of ancillary equipment and instrumentation. Test plant facility

available for trialsEvaporator pilot plants are available for trials on your materials and are available for prolonged test work on customerspremises. This means process requirements can be determined and evaporator systems tailored to suit. Process guarantees are based on test results.

Typical Applications Simple to operate and with proven high performance, the range of wiped film evaporators is suited to processing high-boiling point, viscous and/or heat-sensitive materials

with maximum efficiency. This technology involves separating volatile compounds by introducing a mechanically agitated thin film of feed material to a heated surface.Capable of concentrating solutions to greater than 95% total solids, the low running speeds and wiping action make the range of wiped film evaporators especially suited to liquors which show a tendency to foam. Features and Benefits Short retention

times eliminate product degradation

When processing a wide range of products heat fluxes are minimised eliminating the opportunities for spoiling the quality, taste or flavour of heat sensitive materials.

Vacuum operation improves unit

efficiency

WIPED FILM EVAPORATORS

A worldwide leader in the manufacture of process equipment,

Pfaudler has perfected the use of glassed-

steel technology for glass lined evaporators,

reactors, receivers, storage tanks and

associated equipment.

81

Reducing vapour pressure also reduces boiling points which increases temperature differences.

Floating wiper elements maintain thin film

Wipers create a turbulent fluid film on the evaporator wall giving the desired film thickness for effective evaporation of the process material.

Low maintenance, reduced downtime and optimal running costs

Evaporation rates are achieved at low rotor speeds, results in reducing vibration and wear on seals and elimination of bottom bearing. On larger machines, wipers can be replaced by lifting rotor without disturbing seal and drive assembly. On smaller machines, rotor top seals and the gearbox are easily removed in one assembly for inspection and/or cleaning.

Energy saving features

The use of low power motors is possible as the liquor process provides a lubrication effect for the wiper elements.

High Vacuum WFETypical applications – For applications where the boiling point of the more volatile components is greater than 482°F (250°C), a High Vacuum Wiped Film Evaporator (WFE) should be considered.

With very high boilers, it may be impossible to achieve separation in a conventional multi-effect evaporators operating under vacuum.

Technical DataOperating pressure – Using vacuums as low as 0.01 torr (0.013 mbar) can make separation possible and /or reduce the area required.Internal condenser – U-tube type condensers are inserted inside the High Vacuum WFE (short path). Condenser surface areas are so the size that it take care of condensation and sub-cooling.Entrainment separators – Specially designed full-length internal entrainment separators for high vacuum operations effectively remove entrained droplets. Expendable WFE sizes – The moduler concept can help in providing additional heat transfer area to the original jacketed section at your plant site to provide increased capacity, with minimum modification.Highly viscous materials – For highly viscous materials, the bottom cone can be heated and extruder blades can be fitted to mechanically aid the discharge of the bottom material. Spring mounted blades may be used for materials with viscosities above 2,000 cps. Maximum viscosity at operating temperature 20,000 cps.Capacity – From less

than 1kg/hr to more than 4500 kg/hr of feed material.

Materials of construction – Carbon steel, stainless steel 304/316, hastelloy, titanium, glass lined mild steel, monel and incoloy.Rotor speed – Depending on the size of WFE. e.g. 280 rpm for 1 sq.m. to 60 rpm for 21 sq.m.Low power motor – Low rotor speed significantly reduces motor power required e.g. the 103.4 sq.ft. WFE uses only a 5.5 kw motor.Jacket temperature/pressure – Maximum pressure 8.6 bar dependent on process requirement. Maximum temperature using thermal oil is 357°C.Range – Based on heated

surface area – 1.2 sq.ft. (0.11 sq.m.) to 231 sq.ft. (21.5 sq.m.)Wipers – Centrifugal wiper blades in PTFE are standard. Carbon and other materials are also used.

1 DRIVE MOTOR

2

4

3

FEED INLET

DISTRIBUTORPLATE

WIPERS

HEATEDJACKET

ENTERTAINMENT SEPARATOR

INTERNALCONDENSER

BOTTOMOUTLET

VACUUMOUTLET

DISTILLATEOUTLET

EXTRUDERBLADES

6

7

10

5

11

9

8

HIGH VACUUM WIPED FILM EVAPORATOR


82

Evap. Model Internal Jacket Surface No. Condenser Volume Volume NominalArea Area Litre Dia

Sq.m Sq.m A B C D E F G

0.1 1.2-6V - 3.7 0.34 2.65 220 135 505 230 240 880 150

0.4 4.2-12L - 7 0.65 7.5 375 236 890 380 860 2000 300

0.4 4.2-12V - 19 1.77 7.5 375 212 1000 380 860 2070 300

0.8 8.8-12L - 12 1.11 16.6 375 230 1300 800 860 2400 300

0.8 8.8-12V - 27 2.55 16.6 375 212 1425 1230 840 2500 300

1.2 13.4-12L - 16.7 1.55 16.6 375 230 1725 1230 1020 2975 300

1.2 13.4-12V - 35 3.25 25 375 212 1850 1230 1020 3100 300

2.3 25-36L - 075 3.5 98 1000 345 1425 810 720 2500 900

2.3 25-36V - 121 11.25 98 1000 325 2027 810 720 3100 900

4.75 51.2-36L - 75 7.0 200 1000 345 2275 1660 720 3340 900

4.75 51.2-36V - 172 16.0 200 1000 325 2885 1660 720 3930 900

7.2 77.3-36L - 113 10.5 300 1000 345 3125 2500 1300 4780 900

7.2 77.3-36V - 210 20 300 1000 325 3740 2500 1300 5370 900

9.5 103.4-36L - 150 14 400 1000 345 3975 3360 1645 5970 900

9.5 103.4-36V - 274 25.5 400 1000 325 4587 3360 1645 6560 900

16.2 175-60L - 265 24.6 840 1650 550 4225 3340 1600 6890 1500

16.2 175-60V - 450 41.8 840 1650 525 4825 3340 1600 7490 1500

21.5 231-60L - 350 32.5 1125 1650 580 5360 4470 2150 8090 1500NOTE: DIMENSIONS SUBJECT TO CHANGE. INDICATES HIGH VACUUM DESIGN

Dimensions (mm)

SpecificationsforAlloyUnits

PFAUDLERDRIVE

PFAUDLERDRIVE

JACKETHEATING

VAPORINLET

ORLIQUID

OUTLET

JACKETHEATING

VAPORINLET

ORLIQUID

OUTLET

FEED INLET

FEED INLET

JACKETHOT OIL

INLET

JACKETHOT OIL

INLET

JACKET CONDENSATE

OUTLETJACKET CONDENSATE

OUTLET

RESIDUEOUTLETRESIDUE

OUTLET

CONDENSER COOLANT

CONDENSER COOLANT

CONDENSER

DISTILLATEOUTLET

DISTILLATEOUTLET

VACUUMOUTLET

VACUUMOUTLET

W/INTERNALCONDENSER

WFE

HIGH VACUUM

(MICRO RANGE)OPERATION

A

G

E

B

CF D

WFE

1 TORR RANGE

OPERATION

E

A

G

B

CF D

W/INTERNALCONDENSER

83

Wiped Film Evaporator Design Styles

Features: Operating pressures

to 0.5 Torr No bottom bearings Standard size

removable internal condenser

Full shell length louvered entrainment separator

Low rotor speed due to direct contact wipers

Applications:General chemicals and pharmaceuticals, solvent recovery, waste streams, food and oil re-refining.

Operations:Stripping, concen-tration, dehydrating of moderately viscous and heat sensitive materials.


to 0.01 Torr No bottom bearings Large high vacuum

design internal condenser

Large vapor outlet nozzle

Full shell-length high vacuum chevron entrainment separator or open rotor

Low horsepower requirements

Low rotor speed due to direct contact wipers

Applications:High purity chemicals, vitamin E, resins, waxes, plasticizers, and high boilers.

Operations:Stripping, concentration, deodorization, separation and purification of moderately viscous and heat sensitive materials requiring high vacuum operations.

Standard Vacuum Co-Current Design

High Vacuum Co-Current Design


to 1.0 Torr No bottom bearings Full shell length

louvered entrainment separator

Top vapor outlet Low horsepower

requirements Low rotor speed due

to direct contact wipers

Cone bottom head with optional heat transfer jacket

Applications: General chemicals and

pharmaceuticals, solvent recovery, waste streams, food

Used as reboiler for fractionation columns

Operations: Distillation,

concentration, dehydrating of delicate materials requiring complete removal of volatile phase to less than 1% remaining in product residues

Steam or nitrogen stripping capability

High Viscosity Counter-Current Design


to 1.0 Torr No bottom bearings Spring-mounted

wipers and entrainment separator

Top vapor outlet Heavy duty drive

and motor assembly Cone bottom head

for easy product discharge

Auger assembly to assist bottoms discharge

Low rotor speed due to direct contact

Applications:High viscosity or hard-to-handle polymers, general chemical, coating, waste streams, and food.

Operations: Concentrations

of moderate to very highly viscous products

Steam or nitrogen stripping capability

Top Vapor Outlet Counter-Current Design


84

Typical Configuration:All designs within the range are available as either single or multiple effect. GMM Pfaudler engineers will calculate the optimum number of effects and configurations based on the physical practicalities, capital and running costs.

Features and Benefits: Tailored to suit particular

applicationsThe experience of GMM Pfaudler staff combined with an extensive

library of evaporator designs, means evaporators can be quickly matched to particular requirements.

Designing the most cost-effective solution

At the design stage, factors such as capital cost, equipment’s life and running costs are balanced to ensure an optimum solution.

Energy efficientThe inclusion of a mechanical vapour recompressor enables

vapour from the process to be reused in heating, replacing for steam economy.

Comprehensive serviceA total turnkey solution is available encompassing design, engineering, procurement, fabrication, site construction, plant commissioning, operator training and project management.

85

Single Fluid Heating & Cooling Systems are designed to be affordable, self contained, compact units which incorporate all the essential functions of the heating and cooling process.

Single fluid heating and cooling systems operate with only one heat transfer fluid circulating throughout the reactor jacket. The temperature of the fluid, and therefore the reactor temperature,

are adjusted for heating or cooling by external means. Often in the case of heating, this would be steam or via electric elements. In the case of cooling, this could be cooling water, glycol, and for our advance heater/chiller units, mechanical refrigeration.

GMM Pfaudler’s flexibility combines of these primary services to be combined together in one unit.

The modular design of the systems means that GMM Pfaudler engineers can propose an individually designed solution to meet the requirements of even the most complicated processes in your project. This also minimises installation time and cost and provide factory tested systems.

Accurate temperature control to +/-1°C without risk to your reactor

Rapid heating and chilling profiles can be designed, reducing batch times

Repeatability and

accurate recordable measurement for meeting FDA requirements

Programmable heating and cooling ramps for accurate unsupervised

operations No switching between

jacket service fluids, preventing cross contamination, corrosion or thermal shocks to the vessel

Smooth, continuous temperature control, with no gaps because there is no fluid changeovers

No interruption of process and no hot spots, resulting in higher product

yields and quality. Off batches are minimized, if not eliminated

Savings on expensive raw materials can be made because the yield is maximized without adding excess reactions

Suitable for the very cold operating temperatures required by today’s new chemical formulae and reactions

Fully automatic capability, hence less manpower required

Advantages of Single Fluid Heating & Cooling Systems in Reactor Operations are:

SINGLE FLUID HEATING & COOLING

SYSTEMS

SINGLE FLUID HEATING & COOLING SYSTEMS

86

Single Fluid Systems DesignCooling CurvesObviously, there is no universal system because of the variables involved in the heat transfer function. At GMM Pfaudler we look first at your specific reactor systems, new or existing, to determine its heat transfer requirements. Then we select the arrangement and design the modular heating/cooling package that will function more efficiently and cost effectively for you.

Method: On ‘Y’ axis, select temperature of batch you wish to cool from. Move horizontally across, to the line which starts on the ‘Y’ axis from that value you wish to cool to. Then move vertically down to the ‘X’ axis, read the time to cool the batch with that particular heater/chiller unit.

Method: On ‘Y” axis, select temperature you wish to reach. Move horizontally across, until you intersect a heating line. Then move vertically down to the ‘X’ axis, read the time to heat the batch with that particular heater/chiller unit.

Heating CurvesIn an extensive research program, GMM Pfaudler has translated and updated many of its existing computer programs-originally developed to understand complicated reactor, mixing, and agitation processes incorporating them into an overall heat transfer design program.

These computer programs and the extensive knowledge built-up over many years is now available to you, saving time and engineering costs on your project.

Areas covered in our assessment of your heat transfer requirements include: Size of vessel and heat transfer area Heat transfer area type of reactor jacket

conventional or half-pipe Size and number of agitation nozzles Pressure drop and fluid flow through jackets Types of heat-transfer liquids and properties Mixer speeds, agitation design considerations and

process requirements Heating and cooling curves time/temperature

With over 50 years experience of producing Glass Lined equipments for the chemical and fine chemical industries, we can supply heating and cooling equipment matched perfectly to the reactor systems. This is a unique service provided by GMM Pfaudler.

Cooling TimesReactor AE 1000Heater/Chiller

TEM

PER

ATU

RE(

ºC)

TIME (HOURS )


TEM

PER

ATU

RE(

ºC)

TIME (HOURS )


TEM

PER

ATU

RE(

ºC)

TIME (HOURS )

Heating TimesFrom 20CAE 1000Heater/Chiller

TEM

PER

ATU

RE(

ºC)

TIME (HOURS )

87

Heat transfer calculations are carried out via advanced computer programs that take into considerations all the variables affecting the OHTC in a reactor.

To achieve best overall heat transfer performance, the optimum heat transfer fluid is chosen from those currently available to best meet the required operating ranges of the reactors.

GMM Pfaudler also has an ongoing programme to evaluate new fluids coming on the market to provide our clients with the best temperature control system for their reactors.

Dowtherm is a trademark of Dow Chemical USA. Santotherm is a trademark of Monsanto Company. Syltherm is a trademark of Dow Corning Corporation. Optimising heat transfer Corporation.

Optimising Heat Transfer

Control Method A state-of-the-art PLC control system allows for very accurate temperature control, temperature profiles and programmable ramping of process parameters. The controls can be individually tailored to accommodate your full process control system including all safety systems. Full PLC, FDS and IQ documentation can be provided for your software validation.

A data logging historian can be incorporated in the software package to allow for full historical analysis of actual temperature profiles, reactor system information, and other relative data comply with FDA requirements and quality assured manufacturing systems.

TYPICAL REACTOR TEMPERATURE PROFILE WITHOUT PLC CONTROL

TYPICAL RAMPED TEMPERATURE PROFILE WITHOUT PLC CONTROL

TEM

PER

ATU

RE(

ºC)

TEM

PER

ATU

RE(

ºC)

TIME(HOURS )

TIME(HOURS )

140.0

120.0

100.0

80.0

60.0

40.0

20.0

0.0

-20.0

-40.0

0 2 4 6 8 10 12 14 16

140.0

120.0

100.0

80.0

60.0

40.0

20.0

0.0

-20.0

-40.0

0 2 4 6 8 10 12 14 16

SINGLE FLUID HEATING & COOLING SYSTEMS

BE 4000 litre glassed reactor with CBT Tolueneat 20º C inreactor

OVE

RAL

L H

EAT

TR

ANSF

ER C

OEF

FICI

ENT

‘U’

WA

TTS/

M2

ºC

JACKET FLUID TEMPER ATURE º C

Downtherm J and San tot herm LT

50% Eth ylene Gly col

Syltherm XL T

Dowtherm Q

San tot herm D-12

San tot herm 59

88

Components Of GMM Pfaudler Temperature Control Units

Heat Exchangers – We utilize space saving welded plate heat exchangers as well as the more traditional shell and tube exchangers. Pumps – We utilize single mechanical seal pumps. We can utilize the latest magnetic driven pump technology, if required. All pumps are sized for the required jacket flow rates and agitation nozzles.

PLC Control Systems – We build in-house advanced PLC and software based control systems to accurately mix and control thermal fluid flow and temperature.

Electric Heaters - We design and manufacture a range of in-line electric thermal fluid heaters that are designed to have very low heat fluxes and hence protect the thermal fluid life.

Control Valves – We use bellow sealed control valves to prevent leakage of thermal fluids, and give very high turn down rates, thus giving highly accurate temperature control possibilities.

Explosion Proof – All the components are suitable for operation in hazardous area. Our system can be placed in area with zone IIA/IIB classification.

The Single Source Reality is GMM Pfaudler

For those customers seeking a single supply source to their new process plant, GMM Pfaudler is a one-stop-shop for the complete reactor package.

GMM Pfaudler can supply complete skid mounted reactor systems, including condensers, distillation columns, pipework, support structures and related process equipment. Types of Temperature Control Units we offer:HC-Temperature Control UnitsThe HC (Heating-Cooling) range of temperature control loops uses existing on-site services such as steam, ethylene glycol, cooling water, liquid nitrogen as a heating or cooling source. Separate heat exchangers are used for cooling and heating duty along with control valves and circulation pump.

HR-Combined Heater-Chiller UnitThe HR (Heating-Refrigeration) range of temperature loops are based on combining specialist refrigeration packages appropriate heating equipment. These units can be designed to operate between -70°C and +300°C.

89

NOTES

90

NOTES

infrastructure - plant equipment

Documents