Chemical grade filtration, washing and drying machine

Product Detail

In the post-treatment processes of the production of pharmaceuticals, pesticides, explosives, dyes, pigments and other fine chemicals, there are often unit operations such as filtration, washing and drying. These unit operations are usually operated independently by unit equipment such as centrifugal filters, washing tanks and dryers, and materials are conveyed between the equipment through pipelines or other means. Large-scale devices with multiple unit equipment connected into a system, long processes, low efficiency and difficult-to-regulate production processes, for suspensions with high solid content, often cause solid adhesion to the wall and blockage of pipelines, making normal production difficult. Although open production is convenient for dealing with clogging problems, it is difficult to meet the specification requirements for pharmaceuticals, food, biological products, etc. Moreover, for flammable, explosive, toxic or highly toxic materials, there are also safety hazards.

In order to overcome the problems and deficiencies existing in the above-mentioned unit equipment combination and meet the transformation of the chemical industry towards high quality, high added value, multiple varieties and small batches, our company has carried out a large amount of design and research and development work. Finally, we have successfully developed a multi-functional cylinder-cone reaction filtration and drying machine integrating filtration, washing and drying, achieving a significant improvement in the technical performance of the equipment. From structural design to application, it closely follows the corresponding regulatory requirements of the pharmaceutical industry. This equipment has three main functions: filtration, washing and drying. It also has multiple functions such as reaction, extraction, crystallization, concentration, evaporation, mixing and crushing. It is a high-tech device and has the following advantages:

(1) Closed operation, with multiple process procedures completed within the same equipment, reduces the impact of dust and microorganisms on material quality, minimizes the loss of valuable materials, and thereby enhances product quality and output.

(2) Reduce the material conveying links, especially the conveying of filter cakes, shorten the production cycle and enhance production capacity.

(3) Filtration and washing operations can be carried out under vacuum or pressure, and the process operation is flexible and easy to control.

(4) For the handling of flammable, explosive, toxic or highly toxic dangerous goods, reduce environmental pollution, improve the working environment and ensure operational safety.

(5) Short processes, reduced equipment, less factory space, and lower engineering investment.

Structure and Principle of Chemical-grade filtration, washing and drying machine

The filtration, washing and drying machine (commonly known as "three-in-one" in the industry) can achieve continuous processes such as filtration, washing, drying, sterilization and unloading of materials. Its operation mode belongs to batch operation (intermittent operation), and it is widely used in the fields of pharmaceuticals, food, pesticides, chemicals, etc. The filter washing and drying machine is mainly composed of the vertical tank body of the pressure-bearing part, the heating system, the stirring system (stirring shaft, stirring paddle, mechanical seal, etc.), the stirring lifting mechanism, the transmission mechanism, the filter medium, the discharge valve, the spray device, the sterilization device, the hydraulic pump station, the main electrical control cabinet (including frequency converter, PLC), and other components, achieving the integration of machinery, electricity and instrumentation.

After the basic operation processes such as filtration, washing, drying and solid unloading of a batch of materials are completed, the filtration, washing and drying machine can still use solvents to dissolve the materials that need further treatment and continuously carry out the next operation process.

The process flow of chemical-grade filtration, washing and drying machine

(1) Filtration

The solid-liquid mixture slurry produced by the upstream reaction vessel or crystallization equipment is fed into the tank of the three-in-one equipment, and the solid-liquid mixture is filtered and separated by the pressure difference as the driving force. In practical applications, there are pressure filtration, vacuum filtration, and combined pressure and vacuum filtration forms, etc. Pressurization and filtration use clean compressed air, nitrogen or other inert gases. The specific type of compressed gas should be selected based on the characteristics of the solid-liquid mixture. For instance, if a solid-liquid mixture is prone to oxidation or contains explosive media, compressed air cannot be used; instead, inert gas should be selected. Based on practical experience, in the pharmaceutical industry, a filtration pressure of 0.2 to 0.3MPa is generally sufficient for general products to achieve filtration. In the chemical or food industry, some products require a higher filtration pressure, with some reaching up to 1.0MPa.

(2) Washing

After the filtration process is completed, the next process operation, namely washing, needs to be carried out. The three-in-one equipment tank is equipped with a specially designed spray device, which can evenly distribute the cleaning (washing) liquid in the tank. By turning on the stirring system, the stirring lifting mechanism and the transmission mechanism, the blades can rotate and move up and down axially, ensuring that the materials are thoroughly washed and the impurities adhering to the surface of the grains are removed. The washing liquid used for washing and the number of washes should be determined according to the characteristics of the material and the production process.

(3) Drying

The drying process of the three-in-one equipment can adopt hot air drying or vacuum drying. When using hot air drying or vacuum drying, clean inert gas must be used because dust will be generated during the drying process. It is necessary to consider that the operating environment of the equipment is explosion-proof. At present, the mainstream drying process for the three-in-one equipment is vacuum drying. The main factors influencing the vacuum drying process are vacuum degree, drying time, and the characteristics of the stirring paddle, etc.

The vacuum drying process uses a vacuum system to extract the inert gas inside the tank, reducing the number of gas molecules and isolating it from air. It is mainly suitable for materials that are prone to oxidation and deterioration, as well as for materials where solvents need to be recovered during evaporation and heat-sensitive materials. Under vacuum conditions, the chance of material contamination by bacteria can be reduced or the growth of certain bacteria can be inhibited. Therefore, it is particularly suitable for the drying of sterile materials.

Performance features of chemical-grade filtration, washing and drying machine

In recent years, chemical-grade filtration, washing and drying machines have been rapidly promoted and applied due to their superior performance of being able to complete filtration, washing, drying, sampling, automatic discharge and cleaning in the same container. They have gradually replaced traditional crystallization and drying production equipment such as centrifuges, suction filtration tanks, box-type vacuum dryers and double-cone rotary vacuum dryers. Become a new type of equipment for fine chemical filtration and drying production.

(1) Multi-functional integration and continuous operation

The three-in-one equipment completes the processes of stirring, filtration, washing and drying in a single closed device, thus avoiding the mixture of foreign substances and microbial contamination during the material transfer process, and fully ensuring the product quality.

(2) The equipment has a simple structure, which improves the production environment

The three-in-one equipment completes the entire process from feeding to the discharge of the finished product after drying in one device, significantly reducing the total number of required process equipment and achieving the function of one machine equivalent to multiple conventional filtration devices. As the entire operation is carried out in a sealed state, neither liquids, gases nor dust are discharged into the clean room, and there are no factors that cause pollution or harm to the human body.

(3) The process flow is simplified, the floor space is small, and the capital investment is saved

Filtration, washing and drying can be completed in the same system, and the factory space is also maximized. In an era where land is extremely precious, the volume of the required clean factory can be greatly reduced, the basic investment cost is low, and a large amount of capital investment can be saved. This process is more suitable for the needs of large-scale production. It shortens the process, reduces equipment, saves factory space, lowers engineering investment, and at the same time improves product quality, reduces labor intensity, and has good economic and social benefits.

(4) Fully enclosed production process, solvent recovery and utilization

The three-in-one system of filtration, washing and drying is a fully enclosed system. Operating in a closed system can prevent toxic substances from polluting the air and reduce the occurrence of poisoning accidents among operators. The dried products can be mechanically conveyed to weighing, packaging and other sections. The materials and solvents are almost completely recycled, avoiding waste caused by material omission and solvent evaporation.

(5) Clean production, thorough cleaning

The three-in-one filtration, washing and drying system is equipped with a dust collector to collect the dust generated after drying, which can meet the production requirements of clean type. The system is equipped with automatic spraying and stirring functions, which can thoroughly clean the filter cake, thereby reducing the amount of sewage discharged and lowering the cost of wastewater treatment.

Technical Parameter Table of Chemical Grade Filtration, Washing and Drying Machine