Conical three-in-one multi-functional equipment for filtration, washing and drying

In the post-treatment processes of the production of active pharmaceutical ingredients, pesticides, explosives, dyes and other fine chemicals, there are often unit operations such as reaction, crystallization, filtration, multiple washing and filtration, and drying. These unit operations are usually operated independently by unit equipment such as reaction vessels, crystallization tanks, filter presses or centrifugal filters, washing tanks and dryers A large device with a long process is formed by connecting multiple unit devices. Materials are conveyed between the devices through pipelines or other means. Each unit operation corresponds to the corresponding unit device. The equipment is highly dispersed, and leakage at the connection points of the equipment causes material and environmental pollution.

The integrated filtration, washing and drying machine integrates multiple unit operations in the post-treatment process of fine chemical production into one device. This equipment can successively complete the entire process of filtration, washing, drying and solid unloading in a closed environment, avoiding product transportation loss and contamination during process conversion. It features a fully enclosed and fully automatic design, making operation convenient. It is highly suitable for the production of fine chemicals, pharmaceuticals and their intermediates, as well as flammable, explosive and highly toxic special chemicals.

There are numerous types of multi-functional filtration, washing and drying machines available on the market for the fine chemical industry's refining and purification. However, most of the existing varieties have the following drawbacks:

(1) The conventional stirrer cannot ensure that the materials are thoroughly mixed during the washing, filtration, drying and other processes without rapid and uniform stirring.

(2) The washing effect is poor. Conventional stirrers cannot crush and loosen the crystal filter cake, causing it to mix with the cleaning solution in a paste-like or sludge-like state. The crystals are stirred and cleaned through stirring.

(3) The filtration is not thorough, the filter cake material layer is thick, and the filtration area is small. When producing high-demand and high-efficiency products, the filtration needs to be used multiple times, which wastes time and resources.

(4) The operation is inconvenient and the filter is difficult to clean after use.

(5) The drying rate is slow. The integrated filtration, washing and drying machine is equipped with a filtration device. Although it has an outer jacket heating, the heat transfer effect is relatively low.

(6) It is impossible to achieve the closed and automatic turnover of materials

The main limitations of traditional flat-bottomed filtration equipment such as tank-type three-in-one and vertical dryers are that during the final unloading of materials, the operation is complex and it is difficult to completely discharge the materials. Each unloading process not only takes a long time but also causes a large amount of material residue, affecting the yield and easily leading to the leakage of organic solvents. The key point is that the bulk materials formed after the unloading of the above-mentioned traditional equipment are mostly transported to the next packaging process by manual material drums. The materials need to cross multiple production sections, and during the transportation process, it is easy to cause secondary pollution and safety accidents of the materials, thus not meeting the requirements of fine chemicals for fully enclosed production throughout the process.

(7) The rotary joint for the main shaft heating is prone to sealing leakage problems

Conventional rotary joints adopt a spherical sealing structure, achieving sealing by the mutual compression of the contact surface of the spherical surface (concave-convex balls). This can easily lead to scratches on the sealing surface of the rotating shaft, sudden temperature changes causing the spring to become weak or the sealing components to thermally deform, jamming of the support ring or guide ring, leakage of the main sealing element, and restrictions on the axial displacement of the shell at the connection points of the inlet and outlet hoses. This leads to the accumulation of tolerances in the shell, causing deflection and resulting in leakage and other phenomena.

Based on new process technology and rich production experience, Wuxi Srui has continuously improved and innovated, and finally successfully developed a conical three-in-one filtration, washing and drying system that integrates filtration, washing and drying. It has also successfully applied for multiple patents (Patent No. (ZL 202022908020.2, ZL 202022906527.4), improve the filtration, washing and drying effects of the existing three-in-one multi-functional equipment, and solve the problem of low production efficiency of the current technology.

Technical features of conical filtration, washing and drying three-in-one

(1) The production system process is fully enclosed

Due to the innovative application of the fully enclosed material conveying system, a fully enclosed production process from crystallization to the end of packaging can be fully realized. The conical filtration, washing and drying three-in-one system operates in a fully enclosed manner, and the production process is more in line with GMP requirements and standards.

(2) Safety and environmental protection

Due to the fully enclosed operation of the conical three-in-one, it can completely avoid the pollution of the operating environment air by solvents during the production process, and at the same time reduce the occurrence of poisoning accidents of operators caused by contact with toxic substances. Today, with the growing calls for environmental protection and labor protection, this advantage becomes even more important.

(3) High-speed washing: As this equipment can re-stir and re-suspend the filter cake during the washing operation, the filter cake can be thoroughly washed.

(4) Operate under pressure or vacuum conditions to achieve solid-liquid separation. During filtration, the filter cake is evenly distributed and the solid-liquid separation effect is good.

(5) The material is heated in the container by closely adhering to the inner wall of the container and rotating upward from the inner heating ribbon to the upper part of the container, and then moving downward in a vortex along the main shaft. The material is constantly in a dispersed motion throughout the entire drying process, ensuring balanced heating.

(6) Clean production. The conical filtration, washing and drying three-in-one system can operate in a closed manner and is equipped with a dust collector to completely collect the dust generated after drying, which can meet the production operation requirements of high cleanliness.

(7) The product yield is high and the solvent recovery is complete. Because the entire production system operates in a fully enclosed manner, materials and solvents can be 100% completely recycled, avoiding waste caused by material omission, residue and solvent evaporation. This brings significant economic benefits, especially when handling materials and using solvents of high value.

(8) It has a high degree of automation and is easy to master. Each process is carried out in stages, with complete safety measures. Operators can complete the operation after simple training, and the work intensity is greatly reduced.

(9) For materials with strong corrosiveness, the interior of the equipment can be lined with corrosion-resistant materials. The stirring shaft, mechanical seal and discharge ball valve components are made of special alloys with excellent corrosion resistance.

(10) Before filtration, stirring, mixing and pulping can be carried out in the machine body. After filtration, various process operations such as cleaning, regeneration and drying can be performed in the machine body. It features simplified process flow, enhanced production efficiency, prevention of material contamination, convenient material replacement, and integration of mechanics and electronics. At the same time, it significantly reduces the factory area for the entire production process, lowering the basic investment cost for customers.

Flow chart of the conical filtration, washing and drying three-in-one process

Wuxi Shuangrui is committed to promoting technological innovation in closed-loop circulation dryers and multi-functional filtration, washing and drying machines, and values the full trust given by customers. Intellectual property rights are the common lifeline of Shuangrui Machinery and its customers. At Wuxi Sunray, we adhere to the foundation of our business as honesty and dedication, and maintain a zero-tolerance policy towards infringement. We resolutely crack down on any criminal acts that infringe upon intellectual property rights. This is the supreme responsibility, obligation and commitment of Wuxi Sunray. We must sincerely repay our customers' trust and completely eliminate any infringement.