Chemical Machinery & Plant #3400685

Distillation plant aids in purifying a liquid by a process of heating and cooling and repeating it if needed until the extraction of the desired product is not achieved.

 

Our Engineers, Designers and Experts have an enormous and meticulous understanding of today’s market Need, Standards and requirements that is why, when it comes to a product that requires a high level of resistance to corrosion, high pressure and purity. Ablaze Export Pvt. Ltd.is the name our clients all around the globe have always kept their trust and faith in.

 

Salient Features :

• Suitable for operation under high vacuum and low pressure.
• Setup can be configured up to 600 DN for large size reactors.
• Visual monitoring of the process, improving safety and reliability of production.
• Customized compact design as per available space.
• Measure and control devices can be easily equipped.
• High corrosion resistant Coupling and Fasteners.
• Shell and Tube type Heat Exchanger available up to 40m2 for improved heat transfer efficiency.

This is a versatile unit and can be used as Reaction Distillation Unit, Fractional Distillation Unit or a combination of both. All features of Reaction Distillation Unit and Fractional Distillation Unit are incorporated. The units are available in vessel sizes of 20, 50, 100, 200L & 300L and is suitable for operation under atmospheric pressure and full vacuum.

Sulphuric acid is used in many processes in chemical plants, thus making spent acid quite diluted. Disposing of this spent acid becomes an environmental pollution problem besides a waste of precious resource. The diluted spent acid can be efficiently re-concentrated up to a maximum concentration of 96% (ww) and reused in the main plant process, thus saving the environment and that too by improving the economical bottom line. Thus, sulphuric acid recovery or concentration plant is a fantastic option for high sulphuric acid users in process plants. Concentration of Sulphuric acid is mostly performed under vacuum in order to reduce the operating temperature, especially for high concentrations. We offer turnkey solutions right from know-how & technology, to supply, installation & commissioning. Our plant comprises of equipments wherin the wetted parts are made up of Borosilicate glass 3.3, Fluoropolymers (PTFE, PFA, FEP, PVDF, PP, etc), High Nickel alloys, Graphite & exotic metals (Ta, Ti, Nb, etc.). The plants can be totally automated by PLC or DCS based systems and even integrated with computers (SCADA etc).

The acidified feed containing Bromide salts is fed to Reactioncum- Air blowing tower, where dry Chlorine gas and Low-Pressure Air are injected. The Chlorine gas liberates free Bromine which is stripped out by Air in form of vapors. These vapors enter Absorption tower where Alkali solution is circulated and a Bromide-Bromate solution is formed. The Bromine content in the resultant solution is highly enriched compared to the original content. The unabsorbed air is vented out.

 

The enriched Bromide-Bromate solution is subjected to acidification in the liberation tower, where Bromine vapors are liberated and stripped out by steam injected at the bottom of the tower. The vapors leave the top of the tower.

 

These vapors are condensed in a series of condensers, and condensate is collected in the phase separator. The water phase is separated from Bromine and is refluxed to the tower. The Bromine so separated is Crude Bromine and is subjected to distillation.

 

Under distillation, Chlorine is removed and pure Bromine collected as bottom product. This Bromine is cooled through Product coolers and collected in product receiver/s. A Vent condenser condenses most of the Bromine and recycles into the system. The non-condensable are taken to the Vent scrubber.

 

The dibrominated effluent from the Air blowing tower may be taken for neutralization and effluent treatment.

 

Bromine finds its application directly and indirectly in the manufacture of pesticides, agrochemicals, pharmaceuticals, fire-retardants, photography chemicals, and many others. Bromine occurs in nature as Bromide salt present in seawater and in-land brine which is used for the grassroots production of Bromine. It is also recovered from industrial effluents/ byproducts where it occurs as different Bromide salts. Ablaze has a long and successful record of design and supply of several Bromine Recovery Plants – both grass-roots and from industrial effluents. Being manufacturer of Borosilicate Glass equipment, PTFE components and PTFE lined components, Ablaze is well qualified to handle such recovery systems as these are the major Material of Construction used in such systems. Custom made designs are offered for various Bromine Recovery Plants, depending on the source of Bromide and the end use of final product Bromine. Typical Product quality for Bromine recovered from such recovery plants is as follows:

• Bromine 99.5% w/w min
• Chlorine 0.3% w/w max
• Moisture 0.1% w/w max

However, the system can be designed to give the desired product quality as per the customer requirement. For eg. system can be designed to give dry Bromine if so required. There are two established Processes for the Recovery of Bromine from aqueous Bromide solutions.

The acidified feed containing Bromide salts is preheated and fed to Reaction-cum-stripping tower, where Chlorine gas and steam are injected. The Chlorine gas liberates free Bromine which is stripped out by live steam in form of vapors.

 

These vapors are condensed in a series of condensers, and condensate is collected in phase-separator. The water phase is refluxed to the tower and separated Crude. Bromine goes for distillation to remove dissolved Chlorine. Pure Bromine after distillation is collected as bottom product. This Bromine is cooled and collected in product receiver/s.

 

A Vent condenser condenses most of the Bromine and recycles into the system. The non-condensibles are taken to the Vent scrubber.

 

The debrominated effluent from the stripping tower exchanges heat with the feed and is relatively cooled down. It may be taken for neutralization and effluent treatment.

 

Bromine finds its application directly and indirectly in the manufacture of pesticides, agrochemicals, pharmaceuticals, fire-retardants, photography chemicals, and many others. Bromine occurs in nature as Bromide salt present in seawater and in-land brine which is used for the grassroots production of Bromine. It is also recovered from industrial effluents/ byproducts where it occurs as different Bromide salts. Ablaze has a long and successful record of design and supply of several Bromine Recovery Plants – both grass-roots and from industrial effluents. Being manufacturer of Borosilicate Glass equipment, PTFE components and PTFE lined components, Ablaze is well qualified to handle such recovery systems as these are the major Material of Construction used in such systems. Custom made designs are offered for various Bromine Recovery Plants, depending on the source of Bromide and the end use of final product Bromine. Typical Product quality for Bromine recovered from such recovery plants is as follows:

• Bromine 99.5% w/w min
• Chlorine 0.3% w/w max
• Moisture 0.1% w/w max

 

However, the system can be designed to give the desired product quality as per the customer requirement. For eg. system can be designed to give dry Bromine if so required. There are two established Processes for the Recovery of Bromine from aqueous Bromide solutions.

Ablaze offers in various sizes of reaction distillation units (Borosilicate Glass Flask) 20 Liter, 50 Liter, 100 Liter, 200 Liter & 500 Liter and is suitable for operation under atmospheric pressure/vacuum. We are leading Manufaturer & Suppliers of Reaction Distillation Pilot Plants Glass Reactor in India.

 

The distillation cycle is used as a thermal separation method, if the chemical composition of the vapor-phase is different from the chemical composition of the liquid-phase. It applies especially to material mixtures with different boiling points, meaning different volatility. Design of processes and plants for the separation, purification, concentration and recovery of chemical components by distillation if one of our skill sets.

 

Reaction Distillation is the process of separating the components or substances from a liquid mixture by using selective boiling and condensation.

 

Reaction Distillation may result in significantly complete separation (nearly pure components), or a partial separation may result in an increase in the concentration of selected components in the mixture. The technique can be useful for controlled reactions including hydrolysis and thermal decomposition.

 

This system is used to carry out stirred reactions and for the quick distillation of reflux. In a heating cooling bath, the reaction vessel is placed and fitted with the addition of a condensation vessel and a motorized stirrer. The material is sub-cooled and stored in a receiver flask.

 

Salient Features :

• Reactor up to 500equest

Ablaze offers Glass Spherical Flask with Oil Bath unit. It consists of a Glass Reactor mounted in a heating bath and fitted with a condenser for condensing the fumes. Drain valve recipient can be added for condensate receipt. The unit is available in vessel sizes of 50 Liter, 100 Liter , 200 liter & 500 Liter and is suitable for operation under atmospheric pressure and full vacuum.

 

We are one of the best Manufacturer of Simple Distillation Unit in Vadodara, Gujarat, India. Distillation Unit: This complete set features high quality borosilicate glass parts and all the hardware necessary for simple distillation.

 

Simple Distillation Unit is a system in which two fluids can be separated with various boiling points. Simple distillation (the procedure outlined below) can be used effectively to separate liquids with at least 50 degrees of difference in boiling points.

 

These are first heated in a flask in order to separate two or more liquids by quick distillation. Usually, the more volatile fluid (the liquid with the lower boiling point) evaporates first, and the vapor falls into a condensing column where it can revert to a liquid (condense) on the cool glass walls and then flow into a collection vessel.

 

Salient Features :

• Reactor up to 500-liter capacity
• ” ZERO” Hold Up with Temperature Sensing Valve
• Quick Closer for the addition of Solid
• Visual monitoring of the process, improving safety and reliability of production
• Dual functional heating & cooling oil/water bath
• Can be designed for the batch as well as continuous operations
• All wetted parts are made from Borosilicate Glass, and PTFE, providing universal corrosion resistance
• Low CAPEX, and easy to maintain
• Wide range of operation -90°C to +250°C available on request

Reflux Reaction Distillation Unit is a flexible unit that can be used either as a Reaction Distillation Unit, Fractional Distillation Unit or as a combination of both. It incorporates all characteristics of the Reaction Distillation Unit and Fractional Distillation Unit.

 

Reflux Reaction Distillation Unit Glass Reactor Pilot Plant Manufacturer & Supplier.  Units are available in 50, 100, and 200 liters up to 500 liters in vessel sizes. Suitable for atmospheric pressure and full vacuum operations.

 

This system can be used as a breakdown or distillation or as a mixture of both reactions. The Reflux Reaction Cum Distillation System is available with high capacity, reliable efficiency, long service life, high reliability, and competitive market prices.

 

We are committed to providing our customers with a broad range of reflux reaction and distillation systems. The provided distillation unit is commonly used for the study and processing of the distillation material in various laboratories.

 

The term reflux has been used in many industries using columns and fractionators for large-scale distillation, such as oil refineries, petrochemical, chemical, and gas plants.

 

In this sense, reflux refers to a part, as shown in the scheme of a typical industrial distillation column, that of the overhead fluid component of a distillation column or fractionator which is returned to the upper portion of the column. The downflowing reflux fluid in the column provides the up flowing vapors with cooling and condensation, thus increasing the distillate column efficiency.

 

Salient Features :

• Reactor up to 500-liter capacity
• ” ZERO” Hold Up with Temperature Sensing Valve
• Quick Closer for the addition of Solid
• Visual monitoring of the process, improving safety and reliability of production
• Dual functional heating & cooling oil/water bath
• Can be designed for the batch as well as continuous operations
• All wetted parts are made from Borosilicate Glass, and PTFE, providing universal corrosion resistance
• Low CAPEX, and easy to maintain
• Suitable for installation in fume hoods
• Zero Hold-up in reflux
• Wide range of operation -90°C to +250°C available on request

Sulfuric acid finds its application directly and indirectly in the manufacture of fertilizers, dyes, intermediates, and many others. Commercial Sulfuric acid is typically available as 98% w/w concentration. Several applications of Sulfuric acid involve the use of medium or high concentration acid, which ends up as relatively dilute acid by picking up water from the reaction. This dilute acid may be concentrated to bring it to the desired concentration level and recycled in the process. This takes care of an effluent problem and also, reduces the requirement of fresh make-up acid.

 

Sulfuric acid is highly toxic and corrosive and reacts readily with metals, depending on its strength and operating parameters. Thus, very few Material of Construction are compatible to handle, process and store Sulfuric acid. Thus, special design and special knowledge are required to set up and operate plants handling Sulfuric acid.

 

Ablaze has a long and successful record of design and supply of several Engineered systems for mineral acids. Being manufacturer of Borosilicate Glass equipment, PTFE components and PTFE lined components, Ablaze is well qualified to handle such systems as these are the major Material of Construction used in such systems. Ablaze also has in-house capabilities for Instrumentation and Automation, which is necessary for reliable and safe operation.

 

Custom made designs are offered for Sulfuric Acid Concentration Plant, depending on the initial and final concentrations of acid, heating medium and cooling medium available, etc.

 

The process basically involves boiling of Sulfuric acid to preferentially evaporate water. The process scheme and operating parameters are selected based on several factors like plant capacity, feed composition/ impurities, initial and

final concentration, utilities available etc.

 

A typical and generic flow scheme is shown for a Concentration of Sulfuric acid. The actual process scheme is decided based on the above factors

 

Feed Dilute Acid is fed to the Evaporator/ Boiler at suitable operating pressure. The preferentially evaporated water is

condensed in a condenser and the condensate collected.

 

Multiple stages and Vacuum operation may be considered depending on final strength, utilities available and the plant capacity. At higher concentrations of acid, proper demister needs to be provided to avoid carryover of Acid Mist

Bromine industry is an important part of big chemical family. Bromine and bromine compounds have wide application in different fields. Primary using of bromine compounds are in flame retardants, drilling fluids, brominated pesticides (mostly methyl bromide), and water treatment. Bromine is also used in the manufacture of dyes, insect repellents, perfumes, pharmaceuticals, and photographic chemicals. Other bromine compounds are used in a variety of applications, including chemical synthesis, mercury control, and paper manufacturingBromine is existing in the sea bittern, as well as Industrial effluents e.g. Aq. HBr Aq. NaBr Aq. KBr. The Bromine concentration in the feedstock varies from 2 gl to 300 gl from industry to industry.Ablaze Offer suitable bromine recovery plant for the various feedstock based on his know-how in this field. ABLAZE suggest both process Hot and cold process for bromine concentration as per gl. Steaming Out Process (Hot Process) : The process is also known as Hot Process because chlorination of bittern is done with simultaneous steam blowing by means of live steam to heat the bittern to near its boiling point to set free the finished product Bromine. Air Blowing Process (Cold Process) : This process is known as Cold Process because the finished product Bromine is set free from bittern by chlorination and air blowing under cold conditions.

Sulphuric acid is an essential product of the chemical industry, and is deployed in the most several of processes. It is used in many organic processes as a catalytic agent for synthesis processes or to dry gases such as chlor, bromine, or chloromethane, whereas in the fertilizing industry, sulfuric acid is a basic ingredient for the final product. Ablaze deal in two types of Sulphuric Acid Chemical Plant that includes :Sulphuric Acid Concentration plantSulphuric Acid Dilution plant Benefits of Industrial Sulphuric Acid PlantHigh product quality is guaranteed, as glass is completely inert to sulphuric acidAvailable in wide range of concentrations and capacitiesSimple and easy to operateOperational reliability due to maintenance free in workingCorrosion Resistant

Distillation is a separation technique used for separating two immiscible liquids based on the difference of their boiling points. Our Automated Continuous Distillation Unit allows the user to define and control the parameters of distillation process, carry out calculations on the data fed manually or automatically received from the process instruments and even save the data and results for evaluation or future use. Application:Our Automated Continuous Distillation Pilot plant finds its application at various levels:1) Industrial R&D sectorsfor separating two immiscible liquids having different boiling points, for concentrating chemical solutions by distilling off water from the solution, studying the process variables by defining and controlling other parameters.2) Educational Laboratoriesfor understanding of students and carrying out experiments such as distillation with defined reflux ratio, distillation at defined operating pressure, pressure drop across column, calculation of relative volatility, calculation of column diameter, etc. We offer two types of Absorption column: Packed column (Different packing can be provided such as Raschig rings, Pall rings, Intalox saddles etc.)Sieve Tray column (Sampling points and thermometer pockets can be provided at different trays so that the tray hold-up can be collected for further evaluation, if required.)

Sulphuric acid is a heavy chemical and finds numerous applications in the industry. It is the product of Contact Process and commercially available as 98.5% (ww) H2SO4 or stronger in the form of oleum. However, many of the processes and applications utilizing sulphuric acid require weaker acid than this. As a result, dilution equipment is often necessary in order to meet the requirement for this weaker acid. During dilution, considerable heat is generated depending on the extent of dilution desired. The Integral heat of solution of sulphuric acid is plotted in fig.1. The heat liberated sometimes is sufficient to produce boiling of the acid and so, provision is made for the re-circulation of a portion of cooled dilute acid, thus ensuring working at controlled temperature. From the above it will be clear that intimate mixing and efficient heat transfer form the pre-requisites for sulphuric acid dilution unit to avoid excessive temperature and local heating and uniform product concentration. Process DescriptionMetered quantity of sulphuric acid is introduced to a heat exchanger with re-circulation of water through a pump from the tank containing pre-determinant quantity of water. The turbulence created in the heat exchanger ensures both intimate mixing and efficient heat transfer. When desired strength of acid is reached, the contents of the tank are transferred to storage and fresh batch can be started again.

The Short Path Molecular Distillation system is primarily used in pilot or lab-scale production. Particularly, to compile the parameters from the experiments before moving into production.

 

The Glass Short Path Distillation System (SPD) has the following advantages over the Stainless Steel Short Path Distillation System (SPD);

 

Following Advantages :

• Concerning the same production capacity, the price of a Stainless Steel SPD system is almost twice as compared to the Glass SPD system.
• Installation of the Glass SPD system is a lot easier as it requires only two people and 1 hour to finish installing.
• The Glass SPD system will be delivered to you in mere 20 days, whereas the Stainless Steel SPD system takes around 60 days or more to get delivered.
• The Glass SPD system is much lighter in weight, occupies smaller space, and is quite easy to move as compared to the Stainless Steel SPD system.
• The Glass SPD system is transparent, and it self-adjusts the circumstances of an experiment a bit quickly, depending upon the situation.
• The Glass SPD system is considered much more durable than the Stainless Steel SPD system concerning anti-corrosion abilities.
• For the Research and Development procedure or the pilot procedure, the Glass SPD system works better, whereas, for large-scale production purposes, you can opt for the Stainless Steel SPD system.

 

Principle

In the liquid-liquid separation process, the Short Path Distillation System must be used;

• When the material’s boiling temperature is too high to evaporate?
• When boiling temperatures of 2 materials are too close to be separated clearly?
• When the material is sensitive to heat and easy go denatured in distillation?
• When a rectification process takes a long time but with the poor receiving rate?

 

Suitability

The Short Path Distillation System is also known as Molecular Distillation System. The Short Path Distillation System is exclusively a new substance separation technology that helps in separating liquid-liquid mixture under any temperature lower than the boiling point.

 

Short Path Molecular Distillation is highly suitable for the process of separating the substances that have a high boiling point, is sensitive to heat, and quite easy to be oxidized.

 

Advantages of Short Path Molecular Distillation

• Experience and Flavor, both are consumer-oriented advantages; however, for the producers, many other benefits come after they employ a Short Path Wiped Film Distillation method or a Short Path Distillation method.
• The other extraction or separation processes tend to use heated beakers. However, the continuous feed also grants your production a compelling degree of scalability, which is not an option for those with the batch mode stills.
• A higher rate of evaporation will allow you to capture more distillates. In contrast, the low processing temperatures ranging between 130-180°C also adds up to the fact that not many solvents are required to move the extracted material during the process.
• The Short Parth Molecular Distillation system will extensively separate cannabis into the highly concentrated CBD and THC distillates. The Short Path Distillation process may result in 99% pure cannabis distillates. Hence, if you wish to produce a purified CBD product, you are highly advised to opt for the Short Path Molecular Distillation process, as it is the commonly accepted method for such processes.
• The Short Path Distillation System is known for its sleek and compact design and is an ideal choice for those who want to use it for massive operations where significant quantities of multiple strains are extracted.
• Last but not least, all these machines are highly comfortable to work on and are fully automated in their functions. 

Organic solvents are widely used in the industry. As a significance, large amounts of liquid waste with various solvents or other impurities must be disposed of. We can recover and recycle your waste solvents back into product grade material. Our solvent recovery plant offers a unique service for the handling, cleansing, purification and recycling of a wide range of solvents. Potentially harmful substances can be cleaned and purified, reducing the need to manufacture virgin solvents from non-renewable resources. Solvent recovery and recycling is achieved through a distillation process that separates the pure solvent from contaminants. We offers tailor-made systems that reduce both the need of fresh solvents and the amount of contaminated solvents:Continuous or Batch distillationRectification in vacuum and pressure systemsExtraction processesDesigning ensures consistency in product outputOffering a comprehensive process and application technology know-how.

Industries conduct a variety of processes as a result of which Hydrogen chloride is formed as a waste gas or a by-product. Every country has its strict guidelines concerning their emission levels for hydrogen chloride that helps maintain the HCL waste gas levels. It can be achieved by conducting the scrubbing process that will take out all the waste gas by absorbing it and producing a hydrochloric acid by-product.

 

Hydrogen chloride is believed to have a high inclination towards the water. It can be absorbed easily as long as an acceptable method is identified to establish contact between the gas and the water. Hydrogen chloride absorption into the water may emit a significant amount of heat that must be removed from the system. Maximum concentration can be achieved theoretically as it relies on the temperature as well as considering the partial pressure of HCI present in the exhaust gas while entering the plant.

 

The suitability of the HCL absorption process depends upon a specific application concerning the nature of the feedstock and the requirement of the product. The three fundamental types of the HCL Gas Absorber are Continuously, or Batch wise operated scrubbers, Adiabatic and Isothermal absorbers.

 

Adiabatic Type

HCL Gas absorber systems are useful in absorbing the Hydrochloric gas which is legally not allowed to let out free into the atmosphere, as it may help in producing the Hydrochloric acid.

 

Hydrogen Chloride is considered to be highly soluble in water. Still, the absorption process is convoluted by the extreme heat of solution and the partial pressure coming over the warm concentrated solutions. Practically, the fundamental problem you will face while making concentrated solutions is to have an efficient heat removal process. Using this type of absorber will help you absorb the heat and remove it via the evaporation process of water and acid in the system. The condensed vapor is then diluted along with the makeup, and hence most of it is removed through the condenser. Cooling and the concentration of the liquid phase are supported by the water evaporation process to preserve the vapor-liquid equilibrium levels in the lower part of the section.

 

Working Principle of HCL Gas Absorber

Hydrogen chloride has the best soluble properties and inclination towards the water; it becomes easy for the absorption process to get accomplished effortlessly. The Hydrogen Chloride absorption into the water can emit a tremendous amount of heat, and this heat needs to be disposed of from the system, or else it may cause considerable damage to the system. The maximum concentration can be achieved theoretically as it relies on the temperature as well as considering the partial pressure of HCL present in the exhaust gas while entering the plant.

 

The suitability of the HCL absorption process depends upon a specific application concerning the nature of the feedstock and the requirement of the product.

 

Types of HCL Gas Absorbers

The three kinds of HCL Gas Absorbers are as follows

• HCL Scrubbers operated batch-wise.
• Adiabatically - Continuously operated.
• Isothermal absorbers. 

 

Table

The column mentioned below is built with a series of packed sections, which has a gas introduction point, a Condenser, and a Cooler. In this process, the water is poured from the top, and the acid gets collected at the bottom.

 

HCL absorption columns vary in sizes and are available in the sizes ranging between 80DN to 300DN diameter, where the gas rate varies between 10 Kgs/hr to 300 Kgs/hr approximately.

Efficient gas absorption depends on the following:

• Intimate Contact
• Efficient Heat Transfer

This is achieved in a Falling Film Absorber which is essentially a shell & tube heat exchanger in which both gas to be absorbed and absorbing liquid flow co-currently downward with the extraction of heat by circulation of coolant in the shell. The absorbing liquid is circulated through a tank till the desired concentration is achieved. The liquid flows at such a rate that the tubes do no flow full of the liquid but instead, descends by gravity along the inner walls of the tubes as a thin film. Obviously, this produces a much greater linear velocity for a given rate flow that could be obtained if the tube flowed full.

 

The equipment works as a number of water cooled-wall columns in parallel and each tube is provided with distribution system on top to effect uniform distribution of both liquid and gas and also the formation of a thin liquid film on the inner surface of the tube.

 

Other Area of Applications :

• Hydrogen Chloride Gas / Sulphur Dioxide Gas Absorption
• Hydrogen Chloride Gas / Chlorine Gas Absorption
• Hydrogen Bromide Gas absorption
• Hydrogen Chloride Gas / Chlorine Gas / Sulphur Dioxide Absorption

 

Salient Features :

• High absorption efficiency
• High acid concentration is achievable
• Low outlet temperature
• Easy operation and maintenance
• Safe Operation due to a low isothermal temperature
• Handle a wide range of gas loading with minimum liquid flow rates to maintain full tube wetting
• Variation in Hydrogen Chloride Gas flow rates or Composition causes no operation problem.
• All the wetted parts of the falling film absorber are corrosion resistant to all the aggressive gases even at elevated temperatures