Heating & Cooling Solution

Traditional Heating & Cooling Systems

Active Pharmaceutical Ingredient (API) manufacturing involves batch reaction, work-up, distillation, crystallization, hydrogenation, layer separation, filtration and drying as unit processes. Again, batch reaction involves heating and cooling stages ranging from -50^oC to +250^oC. Traditionally, this was being done with multiple utilities such as chilled brine, chilled water, cooling water, hot water, low pressure steam, high pressure steam, thermic fluid etc.

Limitations :

• Different heat transfer fluids (HTFs) may require separate coils, heating and cooling jacket zones or external heat exchangers.
• Time consuming changeover of HTFs and associated risks of human error.
• Cross contamination of HTFs.
• Multiple utilities can corrode the reactor jacket.
• Condensate recovery is not feasible.
• Inefficient management of HTFs leading to inaccurate temperature control.
• Process parameter deviations adversely affect product quality.
• Complicated mechanical design, and Increases capital/maintenance costs.

Solution :
Single fluid heating cooling systems (SFHC) / Temperature Control Unit (TCU) are coming-up as an ideal solution to overcome most of the limitations with traditional multiutility based heat transfer and control system. where high accuracy and wide temperature ranges are critical for the development of new compounds and API's.

How it Works? :
Single fluid heating cooling system is normally connected to a single reactor, where the Temperature of the system is varied as per the process requirement, Thus maintaining the constant temperature difference between the process and fluid temperature.

This gives precise control over heating and cooling cycle. Thus, not only the temperature is controlled as a critical process parameter but also the heating-and-cooling time is controlled as a critical parameter. This results in batch-to-batch consistency and higher yield.

Features :

• Temperature range - 35°c to 250°c with precise temperature control, +/-1°c.
• Rapid heating or cooling, reducing batch time.
• All wetted parts are in stainless steel.
• Totally enclosed skid & mounted on wheels for easy mobility.
• No switching between jacket service fluids, preventing cross- contamination, corrosion or thermal shocks to the vessel.
• Remote control panel with flameproof enclosures (suitable for gas group IIA, IIB)
• Automation - System is controlled by PLC system which can be integrated with SCADA

Advantages :

• Accurate temperature control to +/-1^oC without risk to your reactor.
• Rapid heating and chilling profiles can be designed, reducing batch times.
• Repeatability and accurate recordable.
• Measurement for meeting FDA requirements.
• Programmable heating and cooling ramps for accurate unsupervised operations.
• No switching between jacket service fluids, preventing cross contamination, corrosion or thermal shocks to the vessel.
• Smooth, continuous temperature control, with no gaps because there is no fluid changeovers.
• No interruption of process and no hot spots, resulting in higher product yields and quality. Off batches are minimized, if not eliminated.
• Savings on expensive raw materials can be made because the yield is maximized without adding excess reactions.
• Suitable for the very cold operating temperatures required by today’s new chemical formulae and reactions.
• Fully automatic capability, hence less manpower required.

Usage :

• SFHC / TCU finds its purpose in various temperature based applications like,
• Crystallization Reactions - For better productivity
• Non - Aqueous Reactions: Critical application where Aqueous utilities are to be not used for heating/cooling, which leads to hazardous conditions (e.g. reactions which involve materials like Sodium) - For Safety
• Metal Reactions - For better batch-to-batch repeatability
• Alternate Heating & cooling process application (where utility change over is a wastage of time & tiresome job)
• Applications where sudden temperature rise, causing thermal shocks.
• Multi product plant

Why Us? :

• Pioneers in SFHC / TCU for the last 10 years.
• Pharma Process domain expertise.
• Prompt service support with dedicated servicing team.
• Swift response for the customer queries through dedicated technical team.
• Customer friendly.
• Competitive pricing.
• Right & Reputed international component selection.
• Better delivery periods.
• In-house chemical process engineers.

History

• Hot Water Systems are engineered to provide accurate, reliable and cost effective temperature control for process load.
• The Hot Water System is available for use with plant steam or electricity as the heat source. Both steam and electric units come in
• single and dual zone configurations.
• Flowtech also designs and manufactures specialized equipment for non-standard applications. Our engineers have extensive experience in process chilling and heating applications for such industries as Chemicals, Petroleum, Plastics, Rubber, Paper, Power, Steel, Food And Pharmaceuticals.

Why Hot Water System needed ?

• The temperature in the jacket can be controlled much more accurately with hot water than with steam. This higher degree of control protects against damage to or loss of product through overheating.
• Hot water distributes heat more evenly than steam. This eliminates hot spots which often cause product to bake onto the walls of the vessel, and at worst, ruin the entire batch.
• Hot water ensures a better quality end product. This is particularly important in processes requiring very precise product temperature control.
• In critical processes utilizing glass-lined reactors, steam shocks can damage the glass lining. Hot water allows smooth transitions from heating to cooling with no thermal shock.

Type Of Hot Water System

• 1. Direct steam heating.
• 2. Indirect steam heating (Using PHE or Shell and Tube condenser).
• 3. Electrical Heating.

Features

• Compact and Complete Package Solution
• Optimum design for the major component of the system – Heat Exchangers
• Made to order solutions to meet all process requirements
• Factory assembled skid for ease of installation
• Unmatched heating control for consistent and desired temperatures
• Hassle free condensate removal and recovery with no energy losses
• Standard units supplied with PID controllers. Special control packages available with PLC systems.

Advantages

• Each Hot Water System is designed to maximize the productivity of the process.
• Kerone quality and reliability provide excellent value for investment.
• Reliable temperature control improves process consistency, reduces scrap, speeds start-up and increases production rates.
• Instantaneously available when you need for fluctuating process loads and urgent demands.
• Ensures accurate temperatures for hot water required for the most heat sensitive processes.
• System designed with heat exchangers with very high heat transfer rates and efficiency.
• Swift & easy installation.
• Single point connections for all utilities
• All units are factory tested prior to shipment

General Specifications

• System Design Pressure - 4 to 5 Kg/cm².
• Max. Steam Pressure - 2 to 3 Kg/cm².
• Max. Cooling Water pressure-2 to 3 Kg/cm².
• Max. Operating temperature - 90°C
• Sizing can vary per application

Necessity of Skid Mounted Reaction Units
Expensive and high-grade products are not produced in large quantities, as they are typical for pharmaceutical industry, & also forfine/special chemical areas. Small, flexible facilities are necessary for these applications, which can be easily cleaned quickly be adjusted for the next product. They need corrosion resistant materials that do not interact with the product and do not contaminate it. In addition, it is frequent that only limited space is available for the assembly of the facility, and therefore compact design is preferred.

Solution
Traditionally, the fine chemical and pharmaceutical industries have favoured batch reaction, so we have provided multipurpose reactors which can perform various chemical reactions. KERONE has developed a systems perspective to reaction technology, whereby a fully functional reaction unit, including peripheral equipment, is built and assembled in our workshop as a skid, then delivered to the customer as a complete operational system.

Features

• Reactor of respective size with Mechanical seal, suitable agitator.
• Motor, Gear Box, Bottom valve & Cladded insulation.
• Main Condenser & Vent condenser with distillate cooler & vapour column from reactor.
• Liquid reactant addition vessel of suitable size.
• Two distillate receivers of suitable size.
• Distillate & reflux lines within skid.
• Vacuum manifold & vacuum lines within skid.
• All valves within skid for process, vacuum & utility lines.
• VFD with Local flameproof panel for speed variation.
• Reactor base lowering system with hydraulic or manual option.
• Skid of suitable size to mount all above equipment together to form "Kilo lab reaction unit".
• Following reactions / Operations could be carried out in the system.
• Any type of reactions involving Liquid – Liquid, Liquid-Solid, Liquid–Gas reactions.
• Any operation like continuous addition of liquid reactant, mixing of the two phase liquids, layer separation etc.
• Any distillation operation involving reflux, moisture separation (Dean Stark), high vacuum distillation etc.
• Any reaction involving highly viscous material, OR crystallization operation.
• Any customer specific requirement could be discussed at the design stage.

Plug & Play Feature

• All the process piping is complete within the skid & requires external connections only.
• Vacuum pump connection to the reactor system needs to be connected at one place only. Distribution of the vacuum within skid is already provided.
• All the cabling within the skid is provided. The customer needs to connect only power connection to the system.
• Condenser utility supply manifold is provided within the skid.
• All the basic requirements of measurement & safety like vent valves.
• Pressure gauges, drain valves & static jumpers are provided with the system.
• Reactor vessel support & platform is provided within the system.

GMP compliant Features

• All the wetted & non wetted parts are of Suitable grade stainless steel.
• All the surfaces are polished to avoid any deposition of the reaction mass on the surface & improve the cleanability of the same.
• All the gaskets used in the system are of PTFE which are very easy to clean. These gaskets are also compatible over wide range of
• temperature & pressure in almost every solvent.
• All the piping & condensers are designed in such a way that there is no any liquid hold up in the system at the end of the batch.
• After every batch the reactor base could be removed very easily & can be cleaned so as to ensure no contamination from previous batch.
• Mechanical seal area of the top dish could be flushed thoroughly from the bottom side. Lantern stool of the agitator could be lifted easily without dismantling any nozzle of the reactor for cleaning purpose.
• We can provide CIP system to flush all nozzles of the reactor using suitable solvents.
• We carry out validation of the system in cGMP point of view & submit all the relevant documents along with the system.

Instrumentation Provided

• Temperature scanner for the temperatures of Vapor, Utility Inlet & Outlet.
• Temperature Control loop with control valve on utility side & profile temperature controller in flameproof construction.
• Pressure control loop with Pressure transmitter & Pressure controller in flameproof construction.
• Compound gauges on reactor, receivers, vacuum manifold.
• VFD with local flameproof panel to operate remotely.
• SCADA system to monitor & record the data

Product Range

• Reactor Capacity - 10 L to 500 L
• Temperature - 90 to + 300 Deg. C.
• Design Pressure Full vacuum to 10 kg/cm2.
• MOC - SS-304, SS-316, Or any other user specific requirement.
• Operating RPM of Agitator 0 - 300 RPM.
• Aagitator can be easily changed with atleast 9-10 types of agitators.

Specifications

• Material : Stainless Steel
• Material grade : SS-304, SS-316
• Operating RPM of Agitator : 0 -300 RPM

Expensive and high-grade products / solvents are not produced in large quantities, as they are typical for pharmaceutical industry & also for fine/special chemical areas. Small, flexible facilities are necessary for these applications, which can be easily cleaned and quickly adjusted for the next product. They need corrosion resistant materials that do not interact with the product and do not contaminate it. In addition, it is frequent that only limited space is available for the assembly of the facility, and therefore compact design is preferred.

Solution

• Traditionally, the fine chemical and pharmaceutical industries have favoured batch distillation.
• Hence we have provided multipurpose distillation unit which can perform various types of distillations.
• KERONE has developed a systems perspective to distillation technology, whereby a fully functional distillation unit, including peripheral equipment, is built and assembled in our workshop as a skid, then delivered to the customer as a complete operational system.

Features

• Reactor of respective size with Mechanical seal, suitable agitator, Motor, Gear Box, Bottom valve & Cladded insulation.
• Column with Collector & Distributor of suitable MOC.
• Main & Vent condenser with product cooler.
• Reflux – Forced / Gravity whichever is suitable.
• Column Packings – Pall Rings, Raschig Rings, Saddles, Structured Packings, etc. with any suitable MOC.
• Rotameters, Temp. sensors with scanner, Pressure / Vacuum Gauges.
• Two distillate receivers of suitable size.
• Distillate & reflux lines within skid.
• Vacuum manifold & vacuum lines within skid.
• All valves within skid for process, vacuum & utility lines.
• VFD with Local flameproof panel for speed variation.
• Reactor base lowering system with either hydraulic or manual operation.
• Skid of suitable size to mount all above equipment together to form "Kilo lab distillation unit".
• SCADA System.
• Many types of Distillation Operations could be carried out in the system like,
  • Simple Distillation.
  • Vacuum / High Vacuum Distillation.
  • Fractional Distillation.
  • Azeotropic Distillation

Plug & Play Feature

• All the process piping is complete within the skid & requires external connections only.
• Vacuum pump connection to the distillation system needs to be connected at one place only. Distribution of the vacuum within skid is already provided.
• All the cabling within the skid is provided. The customer needs to connect only power connection to the system.
• Condenser utility supply manifold is provided within the skid.
• All the basic requirements of measurement & safety like vent valves, Pressure gauges, drain valves & static jumpers are provided with the system.
• Reactor vessel support & platform is provided within the system.

GMP compliant Features

• All the wetted & non wetted parts are of Suitable grade stainless steel.
• All the surfaces are polished to avoid any deposition of the reaction mass on the surface & improve the cleanability of the same.
• All the gaskets used in the system are of PTFE which are very easy to clean. These gaskets are also compatible over wide range of temperature & pressure in almost every solvent.
• All the piping & condensers are designed in such a way that there is no any liquid hold up in the system at the end of the batch.
• After every batch the reactor base could be removed very easily & can be cleaned so as to ensure no contamination from previous batch.
• Mechanical seal area of the top dish could be flushed thoroughly from the bottom side. Lantern stool of the agitator could be lifted easily.
• without dismantling any nozzle of the reactor for cleaning purpose.
• We can provide CIP system to flush all nozzles of the reactor using suitable solvents.
• We carry out validation of the system in cGMP point of view & submit all the relevant documents along with the system.

Instrumentation Provided

• Temperature scanner for the temperatures of Vapor, Utility Inlet & Outlet.
• Temperature Control loop with control valve on utility side & profile temperature controller in flameproof construction.
• Pressure control loop with Pressure transmitter & Pressure controller in flameproof construction.
• Vacuum gauges on reactor, receivers, vacuum manifold.
• VFD with local flameproof panel to operate remotely.
• SCADA system to monitor & record the data

Product Range

• Distillation Capacity - 10 L to 500 L
• Temperature - 90 to + 300 Deg. C.
• Design up to 10 kg/cm2 Pressure to Full vacuum.
• MOC - SS-304, SS-316, Or any other user specific requirement.
• Operating RPM of Agitator 0 - 300 RPM.
• Aagitator can be easily changed with atleast 9-10 types of agitators.