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Air Storage Tank

Function

Description

Pressure Stabilization

Dampens pressure fluctuations from the compressor, ensuring a steady pressure supply to the system.

Energy Storage

Stores compressed air to meet peak demand, reducing the load/unload frequency of the compressor.

Condensate Separation

Acts as a "secondary cooler," allowing air to cool and condensate (water, oil) to settle out, protecting downstream dryers and filters.

Pulsation Dampening

Reduces pulsations from reciprocating compressors, protecting piping and equipment from vibration damage.

Emergency Reserve

Provides a temporary reserve of compressed air in case of power failure or compressor shutdown for emergency operations.

4. Main Types & Classification

4.1 By Installation Position

Type	Position	Application
Wet Tank	Installed before the air dryer.	Stores untreated, saturated compressed air for primary separation of bulk water.
Dry Tank	Installed after the air dryer.	Stores clean, dry air for critical applications.

4.2 By Orientation

Type	Characteristics
Vertical Tank	Most common design, occupies minimal floor space, easy to install.
Horizontal Tank	Lower center of gravity, easier to transport, suitable for large volumes or limited headroom.

4.3 By Pressure Rating

Type	Pressure Range
Low Pressure	< 1.6 MPa
Medium Pressure	1.6 - 10 MPa
High Pressure	> 10 MPa (e.g., CNG storage)

5. Technical Parameters

Air receiver tanks are designed according to international pressure vessel codes. Standard parameters are as follows:

Parameter	Standard Range / Specification	Notes
Design Standard	GB/T 150, ASME BPVC Sec. VIII, PED, etc.	Subject to customer requirements.
Volume	0.1 m³ - 100 m³ (Standard)	Larger volumes (e.g., 200 m³) can be custom-designed.
Design Pressure	0.8 MPa / 1.0 MPa / 1.3 MPa / 1.6 MPa / 2.5 MPa / 3.3 MPa	Custom pressures available up to 35 MPa.
Design Temperature	-20°C to +150°C	Higher/Lower temperatures available upon request.
Working Medium	Compressed Air, Nitrogen, Oxygen, Inert Gases	Medium determines material compatibility.
Main Material	Q345R (16MnR), Q235-B (Carbon Steel)	Carbon steel is standard.
Corrosion Allowance	1.5 mm - 3 mm	Based on service life and medium corrosivity.
Connection Type	Flanged (HG/T, ANSI, DIN) or Threaded (Rp, NPT)	Based on pipe size and specification.
Surface Treatment	Anti-corrosion primer and topcoat (e.g., Epoxy). Internal inert gas preservation available.

Typical Specifications (Example Data)

Medium	Volume (m³)	Design Pressure (MPa)	Material	Outer Dim. D×H (mm)	Weight (kg)
Air	1	1.0	CS,SS	Φ800×2300	460
Air	2	1.0	CS,SS	Φ1000×2800	720
Air	5	1.0	CS,SS	φ1400×3600	1520
Air	10	1.0	CS,SS	φ1800×4400	2750

6. Features & Advantages

Safety & Compliance: Designed and manufactured strictly according to ASME, GB, or PED codes. Each unit is inspected by third-party agencies and supplied with a complete quality dossier.

Robust Construction: Made from high-quality carbon steel plates (Q345R) with automatic welding to ensure reliable seam quality.

Durable Corrosion Protection: Internal surface is treated for preservation; external surface is sandblasted to Sa2.5 grade and coated with durable epoxy paint.

Standard Fittings: Equipped with a nameplate, manual drain valve (or optional auto drain), safety valve connection, pressure gauge, and manhole for larger sizes.

Easy Maintenance: Simple design with no moving parts, requiring minimal maintenance. Easily accessible drain port.

7. Application Areas

Industry	Application
Manufacturing	General plant air for pneumatic tools, controls, and actuators.
Petrochemical	Instrument air systems, process gas buffer tanks.
Power Generation	Compressed air for soot-blowing, controls, and maintenance.
Pharmaceuticals/Food	Sterile compressed air storage, requiring stainless steel or sanitary design.
CNG/LNG Stations	High-pressure gas storage for vehicle fueling.

8. Selection Guide

To select the correct air receiver tank, the following factors should be considered:

Pressure: The tank's design pressure must be equal to or greater than the maximum operating pressure of the compressor system. A 10-20% safety margin is recommended.

Volume: A common rule of thumb is 10-20% of the compressor's output (e.g., for a 10 m³/min compressor, select a 1-2 m³ tank). More precise sizing depends on demand fluctuation and compressor type.

Orientation: Choose vertical (standard) for smaller footprints or horizontal (for large volumes/low headroom).

Material: Carbon steel is standard. For corrosive gases or high-purity applications (pharma/food), stainless steel (304/316L) is required.

Regulations: Verify local code requirements (e.g., ASME U-stamp for USA, PED CE mark for EU). Simple pressure vessels (Volume ≤1m³, Pressure ≤1.0MPa) may have different inspection rules.

">1. Product IntroductionAn air receiver tank, also known as a compressed air stor···

Extraction Column

Type

Working Principle

Structure

Application

Spray Column

Simplest form; one phase is sprayed through nozzles into the other.

No internals besides inlet distributors.

Limited to 1-2 theoretical stages; used for washing, neutralization, or with solids present.

Packed Extraction Column

Uses random or structured packing to promote droplet formation and reduce axial mixing.

Packing (Raschig rings, Pall rings, Intalox saddles) supported on grids.

Low height equivalent to a theoretical stage (HETS), good for corrosive systems, up to 3-5 stages.

Sieve Tray Column

Perforated plates with downcomers create repeated dispersion and coalescence stages.

Multiple sieve trays with downcomers; can be pulsed to enhance performance.

Higher efficiency, good for systems with high interfacial tension, predictable scale-up.

Rotating Disc Contactor (RDC)

Rotating discs on a central shaft create shear to disperse droplets, with stator rings dividing the column into compartments.

Rotor discs and stator rings; speed is adjustable.

High throughput, wide range of applications, moderate efficiency, handles dirty liquids well.

Kühni Column

Compartmentalized column with radial turbine agitators in each stage, separated by perforated stator plates.

Multi-stage turbine agitators; each stage can be optimized.

High efficiency (up to 30+ stages), excellent for difficult separations.

Pulsed Column

A reciprocating motion (air or mechanical pulsing) is applied to the liquid contents to enhance dispersion.

Sieve plates without downcomers; pulse generator.

High efficiency, no moving parts in column, ideal for radioactive or corrosive service.

3.2 By Column Orientation

Type	Characteristics
Vertical Column	Most common, standard for industrial applications.
Horizontal / Centrifugal Extractor	Uses centrifugal force for phase separation; short contact time, small footprint.

4. Technical Specifications

Extraction columns are custom-designed based on specific process data. The following are general parameter ranges:

Parameter	Typical Range / Specification	Notes
Design Standard	ASME Section VIII, PED, GB/T 150, TEMA	For pressure-rated columns.
Column Diameter	30 mm (lab) to 4.5 m (industrial)	Selected based on required throughput.
Column Height (Active)	3 m to 30 m	Determined by required theoretical stages.
Number of Theoretical Stages	2 to 30+	RDC columns typically 3-8; Kühni up to 30+.
Operating Turndown Ratio	2:1 to 3:1	Acceptable flow variation range.
Phase Flow Ratio	Up to 70:1	Heavy to light phase ratio.
Minimum Density Difference	> 50 kg/m³	Essential for gravity separation; special designs handle lower differences.
Continuous Phase Viscosity	< 500 mPa·s	Higher viscosity reduces efficiency.
Interfacial Tension	Can handle 1-2 mN/m (low tension) with optimized internals.
Materials of Construction	304/316L SS, Carbon Steel, Glass-lined, Hastelloy, Titanium, FRP	Selected based on corrosivity and purity.
Impeller Speed (RDC)	Typically 10 - 100 rpm	Low speed for reliable operation.

5. Structural Components

A typical agitated extraction column (e.g., RDC) consists of:

Component	Description
Column Shell	The vertical cylindrical pressure vessel.
Rotor with Discs	A central rotating shaft fitted with flat discs to impart shear.
Stator Rings	Annular baffles fixed to the column wall, dividing the column into compartments.
Liquid Distributors	Nozzles and distributors at inlets to introduce phases evenly.
Phase Separators / Settlers	Enlarged diameters at top and bottom for phase disengagement.
Phase Interfaces	Weirs, downcomers, or coalescers to control interface level.
Drive System	Motor, gearbox, and seal (mechanical or packing) at column top.
Internals (for other types)	Packing supports, packing hold-down plates, liquid redistributors (for packed columns).

6. Features & Advantages

High Efficiency: Agitated columns (Kühni, RDC) can achieve a large number of theoretical stages in a single vessel, making them suitable for difficult separations.

High Throughput: Handles large volumetric flows continuously, ideal for industrial production.

Compact Footprint: Compared to mixer-settler cascades, extraction columns are much taller but have a very small footprint.

Handles Difficult Systems: Suitable for systems with low interfacial tension, low density difference, or tendency to emulsify, especially pulsed or agitated columns.

Clean Operation: Sealed system, no moving parts in the column (for packed/pulsed), reducing maintenance and emissions.

Proven Scale-Up: Based on pilot testing and established correlations, scale-up to industrial sizes is reliable.

Versatile Internals: Different packing or tray types can be selected to optimize performance for specific physical properties.

7. Application Areas

Industry	Typical Applications
Petrochemical	Aromatic extraction (BTX), lube oil refining, diesel desulfurization.
Pharmaceutical	Antibiotic recovery (e.g., penicillin, erythromycin), natural product extraction (taxol, artemisinin).
Hydrometallurgy	Copper, cobalt, nickel, and rare earth element recovery from leach solutions.
Fine Chemicals	Organic acid recovery (citric, lactic), solvent recovery (DMF, DMAC), fragrance extraction.
Environmental	Phenol removal from wastewater, acid recovery, dye wastewater treatment.
Food Industry	Edible oil refining, caffeine removal (decaffeination).

8. Selection & Design Guide

To select the correct extraction column, the following factors must be considered:

Liquid-Liquid Equilibrium: Analyze the ternary diagram, distribution coefficient, and selectivity. Determine the required number of theoretical stages.

Physical Properties: Measure density difference, interfacial tension, viscosity, and phase inversion characteristics.

Throughput: Determine the required flow rates of feed and solvent to size the column diameter.

Residence Time: For slow reactions or mass transfer, ensure sufficient contact time.

System Chemistry: Identify corrosivity, tendency to foul or emulsify, and any solids content.

Pilot Testing: For critical applications, conduct pilot column tests to validate design parameters and obtain accurate HETS and flood point data.

Material Selection: Choose appropriate materials of construction based on fluid corrosivity and product purity requirements.

">1. Product IntroductionAn extraction column, also known as a liquid-liquid extra···

Mixing Tank

Type

Characteristics

Application

Single-Shell Tank

Simple construction; consists only of the inner vessel and agitator.

Ambient temperature mixing, general purpose blending, temporary storage .

Jacketed Tank

Vessel fitted with an external jacket (dimple plate, half-pipe coil, or conventional jacket) for heating or cooling.

Processes requiring temperature control (heating, cooling, exothermic reactions) .

Insulated / Double-Wall Tank

Inner vessel surrounded by insulation and an outer protective shell.

Maintaining product temperature, energy conservation, outdoor installations .

3.2 By Orientation

Type	Characteristics
Vertical Tank	Most common; agitator mounted on top; minimizes floor space.
Horizontal Tank	Agitator mounted on side or top; used for large volumes or when headroom is limited.

3.3 By Top Head Design

Type	Characteristics	Application
Open-Top Tank	Removable cover or no cover; easy access.	Batch processes, frequent cleaning, atmospheric mixing .
Closed / Dish-End Tank	Fully enclosed with dished heads; pressure-rated.	Pressure/vacuum operation, sterile processes, volatile materials .

4. Agitator / Impeller Types

The impeller is the heart of the mixing system. Selection depends on fluid viscosity and process objective:

Impeller Type	Flow Pattern	Viscosity Range	Typical Applications
Turbine (Rushton, Pitched Blade)	Radial or axial flow	Low to medium	Gas dispersion, liquid-liquid mixing, solids suspension .
Propeller (Marine-type)	Axial flow	Low	Liquid blending, solids suspension, heat transfer .
Paddle	Radial/tangential flow	Low to medium	Simple blending, solids dissolution .
Anchor	Close-clearance, tangential	Medium to high	Heat transfer, scraping tank walls, viscous products .
Helical Ribbon	Axial/radial	High to very high	High-viscosity mixing, pastes, doughs .
High-Shear / Rotor-Stator	Intense shear	Low to medium	Emulsification, dispersion, particle size reduction .

5. Technical Specifications

Mixing tanks are custom-designed based on process requirements. The following are typical parameters:

Parameter	Typical Range / Specification	Notes
Design Standard	ASME Section VIII, PED, GB 150, GMP, cGMP	Pressure vessel and sanitary standards apply.
Nominal Volume	50 L to 30,000 L (Standard)	Larger volumes available for industrial applications.
Tank Geometry	Vertical or Horizontal	With dished, cone, or flat bottom.
Design Pressure	Full Vacuum (FV) to 1.0 MPa	Higher pressures available.
Design Temperature	-20°C to 200°C	Can be extended for special applications.
Materials of Construction	Stainless Steel: 304, 316L (Preferred for contact parts)	316L standard for pharmaceutical/food.
Surface Finish (Internal)	Ra ≤ 0.4 μm (16 μin) (Hygienic)	Mechanical or electro-polish; Ra 0.8-1.6μm for industrial.
Agitator Speed	0 - 1500 rpm (variable frequency drive optional)	Depends on application and viscosity.
Agitator Power	0.37 kW to 45 kW	Based on volume and viscosity.
Heating/Cooling Media	Steam, Hot Water, Thermal Oil, Glycol, Chilled Water	Depends on jacket design.
Gaskets / Seals	EPDM, Silicone, FKM (Viton), PTFE	Selected based on chemical compatibility.
Control System	Manual or PLC/DSC Automatic Control	For temperature, speed, and level control.

Typical Dimensions by Volume

Nominal Volume (L)	Diameter (mm)	Height (mm)	Agitator Power (kW)
100	500	~2750	0.37-0.55
500	800	~3350	0.75-1.5
1000	1000	~3150-4000	2.2-3.0
2000	1300-1340	~3410	3.0-4.0
5000	1700-1810	~4300	5.5-7.5
10000	2200-2300	~5050	7.5-15

6. Structural Components

A typical mixing tank consists of the following core components:

Component	Description
Tank Vessel	Cylindrical body with dished, cone, or flat bottom; fabricated from stainless steel plates .
Top Head / Cover	Dished head (closed) or removable cover (open); may include manway, charging ports, sight glasses .
Agitator Assembly	Motor, gearbox, shaft, and impeller(s); top-entry or side-entry configuration .
Shaft Seal	Mechanical seal, magnetic drive, or stuffing box to prevent leakage .
Baffles	Vertical strips attached to tank wall to prevent vortexing and improve mixing efficiency .
Heating/Cooling System	Jacket (conventional, dimple plate, half-pipe) or internal coil .
Nozzles / Connections	Inlet, outlet, vent, CIP, instrument ports (temperature, pressure, level) .
Manway / Access Port	For internal cleaning and inspection .
Legs / Supports	Adjustable feet or stainless steel legs for stable installation .
Instrumentation	Temperature sensor, pressure gauge, level indicator, RTD probe .

7. Features & Advantages

High Cleanability (Sanitary Models) : Hygienic design with fully drainable construction; internal surfaces mirror-polished (Ra ≤ 0.4 μm); all welds ground and polished; no dead legs or crevices; complies with GMP, FDA, and ASME BPE standards .

Superior Corrosion Resistance: Contact parts constructed from 316L stainless steel; resistant to a wide range of chemicals, acids, and cleaning agents .

Precise Temperature Control: Available with jackets for heating/cooling; insulation for energy efficiency and operator protection .

Flexible Agitation: Wide range of impeller types and sizes; variable speed drives for process optimization .

Automation Ready: Can be integrated with PLC/DCS systems for automated control of mixing, temperature, CIP, and product transfer .

Customizable Design: Nozzle locations, agitator configuration, and polishing levels tailored to specific process requirements .

Robust Construction: Designed for long service life in demanding industrial environments .

8. Application Areas

Industry	Typical Applications
Pharmaceutical / Biotech	Mixing of APIs, excipients, buffers, and intermediate products; sterile processing .
Food & Beverage	Blending of syrups, juices, sauces, dairy products, and flavorings; heat treatment .
Dairy Industry	Milk storage, fermentation (yogurt), cheese processing, cream mixing .
Cosmetics & Personal Care	Production of lotions, creams, shampoos, and liquid soaps .
Chemical Processing	Dissolving solids, blending solvents, emulsion polymerization, chemical reactions .
Water Treatment	Coagulation, flocculation, pH adjustment, chemical dosing .
Paints & Coatings	Pigment dispersion, resin blending, final product mixing .

9. Selection Guide

To select the correct mixing tank, the following factors must be considered:

Process Requirements: Define the mixing objective (dissolving, blending, suspending, reacting, heating/cooling) .

Batch Size / Throughput: Calculate required working volume based on batch size and cycle time; consider available floor space and headroom .

Fluid Properties:

Viscosity: Determines impeller type and power requirements .

Corrosivity: Determines material grade (316L standard) .

Solids Content: Affects impeller design and outlet valve selection .

Temperature Sensitivity: Determines need for jacket/insulation .

Operating Conditions:

Temperature: Specify operating range; determine heating/cooling requirements .

Pressure: Atmospheric or pressure/vacuum operation .

Cleaning Requirements: Confirm if CIP (Clean-in-Place) capability is required; specifies nozzle design and surface finish .

Regulatory Compliance: For pharmaceutical/food applications, ensure design complies with cGMP, FDA, and ASME BPE standards .

Automation Level: Determine required control complexity (manual, semi-automatic, fully automated with PLC/DCS) .

">1. Product IntroductionA mixing tank, also known as an agitated vessel, blending···

Fixed Tubesheet Heat Exchanger

Component

Description

Shell

The cylindrical pressure vessel containing the tube bundle; welded directly to the tube sheets at both ends .

Tube Sheets (Tubeplates)

Perforated plates at both ends of the shell into which tubes are inserted and secured by expansion (rolling), welding, or a combination of both . Tube sheets are welded to the shell, making the bundle non-removable .

Tube Bundle

An assembly of straight tubes (plain or low-finned) providing the heat transfer surface area . Tubes are fixed at both ends to the tube sheets.

Channel (Front Head / Stationary Head)

Removable cover (bonnet) or channel with flanged connections for tube-side fluid inlet and outlet; houses pass partitions for multi-pass configurations .

Channel Cover / Bonnet

The removable closure for the channel end, allowing access to the tube sheet for inspection and repair.

Baffles / Support Plates

Plates with holes for tubes, installed on the shell side to direct shell-side flow perpendicular to tubes, increase turbulence, and support tubes against vibration .

Expansion Joint (Optional)

A bellows-like element incorporated into the shell to absorb differential thermal expansion between tubes and shell when temperature differences exceed design limits .

Nozzles (Connections)

Flanged or threaded connections for fluid inlet and outlet on both shell and channel sides.

Tie Rods and Spacers

Used to secure baffles and support plates in position.

4. Technical Specifications

Fixed tube sheet heat exchangers are designed according to international standards and custom-sized for specific duties. The following parameters are in accordance with GB/T 28712.2-2023 and typical industry practice :

Parameter	Typical Range / Specification	Notes
Design Standard	GB/T 151, GB/T 28712.2-2023, ASME BPVC Sec. VIII, TEMA, PED	2023 version is current in China .
Materials of Construction	Carbon Steel, Low-Alloy Steel, Stainless Steel (304/316L), Non-ferrous Metals (Copper alloys, Titanium, etc.)	Selected based on fluid corrosivity and temperature.
Shell Diameter (mm)	159, 219, 273, 325, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000 (and larger)	Standard diameters per GB/T 28712.2; other sizes custom .
Design Pressure (MPa)	0.6, 1.0, 1.6, 2.5, 4.0, 6.4 MPa	Higher pressures possible with special design .
Design Temperature (°C)	-196°C to +550°C (depending on material)	Limited by material properties and expansion joint capability.
Tube Length (m)	1.5, 2.0, 3.0, 4.0, 6.0, 9.0 m	Standard lengths per GB/T 28712.2 .
Tube Diameter (mm)	Φ19, Φ20, Φ25, Φ30, Φ32, Φ38 mm	Plain or low-finned tubes available .
Tube Passes	1, 2, 4, 6 passes	Even-numbered passes (2,4,6) most common; single pass allows true countercurrent flow .
Tube Pitch / Arrangement	Triangular (30°) or Square (45°) / Rotated Square	Triangular for higher heat transfer; square for easier shell-side cleaning.
Baffle Type	Segmental (single/double), Disk-and-Donut, etc.	Segmental (25-45% cut) most common .
Heat Transfer Area (m²)	1 to 5000+ m² (custom)	Calculated based on duty requirements.

5. Thermal Expansion and Stress Compensation

A defining characteristic of fixed tube sheet exchangers is the rigid connection between tubes and shell via the welded tube sheets. This creates a critical design consideration: thermal stress .

5.1 Thermal Stress (Differential Expansion Stress)

When the tube-side and shell-side fluids are at different temperatures, the tubes and shell expand (or contract) by different amounts. Because they are rigidly connected, this differential expansion is constrained, generating significant compressive or tensile stresses (thermal stress) in both the tubes and the shell . High thermal stress can lead to:

Leakage at tube-to-tubesheet joints.

Tube buckling or pulling out from tube sheets.

Failure of the shell or tubes.

5.2 Expansion Joint (Compensation Device)

To mitigate thermal stress, an expansion joint (bellows) is often installed in the shell .

Function: It provides flexibility, absorbing the differential expansion by deforming elastically, thus reducing thermal stress.

Limitations:

Typically limited to temperature differences < 60-70°C .

Shell-side pressure limited (generally < 0.6 MPa with standard joints) because increasing joint wall thickness for higher pressure reduces flexibility, negating its purpose .

For higher pressures or temperatures, other exchanger types (e.g., floating head, U-tube) should be considered .

6. Tube Pass Arrangements

Fixed tube sheet exchangers can be configured with one or multiple tube passes :

Pass Type	Configuration	Characteristics
Single-Pass (1-Pass)	Fluid enters one end, flows straight through all tubes, and exits the other end.	True countercurrent flow possible if shell-side flows opposite direction; maximum thermal efficiency; simple construction .
Multi-Pass (2, 4, 6 Passes)	Pass partitions in channel heads divide tubes into groups; fluid flows back and forth.	Increases tube-side velocity (improving heat transfer) but at cost of higher pressure drop; reduces or eliminates true countercurrent flow, lowering LMTD correction factor . Even-numbered passes (2,4,6) preferred for manufacturing convenience .

7. Features & Advantages

7.1 Advantages

Simple Construction: Fewest components and simplest assembly among shell-and-tube types .

Lowest Cost: Most economical shell-and-tube design due to simplicity and reduced material (thinnest tube sheets possible) .

Maximum Number of Tubes: For a given shell diameter, fixed tube sheet design accommodates the most tubes, maximizing heat transfer surface area .

Positive Seal: Welded tube sheet-shell joints eliminate shell-side gasketed joints, minimizing leakage risk (except at channel gaskets).

Multi-Pass Flexibility: Can be designed for any number of tube passes .

7.2 Disadvantages & Limitations

Shell-Side Cleaning Impossible Mechanically: Tube bundle cannot be removed, so shell-side fouling cannot be cleaned by mechanical means (e.g., rodding, high-pressure water lancing). Chemical cleaning only .

Shell-Side Fluid Must Be Clean: Service limited to fluids that are non-fouling, non-corrosive to shell materials .

Thermal Stress Risk: Susceptible to high thermal stresses if temperature difference is significant; requires expansion joint, which limits pressure/temperature range .

Tube Replacement Difficult: Individual tubes can be replaced (plugged) but with difficulty; bundle replacement requires cutting shell.

8. Application Areas

Due to its limitations, the fixed tube sheet exchanger is best suited for services where shell-side fluid is clean, non-fouling, and non-corrosive, and temperature differences are moderate.

Industry	Typical Applications
Petrochemical / Refining	Clean hydrocarbon streams, lube oil cooling, compressor intercoolers/aftercoolers, overhead condensers with clean media .
Chemical Processing	Heating or cooling of solvents, acids (with appropriate materials), aqueous solutions .
Power Generation	Feedwater heaters, turbine lube oil coolers, generator hydrogen coolers (clean shell-side).
HVAC / Refrigeration	Chillers, condensers, evaporators with clean refrigerants or water.
Food & Beverage	Pasteurization (hot water/steam heating of product), process water heating/cooling.
Pharmaceutical	WFI (Water for Injection) cooling/heating, clean utility systems.

9. Selection & Design Guide

To select and design the correct fixed tube sheet heat exchanger, the following factors must be considered:

Shell-Side Cleanliness: Is shell-side fluid clean, non-fouling, and non-corrosive? If fouling is expected, another exchanger type (e.g., floating head) is required .

Temperature Difference: Determine maximum temperature difference between shell and tube fluids. If > 60-70°C, an expansion joint may be needed, but this will limit shell-side pressure .

Pressure Requirements: For shell-side pressures > 0.6 MPa combined with significant temperature difference, consider other designs .

Thermal Duty: Determine required heat transfer area, flow rates, and allowable pressure drops.

Materials Selection: Choose materials compatible with both fluids; carbon steel common for mild services, stainless steels for corrosion resistance.

Flow Arrangement: For maximum thermal efficiency, specify single-pass for true countercurrent flow. If higher tube-side velocity needed, select multi-pass (2,4,6) and account for LMTD correction factor .

Applicable Code: Specify design code (ASME, GB/T 151, TEMA, PED) based on location and insurance requirements.

">1. Product IntroductionA fixed tubesheet heat exchanger, also known as a fixed t···

Bag Filter

Type

Characteristics

Typical Applications

Single-Bag Filter

One filter bag per housing; simple, economical design; available in Size 01 (Φ180×430mm) and Size 02 (Φ180×810mm) configurations .

Flow rates up to 40 m³/h ; smaller installations, point-of-use filtration.

Multi-Bag Filter

Multiple bags in a single vessel; higher flow capacity.

Flow rates >40 m³/h up to 500 m³/h ; industrial-scale operations.

Duplex Bag Filter

Two filter housings with switching valves; allows continuous operation during bag change-out.

Processes requiring uninterrupted filtration.

3.2 By Housing Material (Liquid Filtration)

Material	Specifications	Application
Stainless Steel (304/316L)	Maximum operating temperature 150°C; pressure rating up to 6 bar (87 psi) .	General industrial, food, pharmaceutical, corrosive fluids.
Carbon Steel (Epoxy-Coated)	Economical option for non-corrosive services.	Water treatment, general industrial applications .
PVC/CPVC	Pressure rated 150 psi at 70°F (non-shock); flow rates up to 100 GPM; sizes 1-1/4" to 4" with true-union design .	Sodium hypochlorite, bleach processing, corrosive chemical handling .

3.3 By Application (Air Filtration)

Filter Class	Efficiency	Typical Applications
M5 / F5	ePM10 60% (ISO 16890)	General HVAC, pre-filtration .
F6	60-65% (colorimetric)	Pharmaceutical, hospital ventilation .
F7	80-85% (colorimetric)	Electronics clean rooms, food processing .
F8	90-95% (colorimetric)	High-efficiency applications, final filtration .

4. Technical Specifications

4.1 Liquid Bag Filter (Typical Single-Bag Housing)

Parameter	Specification	Notes
Design Standard	ASME Section VIII (optional), PED, GB/T 151	Custom designs available.
Number of Filter Bags	1 (single-bag)	Multi-bag configurations available.
Filter Bag Sizes	Size 01: Φ180×430 mm; Size 02: Φ180×810 mm	Standard industry sizes.
Recommended Flow Rate	Up to 40 m³/h	Depends on fluid viscosity and bag micron rating.
Maximum Operating Pressure	6 bar (87 psi)	Higher pressures available with special design.
Maximum Operating Temperature	150°C	Limited by filter bag and seal material.
Materials of Construction	304/316L Stainless Steel, Carbon Steel, PVC/CPVC	Selected based on fluid compatibility.
Inlet/Outlet Connections	DIN, ANSI, BSP, NPT	Flanged or threaded.
Filtration Area (per bag)	Size 01: 0.25 m²; Size 02: 0.48 m²	Eaton UNIBAG specifications.

4.2 Liquid Filter Bag Specifications (Eaton UNIBAG Example)

Parameter	Specification
Model	PEU-10-P02UK-WW-30L
Filter Bag Size	Size 02: Φ180 × 810 mm (7" × 32")
Filter Media	Polyester needlefelt
Retention Rating	10.0 μm (nominal)
Maximum Differential Pressure	2.5 bar
Maximum Operating Temperature	90°C
Maximum Flow Rate	40 m³/h
Filter Area	0.48 m²
Construction	Welded seams, polyester UNIRING
Certifications	ISO 9001, Kosher, Halal

4.3 Air Bag Filter (HVAC) Specifications

Parameter	Typical Range
Filter Class	F5 to F8 (M5 to F8)
Filtration Efficiency	60–95% (colorimetric) @ 1–5 μm
ISO 16890 Classification	ePM10 60% to ePM1 70%
Face Velocity	As per design specifications
Initial Pressure Drop	37–115 Pa
Final Recommended Pressure Drop	250–450 Pa
Maximum Operating Temperature	70–80°C
Media Materials	Glass fiber, synthetic non-wovens
Frame Materials	Galvanized steel, powder-coated steel, aluminum

4.4 3M™ 500 Series Liquid Filter Bag Specifications

Parameter	Specification
Model	527D
Filter Bag Size	7" × 32" (Size 02)
Filter Media	Meltblown polypropylene microfiber
Usable Filter Media Area	38 ft² (3.53 m²)
Micron Rating	15 μm
Flow Rate	189 L/min (50 gal/min)
Features	Patented bypass/transport layer design; welded side seams; stainless steel sealing ring
Compliance	FDA compliant (CFR Title 21); ISO 9001; no silicone or adhesives

5. Structural Components (Liquid Bag Filter)

A typical bag filter housing consists of the following core components :

Component	Description
Filter Housing Vessel	Cylindrical pressure vessel fabricated from stainless steel, carbon steel, or engineered plastics (PVC/CPVC).
Cover / Lid	Removable cover with swing eye-bolt closure for quick access ; includes vent valve .
Filter Bag Support Basket	Perforated stainless steel basket that supports the filter bag, prevents collapse under pressure, and ensures even flow distribution . Electro-polished surface for easy cleaning .
Filter Bag	Replaceable filtration element; available in various materials (polyester, polypropylene, nylon, PTFE) and micron ratings (1–200 μm) .
Inlet/Outlet Nozzles	Flanged or threaded connections; side-entry design allows bag replacement without cutting pipeline .
Drain Port	Bottom connection for system draining .
Pressure Gauges	Optional inlet/outlet pressure gauges or differential pressure gauge/switch for monitoring bag loading .
Mounting Base	Integral base for secure installation .

6. Features & Advantages

6.1 Liquid Bag Filtration

Feature	Description	Benefit
Simple, Economical Design	Straightforward construction with minimal moving parts .	Lower initial investment; reduced maintenance costs.
Quick and Easy Bag Change-Out	Swing eye-bolt closure allows rapid access; side-entry design eliminates need to disconnect piping .	Minimizes downtime; reduces labor costs.
Positive Sealing	Filter bag sealing collar (stainless steel ring or UNIRING) ensures proper seal in housing .	Prevents fluid bypass; maintains filtration integrity.
High Dirt-Holding Capacity	Bag construction provides large filtration area (up to 38 ft² for 3M 500 series) .	Extended service life between change-outs; lower operating costs.
Contaminant Containment	All captured solids remain inside the filter bag .	Vessel interior stays clean; no cleaning required after bag change.
Wide Chemical Compatibility	Available in polypropylene, polyester, PTFE, and other materials .	Suitable for diverse applications from water to aggressive chemicals.
FDA Compliance Available	FDA-compliant materials of construction .	Suitable for food, beverage, and pharmaceutical applications.
Low Operating Costs	Disposable bags eliminate cleaning labor; welded seams prevent particle bypass .	Cost-effective compared to cleanable filter systems.

6.2 Air Bag Filtration (HVAC)

Feature	Description	Benefit
High Dust-Holding Capacity	Large bag surface area captures significant particulate loading .	Extended service life; reduced replacement frequency.
Low Pressure Drop	Optimized bag design minimizes airflow resistance .	Lower energy consumption; reduced operating costs.
Welded Bag Construction	Heat-sealed seams eliminate stitching holes .	Prevents air bypass; maintains filtration efficiency.
Conical Stitched Pockets	Aerodynamic pocket design for optimal airflow .	Reduced turbulence; even air distribution.
UL Certified Materials	Certified materials ensure safety and performance .	Reliable operation; code compliance.

7. Application Areas

7.1 Liquid Filtration

Industry	Typical Applications
Water Treatment	Industrial process water, cooling water, pre-filtration for membrane systems .
Chemical Processing	Acids, caustics, solvents, intermediates, final product filtration .
Petrochemicals & Refining	Hydrocarbon processing, amine filtration, refinery wastewater .
Pharmaceutical & Biotech	API filtration, buffer solutions, process water .
Food & Beverage	Beer, wine, juices, edible oils, syrups, process water .
Paints, Inks, Coatings	Pigment dispersion, finished product filtration .
Metalworking Fluids	Coolants, lubricants, cutting fluids .
Electronics	High-purity water, chemical filtration .
Automotive	Paint systems, parts washing fluids .

7.2 Air Filtration (HVAC)

Industry	Typical Applications
Pharmaceutical	Clean rooms, manufacturing areas .
Healthcare	Hospitals, laboratories, operating theaters .
Electronics	Clean rooms, component manufacturing .
Food Processing	Production areas, packaging facilities .
Commercial Buildings	Office buildings, shopping centers, airports .
HVAC Systems	Air handling units, central air conditioning .

8. Selection & Design Guide

8.1 Liquid Bag Filter Selection

To select the correct bag filter system, the following factors must be considered :

Flow Rate: Determine required flow capacity. Single-bag filters handle up to 40 m³/h; multi-bag systems accommodate higher flows up to 500 m³/h .

Filtration Precision: Select micron rating based on particle size to be removed (available from 1 to 200 μm) .

Fluid Characteristics: Identify viscosity, temperature, and chemical compatibility to select appropriate housing material (stainless steel, carbon steel, PVC/CPVC) and bag material (polyester, polypropylene, nylon, PTFE) .

Operating Conditions: Specify maximum operating pressure (standard up to 6 bar) and temperature (up to 150°C) .

Connection Type: Select flanged (ANSI/DIN) or threaded (BSP/NPT) connections based on piping system .

Configuration: Choose single-bag for smaller flows, multi-bag for larger flows, or duplex for continuous operation .

Certification Requirements: For food/pharmaceutical applications, specify FDA-compliant materials and appropriate certifications (Kosher, Halal, ISO 9001) .

8.2 Air Bag Filter Selection

To select the correct air bag filter, the following factors must be considered :

Air Flow Rate: Determine required volumetric flow (m³/h) based on system design.

Filter Class: Select required efficiency (F5 to F8) based on application requirements .

Dimensions: Specify filter width, height, and bag length based on filter trap dimensions .

Pressure Drop Constraints: Consider initial and final pressure drop limits for system design .

Operating Temperature: Verify compatibility with system temperature (max 70-80°C) .

Frame Material: Select based on environmental conditions (galvanized steel, powder-coated steel, aluminum) .

">1. Product IntroductionA bag filter is a pressure vessel designed for liquid-sol···

Three-phase Separator

Type

Characteristics

Typical Applications

Horizontal Three-Phase Separator

Vessel axis horizontal; large liquid surface area for degassing; longer liquid retention time; easier to achieve oil-water separation; multiple weir and compartment configurations available .

High liquid flow rates, production separators, free water knockouts, refineries .

Vertical Three-Phase Separator

Vessel axis vertical; smaller footprint; better handling of solids; higher gas capacity per liquid volume .

High gas-oil ratio wells, space-limited installations (offshore platforms), well testing .

3.2 By Function

Type	Description	Application
Test Separator	Self-contained skid-mounted unit with metering devices (turbine flow meters, orifice fittings) for measuring individual phase flow rates; often portable or movable .	Well cleanups, production testing, early production facilities .
Production Separator	Continuously operating unit designed for steady-state separation; may include full automation and controls .	Ongoing oil and gas production .
Free Water Knockout (FWKO)	Vessel designed primarily to separate bulk free water from oil; can be horizontal or vertical; used upstream of other separation equipment .	High water-cut streams, desanding applications .

3.3 Special Designs

Design	Features	Applications
Dynamic Feather Vane Separator	Uses specially arranged coalescing Feather Vane pins for enhanced separation; composite weir system improves stability under varying operating conditions; separation efficiency up to 99.5% for droplets ≥30μm .	CTL (Coal-to-Liquid) projects, offshore and onshore terminals, gas-liquid-liquid-solid separation .
Skid-Mounted Digital Separator	Fully automated with PLC/DCS control; skid-mounted for easy transport and installation; includes safety relief valves and bursting disc system .	Remote locations, temporary installations, facilities requiring rapid deployment .

4. Technical Specifications

Three-phase separators are custom-designed according to international standards and specific process requirements. The following parameters represent typical industry ranges :

4.1 General Specifications

Parameter	Typical Range / Specification	Notes
Design Standard	API Spec. 12J, ASME Section VIII, Div. 1, PED, NACE MR0175	NACE MR0175 for H₂S service .
Separator Size	30" x 10 ft to 48" x 15 ft (horizontal); custom sizes available	Vessel diameter × length.
Design Pressure	150 psi to 2,160 psi (1.0 MPa to 15 MPa)	Customizable per client requirements .
Design Temperature	-20°C to 80°C (standard)	Higher temperatures available with special materials.
Liquid Capacity	1,000 bopd to 19,000 bopd (typical for well test separators)	Depends on vessel size and operating conditions.
Retention Time	5 to 23 minutes	Longer for emulsion-breaking or difficult separations .
Separation Efficiency	99.5% (for droplets ≥30μm) ; removes 99% of solids ≥5μm and 99% of liquid droplets ≥10μm	Depends on internal design and operating conditions.
Pressure Drop (Internals)	<5 kPa	Low pressure drop design minimizes energy loss .
Materials of Construction	Carbon Steel (Q345R, A516 Gr.70), Stainless Steel (304/316L), Carbon Steel + Stainless Steel clad, Carbon Steel + Nickel base alloy	Selected based on corrosivity and temperature .
Inlet/Outlet Connections	Flanged (ANSI, DIN) or threaded; sizes as per piping specification .

4.2 Performance Targets

Parameter	Target Value
Liquid droplets in gas	<100 μm
Water droplets in oil	<500 μm
Water content in oil	≤10-30% (depending on application)
Oil content in water	≤150 ppm

4.3 Example: 42" x 10 ft Test Separator Specifications

Parameter	Value
Vessel Size	42" (1067 mm) diameter × 10 ft (3048 mm) length
Design Pressure	1440 psi (9.93 MPa)
Liquid Capacity	10,000 bopd
Overall Dimensions (Skid)	15 ft × 7.5 ft × 9 ft (4.6 m × 2.3 m × 2.7 m)
Service	Well testing, production separation

5. Structural Components

A typical three-phase separator consists of the following core components :

Component	Description
Vessel Shell	Pressure-containing cylindrical vessel (horizontal or vertical) with dished heads; materials selected per service conditions .
Inlet Device (Feed Distributor)	Deflector plate, cyclonic inlet, or distribution baffle to reduce momentum and promote initial gas breakout .
Gas Gravity Section	Upper portion of vessel where primary gas-liquid separation occurs by gravity.
Mist Extractor / Demister	Wire mesh, vane pack, or cyclone device installed near gas outlet to remove entrained liquid droplets from gas .
Coalescing Plates / Baffles	Internals that promote droplet coalescence and enhance oil-water separation .
Weir System	Internal overflow weir(s) that maintain oil layer thickness and control oil-water interface level; composite weir designs improve stability under varying flow conditions .
Interface Level Controller	Instrument that monitors and controls the oil-water interface level, typically using displacers, differential pressure transmitters, or capacitance probes .
Vortex Breaker	Device installed at liquid outlets to prevent swirling and gas entrainment during discharge .
Sand Jets / Desanding Internals	Optional components for removing accumulated solids .
Pressure Relief Devices	Safety relief valves and/or bursting discs to protect against overpressure .
Sampling Points	Connections for collecting representative samples of each phase .
Level Gauges	Sight glasses or magnetic level indicators for visual monitoring of liquid levels .

6. Features & Advantages

6.1 Core Advantages

Feature	Description	Benefit
High Separation Efficiency	Advanced internals (coalescing plates, vane packs, demisters) achieve high removal rates: 99% of solids ≥5μm and 99% of liquid droplets ≥10μm ; up to 99.5% for droplets ≥30μm .	Produces cleaner phases for downstream processing; reduces load on downstream equipment .
Stable Operation Under Varying Conditions	Composite weir systems and robust interface control maintain performance even with fluctuating oil-water ratios and flow rates .	Reliable separation despite changing well conditions; reduces operator intervention .
Automation and Control	Fully automatic operation with PLC/DCS integration; base-mounted pneumatic controllers; pressure, level, and interface control loops .	Minimizes manual intervention; enables remote monitoring and control .
Safety Compliance	Dual safety valves, bursting disc systems; conform to industry standards (ASME, API 12J, PED, NACE) .	Ensures safe operation; meets regulatory requirements .
Skid-Mounted / Modular Design	Pre-fabricated, pre-commissioned skid-mounted units ; quick-connect piping and electrical connections .	Reduces site installation time and cost; enables rapid deployment .
Corrosion Protection	Design consideration for H₂S corrosion allowance; clad materials available .	Prolongs vessel lifetime in sour service .
Low Maintenance	No internal spare parts required for certain designs ; bypass access for maintenance without production stop .	Reduced operating costs; minimal downtime .

6.2 Application-Specific Features

Industry	Feature	Benefit
Offshore Platforms	Special design and certification for offshore operations (e.g., DNV 2.7.3) .	Complies with marine safety standards; suitable for harsh environments .
Well Testing	Turbine flow meters and senior orifice fittings for accurate measurement; dual-circuit regulation for uncertain production rates .	Precise well performance data; adaptability to varying flow conditions .
High H₂S Service	NACE MR0175 materials; corrosion allowance .	Safe operation in sour gas environments .

7. Application Areas

Industry	Typical Applications
Oil & Gas Production	Well cleanups, production/well testing, early production facilities, onshore and offshore production separators .
Refining & Petrochemical	Top of distillation column separators (CTL projects), gas-oil-water-solid separation .
Gas Processing	Free water knockout (FWKO) upstream of dehydration ; gas dehydration separators .
Produced Water Treatment	Oil-water separation for environmental compliance; water quality monitoring .
Pipeline Operations	Slug catchers; inlet separation for compressor stations .

8. Selection & Design Guide

To select and design the correct three-phase separator, the following factors must be considered :

Flow Rates and Compositions: Provide expected flow rates (oil, water, gas), water cut, gas-oil ratio, and operating pressure/temperature.

Fluid Properties: Specify densities, viscosities, interfacial tension, and tendency to form emulsions. These affect droplet settling and separation efficiency .

Required Separation Performance: Define target outlet specifications (e.g., ≤150 ppm oil in water, ≤10-30% water in oil) .

Configuration (Horizontal vs. Vertical) :

Horizontal: Preferred for high liquid rates, oil-water separation, and where longer retention time is beneficial.

Vertical: Preferred for high gas-oil ratios, space-limited installations, and when solids handling is required.

Internal Design Features:

Inlet Device: Cyclonic inlet for high gas content; simple deflector for lower velocities .

Coalescing Internals: Required for difficult separations or fine droplet removal .

Weir System: Adjustable weirs for varying oil-water ratios; composite weirs for stability .

Mist Extractor: Wire mesh (for larger droplets) or vane pack (for finer droplets) .

Corrosion and Materials: Specify materials based on H₂S content (NACE MR0175) and corrosivity .

Automation Requirements: Determine level of automation (local pneumatic controllers vs. full PLC/DCS integration) .

Applicable Code: Specify design code based on location and industry (API 12J, ASME VIII, PED, etc.) .

Special Considerations: For offshore applications, specify DNV 2.7.3 certification ; for portable units, consider skid mounting and transportability .

">1. Product IntroductionA three-phase separator is a pressure vessel designed to ···

Scraped Film Evaporator

Type

Characteristics

Typical Applications

Sliding Scraper

Scrapers held in rotor slots, pressed against wall by centrifugal force; commonly made of PTFE (<150°C) or carbon fiber (>150°C). Most common type .

General purpose, moderate viscosities, heat-sensitive materials .

Fixed Scraper

Metal scrapers rigidly attached to rotor; maintain fixed 1-2 mm clearance from wall; high precision required .

Very high viscosity materials, foam-prone products .

Hinge Scraper

Metal scrapers hinged to rotor; centrifugal force keeps them pressed against wall; provide positive scraping action .

Severely fouling or scaling materials .

3.2 By Configuration

Type	Orientation	Characteristics
Vertical Scraped Film Evaporator	Vertical	Most common configuration; smaller footprint; gravity assists film flow; ideal for distillation and concentration .
Horizontal Scraped Film Evaporator	Horizontal	Suitable for very high viscosity materials or when extremely short residence time is critical; material is conveyed horizontally.
Conical / Centrifugal Film Evaporator	Inclined	Utilizes centrifugal force from rotor in addition to scraping; enhances film formation and reduces residence time further .

4. Technical Specifications

Scraped film evaporators are custom-designed based on process requirements. The following parameters represent typical industry ranges:

Parameter	Typical Range / Specification	Notes
Design Standard	ASME Section VIII, PED, GB/T 151, AD2000	Code of construction varies by application.
Evaporation Area	0.1 m² to 60 m²	Standard industrial range; larger available.
Evaporation Capacity	140 to 4200 kg/h (water/solvents)	Depends on area and material.
Heat Transfer Coefficient	High (superior to falling film)	Enhanced by turbulent film.
Evaporation Intensity	150-200 kg/m²·hr	Typical value for many applications.
Operating Pressure	Full vacuum to 0.5 MPa (typical)	Vacuum to 5 mmHg (667 Pa) achievable .
Operating Temperature	Up to 300°C (standard)	Higher with special materials and heating media.
Residence Time	5 to 10 seconds (typical)	Extremely short; critical for heat-sensitive materials.
Viscosity Range	Up to 100,000 cP (1-100,000 cP typical)	Can handle very high viscosities.
Rotor Speed	Variable; linear speed optimized per design	Typically 2-10 m/s tip speed .
Materials of Construction	Stainless Steel (304, 316L), Carbon Steel, Hastelloy, Titanium, Glass-lined	Selected based on corrosivity.
Surface Finish (Internal)	Precision machined and polished; mirror finish available	Minimizes fouling and product adhesion.

4.2 Typical Model Specifications

Model	Evaporation Area (m²)	Evaporation Capacity (kg/h)	Steam Pressure (MPa)	Vacuum (kPa)	Weight (kg)
LG-2.2	2.2	140	0.3	60	250
LG-5.5	5.5	350	0.4	60	520
LG-8	8	550	0.4	60	750
LG-12	12	850	0.4	60	1020
LG-16	16	1100	0.4	60	1250
LG-20	20	1500	0.4	60	2300
LG-30	30	2100	0.4	60	2950
LG-40	40	2800	0.4	60	3500
LG-60	60	4200	0.4	60	5700

5. Structural Components

A typical scraped film evaporator consists of the following core components :

Component	Description
Drive Unit (Motor & Gearbox)	Provides rotational power to the rotor. Speed selection is critical for optimal film formation and is based on scraper type, material viscosity, and cylinder diameter .
Separator / Top Head	Houses the tangential feed inlet and integral vapor-liquid separator (vane-type or mesh demister). Prevents entrained liquid droplets from exiting with vapor. Proper design prevents material "short-circuiting" to vapor outlet .
Feed Distributor	Rotating component mounted on the rotor that evenly distributes feed liquid onto the heated wall, initiating film formation .
Heated Cylinder / Evaporator Body	The main heat transfer surface. Externally jacketed for heating media (steam, thermal oil). Inner surface is precision-machined and polished to minimize fouling and ensure effective scraping .
Rotor Assembly	Consists of a shaft and frame (typically precision-machined stainless steel) that supports the scraper blades. Rotates concentrically within the cylinder .
Scraper Blades	Mounted on the rotor; available in sliding, fixed, or hinged configurations. Materials: PTFE (low temp), carbon fiber (high temp), or various metals .
Bottom Head	W-shaped design for complete concentrate drainage. Often incorporates a bottom bearing with high-temperature self-lubricating properties for stable rotor operation and easy maintenance .
Vapor Outlet	Top connection leading to a condenser.
Residue Outlet	Bottom connection for discharging concentrated product.

6. Features & Advantages

6.1 Core Advantages

Feature	Description	Benefit
Extremely Short Residence Time	Material is in the heated zone for only 5-10 seconds .	Minimizes thermal degradation; ideal for heat-sensitive products.
High Heat Transfer Coefficients	Turbulent, thin film provides high heat transfer rates, with evaporation intensities of 150-200 kg/m²·hr .	High capacity in a compact unit; energy-efficient.
Handles Very High Viscosities	Positive mechanical scraping allows processing of materials up to 100,000 cP .	Suitable for applications where other evaporators fail.
Self-Cleaning Operation	Continuous scraping prevents fouling, scaling, and product buildup on the heat transfer surface .	Consistent performance over long runs; reduces maintenance downtime.
Low Pressure Drop / High Vacuum	Large vapor space and open geometry result in very low pressure drop, allowing high vacuum operation (up to 5 mmHg) .	Lowers boiling points; preserves product quality.
Handles Difficult Materials	Effective for processing crystallizing, fouling, solids-containing, and high-boiling materials .	Broad application range.
Flexible Residence Time Control	Scraper groove design can be modified to adjust material holdup and residence time .	Adaptable to different product requirements.
Low Holdup Volume	Small internal volume minimizes product inventory and facilitates rapid product changeover.	Ideal for expensive or multi-product campaigns.
Continuous Operation	Designed for continuous feed and discharge; compatible with automated control systems .	Efficient for production-scale processing.

6.2 Limitations

Limitation	Description
Higher Capital Cost	More expensive than simpler evaporator types due to precision mechanical components and drive system.
Mechanical Complexity	Rotating parts require maintenance; seal integrity critical for vacuum operation.
Limited Heating Surface per Unit	Heating surface limited by practical cylinder diameter; large capacities may require multiple units.
Power Consumption	Rotor drive consumes energy, though typically modest relative to evaporation duty.

7. Application Areas

Industry	Typical Applications
Pharmaceutical	Concentration of antibiotics, vitamins, amino acids, and other heat-sensitive APIs; solvent recovery; purification of intermediates .
Chemical / Petrochemical	Processing of polymers, resins, high-boiling solvents, and specialty chemicals; deodorization; stripping .
Food & Beverage	Concentration of fruit juices, milk, whey, gelatin, egg products, and vegetable extracts; aroma recovery .
Cosmetics & Personal Care	Production of emollients, fatty acid esters, and natural oils; deodorization .
Environmental	Concentration of industrial wastewater; recovery of valuable products from waste streams .
Biodiesel / Oleochemicals	Purification of glycerin; deodorization of oils and fats.
Fine Chemicals	Distillation and purification of high-boiling, heat-sensitive fine chemical intermediates.

8. Selection & Design Guide

To select the correct scraped film evaporator, the following factors must be considered:

Material Characteristics:

Viscosity: Determine range (up to 100,000 cP) to select appropriate scraper type and drive power .

Heat Sensitivity: Define maximum allowable temperature and required residence time (5-10 seconds typical) .

Fouling/Crystallization Tendency: Assess severity to determine if self-cleaning action sufficient or if special scraper designs needed.

Corrosivity: Select materials (SS, Hastelloy, etc.) based on fluid compatibility.

Process Requirements:

Throughput: Determine required feed rate and evaporation capacity (kg/h).

Concentration: Define inlet and desired outlet concentrations.

Temperature/Pressure: Specify operating temperature and vacuum level required.

Heat Source: Identify available heating media (steam pressure, thermal oil temperature).

Evaporator Sizing:

Calculate required heat transfer area based on evaporation duty and expected heat transfer coefficient.

Select appropriate model from standard size range (2.2 to 60 m²) or specify custom .

Scraper Type Selection:

Sliding Scrapers: General purpose, most common .

Fixed Scrapers: Very high viscosity, foam-prone materials .

Hinged Scrapers: Severely fouling services .

Material Selection:

Standard: Stainless steel 304/316L for most applications .

Corrosive: Hastelloy, titanium, or glass-lined options .

Auxiliary Equipment: Consider requirements for preheater, condenser, vacuum system, and product collection tanks .

Applicable Code: Specify design code (ASME, PED, GB) based on location and industry.

">1. Product IntroductionA scraped thin film evaporator, also known as a wiped fil···

Cooling Crystallizer

Type

Characteristics

Typical Applications

Double-Pipe (Jacketed) Crystallizer

Concentric pipe design with inner product pipe and outer cooling jacket; features rotating shaft with scrapers (13.2 rpm typical) to prevent wall buildup; available in banks of 10-16 pipes .

Petroleum refining (lubricating oil dewaxing), waxy oil processing, paraffin production .

DTB (Draft Tube and Baffle) Crystallizer

Agitated vessel with internal circulation; promotes uniform mixing and controlled crystal growth; available in lab (5-15L) to industrial scales .

Pharmaceutical R&D, fine chemical production, precise crystallization parameter optimization .

Oslo-Krystal (Fluidized Bed) Crystallizer

Classifying crystallizer with fluidized bed; liquor recirculation through cooling heat exchanger; produces large, uniform crystals with narrow size distribution .

Large-scale industrial production, inorganic salts, fertilizers, continuous operations .

Scraped Surface (Votator) Crystallizer

Tubular heat exchanger with rotating scraper blades; handles high-viscosity materials; automated controls; pressure ratings up to 200 PSI .

Food processing (margarine, butter, shortening), high-viscosity materials .

Hygienic/Bead-Blasted Crystallizer

Smooth bead-blasted internal surfaces; 316L stainless steel construction; meets FDA/GMP standards .

Pharmaceuticals, biotechnology, food-grade applications requiring high purity .

3.2 By Scale

Type	Capacity Range	Features
Laboratory / R&D	5-50 LPH	Precision PID control (±0.5% accuracy); modular design; digital parameter adjustment .
Pilot Scale	50-1000 L	Semi-automated control; scalable design; process validation .
Industrial Production	1,000-100,000 L+	Fully automated; DCS integration; continuous operation .

4. Technical Specifications

Cooling crystallizers are custom-engineered based on process requirements. The following parameters represent typical industry ranges:

Parameter	Double-Pipe Type	DTB/Oslo Type	Scraped Surface Type	Hygienic Type
Design Standard	ASME Section VIII, PED, GB 150	ASME, PED, ISO 9001	ASME, FDA/GMP	ASME, FDA, GMP, ISO 9001
Capacity / Volume	Per pipe: ~105 m² heat transfer area	5 L - 100,000 L	100-20,000 L	100-20,000 L
Design Pressure	2.5 - 4.0 MPa	Up to -0.1 MPa vacuum	100-200 PSI (0.7-1.38 MPa)	As required
Design Temperature	-20°C to 120°C	-20°C to 120°C (lab); custom industrial	Process dependent	Process dependent
Materials of Construction	Carbon steel (industrial)	304/316L SS, Hastelloy, Titanium	304/316L SS	316L SS, Hastelloy, Titanium
Agitation / Rotation Speed	13.2 rpm (scraper)	Variable (lab 0-500 rpm)	Automated	As required
Control System	Manual/mechanical	Digital PID (±0.5% accuracy); PLC/DCS	Automated touchscreen	PLC/DCS
Vacuum Capability	Not typical	-0.05 to -0.1 MPa	Not typical	Optional
Cooling Method	Jacketed double-pipe	Jacket, internal coils, external heat exchanger	Jacketed tube with scrapers	Jacket, coils

5. Structural Components

A typical cooling crystallizer consists of the following core components based on design type:

Component	Double-Pipe Type	DTB/Agitated Type	Scraped Surface Type
Vessel / Shell	Concentric outer pipe (Ø270mm) with inner pipe (Ø200mm)	Cylindrical vessel with dished heads; 304/316L SS	Tubular housing with cooling jacket
Heat Transfer Surface	Annular space between pipes for coolant	Jacket, internal coils, or external heat exchanger	Jacketed tube wall
Agitation / Scraping Mechanism	Central shaft with spring-loaded scrapers; 13.2 rpm; safety shear pins prevent overload	Draft tube and agitator (DTB); marine or turbine impellers	Rotating scraper blades; automated drive
Coolant System	Refrigerant or chilled medium in outer pipe	Chilled water, brine, or refrigerant circulation	Coolant circulation with temperature control
Feed/Discharge Connections	Flanged or threaded inlets/outlets	Inlet, outlet, drain, vent nozzles	Inlet and outlet for continuous operation
Instrumentation	Pressure/temperature gauges	Temperature sensors, pressure transmitters, level indicators	Touchscreen controls, temperature sensors
Supports	Head frame and brackets; lifting holes for maintenance	Legs or skirt supports	Industrial frame
Safety Devices	Safety shear pins prevent overload damage	Pressure relief devices	Pressure relief; automated shutdown

6. Features & Advantages

6.1 Core Advantages

Feature	Description	Benefit
Precise Temperature Control	Advanced PID control systems achieve temperature accuracy of ±0.5% to ±2% depending on model ; programmable cooling profiles.	Enables precise supersaturation control; produces consistent crystal size distribution; reduces fines and agglomeration.
High-Quality Crystal Products	Fluidized bed designs (Oslo) produce large, uniform crystals with narrow size distribution ; controlled nucleation and growth.	Superior product purity; easier downstream filtration and washing; higher market value.
Energy Efficiency	Cooling crystallization consumes less energy than evaporative methods for suitable materials; multi-stage cooling optimizes energy use .	Lower operating costs; reduced carbon footprint.
Handles Difficult Materials	Scraped surface designs process high-viscosity (margarine, shortening) and wax-forming materials (lube oil dewaxing) ; self-cleaning action prevents fouling.	Broad application range; reliable operation with fouling-prone materials.
Hygienic/Sanitary Options	Bead-blasted surfaces ; 316L stainless steel; FDA/GMP compliant materials .	Suitable for pharmaceutical and food applications; easy to clean (CIP); prevents contamination.
Corrosion Resistance	Available in 316L stainless steel, Hastelloy, and titanium for aggressive chemical environments .	Extended equipment life in corrosive service; maintains product purity.
Scalable Design	From 5L lab units to 100,000L industrial crystallizers ; modular options available .	Seamless scale-up from R&D to production; reduced process development risk.
Automated Operation	PLC/DCS integration; touchscreen controls; data logging .	Minimal operator intervention; reproducible results; 24/7 operation capability.

6.2 Type-Specific Advantages

Type	Advantages
Double-Pipe (Scraped)	Large pipe diameter reduces flow resistance and clogging; high evaporation rate ensures sufficient crystallization; long cleaning cycles; low noise; stable operation .
DTB	Excellent mixing; controlled circulation; suitable for batch or continuous operation; precise parameter control for R&D .
Oslo (Fluidized Bed)	Produces largest, most uniform crystals; classifying action removes fines; ideal for continuous large-scale production .
Scraped Surface (Votator)	Handles highest viscosities; up to 30% faster cooling than traditional designs; continuous operation; food-grade materials .

7. Application Areas

Industry	Typical Applications
Petroleum Refining	Lubricating oil dewaxing, paraffin production (double-pipe crystallizers) .
Pharmaceutical	API crystallization, intermediate purification, antibiotic recovery, high-purity crystal formation .
Chemical Processing	Inorganic salts (sodium sulfate, potassium chloride, ammonium sulfate), organic acids (citric, oxalic), fine chemical production .
Food & Beverage	Margarine, butter, shortening production (scraped surface) ; sugar crystallization; edible oil processing; food-grade crystal formation .
Biotechnology	Solute recovery from fermentation broths; protein crystallization; amino acid purification .
Wastewater Treatment	Zero Liquid Discharge (ZLD) systems; recovery of valuable salts from industrial effluents; brine concentration .
Academic / R&D	Crystallization kinetics studies; process optimization; new product development .

8. Selection & Design Guide

To select the correct cooling crystallizer, the following factors must be considered:

Material Characteristics:

Viscosity: Low to moderate: standard agitated or Oslo designs; high viscosity or wax-forming: scraped surface/double-pipe designs .

Temperature Sensitivity: Define maximum allowable temperature; cooling crystallizers ideal for heat-sensitive materials.

Fouling/Scaling Tendency: Scraped designs for severe fouling ; fluidized bed for moderate scaling .

Corrosivity: Select materials (316L SS, Hastelloy, titanium) based on fluid compatibility .

Process Requirements:

Throughput: Determine batch size or continuous production rate (kg/h or L/h). Laboratory: 5-50L; pilot: 50-1000L; industrial: 1,000-100,000L+ .

Crystal Size: Oslo fluidized bed for largest, most uniform crystals ; DTB for controlled distribution; scraped surface for food applications .

Temperature Range: Specify operating temperature (e.g., -20°C to 120°C) .

Pressure Requirements: Vacuum capability may be needed for some applications .

Configuration Selection:

Double-Pipe: Petroleum dewaxing, waxy materials .

DTB: R&D, pharmaceuticals, fine chemicals .

Oslo: Large-scale continuous production, uniform crystals .

Scraped Surface: Food processing, high-viscosity materials .

Hygienic: Pharmaceutical, biotechnology, food-grade .

Control Philosophy:

Manual/Basic: For simple operations or budget constraints.

Semi-Automated: For pilot plants requiring flexibility .

Fully Automated PLC/DCS: For production environments needing reproducibility and data logging .

Pilot Testing: For critical applications, conduct pilot trials to validate design parameters, cooling rates, and crystal size distribution.

Applicable Code: Specify design code based on location and industry (ASME Section VIII Div.1, PED, GB 150, FDA, GMP) .

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Advantages

Industry Reputation Advantages

Industry reputation is the most core intangible asset among brand advantages. Unlike technological advantages, it cannot be proven with patent certificates, nor can it be quantified by factory size, but it often plays a decisive role in the final decision-making process for clients.The essence of in

Manufacturing Scale Advantages

In the equipment manufacturing industry, economies of scale are the cornerstone of customer trust. Because chemical equipment is typically characterized by high unit price, high customization, long service life, and significant impact from malfunctions, customers' biggest concerns when choosing

Customized R&D Advantages

In the equipment manufacturing industry, customized R&D capability is the core hallmark of a company's transformation from a "standard product supplier" to a "solution partner." As competition in downstream industries intensifies and processes become more complex, custome

Service Response Advantages

In the equipment manufacturing industry, service response advantage has become a core differentiator from competitors. It's not just about "fast repairs," but rather the comprehensive capability of a company to provide timely, efficient, and precise service support throughout the entir

Project Experience Advantages

In the equipment manufacturing industry, project experience is a crucial indicator of a company's core competitiveness. It's not merely a client list or completion certificates, but a comprehensive reflection of the technological expertise, management capabilities, risk assessment skills, an

Innovation and Development Advantages

In the equipment manufacturing sector, innovative development advantages are the core capabilities that enable enterprises to maintain long-term vitality, navigate industry cycles, and avoid falling into homogeneous price wars. Unlike competition models that rely on scale or cost, innovative develop

About Us

Wuxi Lancer Equipment Co., Ltd, is a high-tech enterprise specializing in designing and manufacturing pressure vessels and other chemical equipments that conform with GB,ASME,PED,AS,JIS,MOM,DOSH etc, including design, R&D, production, sales, installation, after-sales service, focuses on providing chemical equipments of high requirements and high qualities to petrochemical, coal chemical, fine ...

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News

2026-01-18

The latest version ASME BPVC.VIII.1-2025 has been released.

ASME BPVC.VIII.1-2025 (Boiler and Pressure Vessel Code, Volume VIII, Book 1), the 2025 version of the standard published by the American Society of Mechanical E···

2026-01-18

ASME BPVC.VIII.2-2025 is undergoing significant changes.

ASME BPVC.VIII.2-2025 has also undergone significant changes. The most crucial and strategic change is the elimination of the "dual-class container" s···

2026-01-16

In-depth analysis of GB/T150-2024

The national standard GB/T 150-2024, "Pressure Vessels," was released on July 24, 2024, and will officially come into effect on February 1, 2025. This···