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Technologies

MONTZ Dividing Wall Columns - Separation technology on the rise.

Trend-setting research and continuous improvements to the existing range of services is what has distinguished the Julius Montz GmbH over decades as a creative and innovative enterprise. Today, the company is regarded as one of the leading specialists in the field of fluid separation technology offering a wide range of services and products. One of the key competences is the design and construction of distillation columns with all internals up to the supply of skid mounted distillation units.

Topics like cost and energy savings are increasingly important in chemical industry over many years, especially because fluid separation is particularly effective but also very energy intensive. One possibility to meet these challenges is the application of dividing wall column technology for multi component thermal separation.

For more than 30 years, dividing wall columns are used in the chemical industry. Montz delivered the first dividing wall column and has continuously improved the dividing wall column technology ever since.  With more than 140 dividing wall columns, Montz is the leading global provider of this column system.

Dividing wall columns can be used anywhere when complex mixtures are to be split into pure fractions.  It is particularly advantageous for the production of pure mid-boiling fractions. The separation of a ternary mixture into pure constituents with conventional columns requires a sequential circuit of two columns or a configuration of main columns with side columns.  Using a dividing wall column, this task can be achieved in a single distillation column.

In dividing wall columns, a vertical wall is positioned in the center part of the column shell.  The dividing wall separates the feeding section from the draw-off section.  The gas-tight and liquid-tight dividing wall enables an energy efficient separation of low boiling and heavy boiling components in the feeding section working as a pre-fractionator.  The draw-off section is designed for purification of the mid-boiling species

Such setup saves a second column for purification of the mid-boiling fraction. Column shell, internals, evaporators and condensers of a second column are not necessary.  Further, the control and maintenance efforts are drastically reduced. 

Dividing wall columns are an alternative to multi-column circuits, which reduces investment and operation costs.  As a rule of thumb, investment and operation costs are both reduced by minimum 20 - 30 %.

Montz leading position in the field of dividing wall columns is underlined by a number of patents in the past 20 years, for example the development of a loose dividing wall, which is especially useful for revamps. Also the application range is very wide. Montz delivered dividing wall columns from very small column diameters of 50 mm for pilot plants up to column diameters of several meters for industrial production scale. Due to a close cooperation with the customer an individual solution for every separation problem can be developed.

Contact Pfaudler today to learn more. Montz 

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Innovation

The Disc Turbine use the Bernoulli effect for accelerating the mass flow crossing the glass lined rings.

The mixing process in a batch reactor greatly affects product quality and operating cost. Supported by decades of research and development, pilot testing and real-world application, Pfaudler is designing high performing, highly efficient and cost effective mixing technologies.

Each chemical process is unique and requires a different mixing design. Whether your process is liquid/liquid mixing, solids suspension, high viscous or gas dispersion we provide the solution. 

Round shapes are essential for a save and durable glass lining. However, the shape of the Pfaudler Disc is not only a round one; the turbine is using the Bernoulli-effect which is accelerating the mass flow crossing the glass lined rings. Classical turbine blades are accelerating liquids by pitches and angles. The Pfaudler Disc is stirring the vessel content more gentle with less contact between rotating blades and liquid.

Treatment of products is very smooth and in case of low revolutions / tip speeds, which are recommended for this design, the disc is preferred for suspending, homogenizing, especially shear-sensitive products. The mixing forces will not destroy molecules or gas bubbles. This is because of low shear and low/med. energy dissipation.

The velocities on the wall are not differing significant compared to other turbines so the heat transfer coefficients will not be higher or lower.

In case of high viscosities, multi stage designs are recommended because in case of singe stage designs the flow on top is poor (as known from all other designs of turbines). The limit of single stage design will be roundabout 20 Pas. Multi stage designs can operate up to 50 Pas. In addition, combinations with standard turbines are possible and must be customized depending on process conditions.

Baffling effect can be very low or with low disadvantages also zero. Other vessel geometries like cubes or basins can be treated.

Bottom clearance is higher because of the disc design but also attachable by the well-known Cryo-Lock or forthcoming CryCo lock technology.

A wide range of basic research in classic glass lab vessels and with CFD (Computational Fluid Dynamics) is finished and works standard equipment for vessel BE series is available now.

We have many impeller technologies including pitched blade, curved blade and vertical blade turbine, turbofoil, gas dispersion turbine, anchor and helical ribbon designs, each performing a different function for a specific process in single flight or multiple flight configurations. 

Pfaudler Disc benefits:

• Homogenization
• Operation with or without baffles (no death zones at higher viscosities)
• Solid suspension, especially crystallization
• Low shear / gentle treatment
• No foam, no gas introduction from top
• Low energy consumption, low necessary speed
• Easy to clean
• Low torque moments and forces on gear.

 

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Systems

Sulfuric Acid Concentration and recovery.

Sulfuric acid is a highly corrosive mineral acid with the molecular formula H2SO4.  Sulfuric acid is the most widely produced/consumed chemical at over 200 million tonnes per year.  Chemical plant waste acid streams are often simply neutralized prior to transfer to waste water treatment facilities. Rising operating costs in difficult economical times creates the need to recover the sulfuric acid for further use.  Stricter environmental regulations globally also mandate recovery of sulfuric acid rather than waste treatment.

Pfaudler Technologies

Pfaudler‘s corrosion-resistant materials such as glass-lined steel (Glasteel®), our Edlon fluoropolymer-lined steel technologies and our reactive metals (Zirconium and Tantalum) technologies are required for the safe containment and processing of sulfuric acid.  Pfaudler has the largest number of customer installations of glass-lined and fluoropolymer-lined equipment for corrosive applications in the Chemicals Industry. Pfaudler invented Glasteel® in 1884, pioneered the use of fluoropolymer technologies for process applications with our Edlon division in 1964 and were the first to fabricate process equipment from Zirconium in 1938 in Tantalum in 1946.

Pfaudler Solutions

Pfaudler’s Engineered Solutions Group designs, fabricates and commissions complete process systems with Pfaudler’s Sulfuric Acid Concentration Technology at the core.  At the heart of this Engineered Solutions Group are chemical engineers with vast experience and expertise in all chemical operations, including: Evaporation, Distillation, Mass Transfer, Reaction, Mixing, Heat Transfer, Filtration, Fluid Flow, Drying, and more.

We have designs for concentration up to 96%wt. and capacities up to 1200 MTPD.  These complete systems include the acid concentrator/evaporator plus all ancillary equipment, instrumentation and piping completely assembled on structural steel modules or field fabricated.  Each system is designed specifically for our clients’ process. The layout is custom designed to ensure proper system functionality and to ensure all equipment, instruments and valves are arranged for ease of operation and maintenance.  This single source responsibility ensures the design of every component is integrated into a complete system design to ensure proper system performance.

Benefits

• Efficient compact layouts - to save plant real estate and reduce hold-up volumes.
• Multi-effect design – for operating cost reduction
• Heat recovery options - for energy conservation
• Pilot Test Facility – to confirm performance and collect scale-up data
• Ancillary systems design – organics removal, NOx scrubbers and utility systems
• Field services – installation, maintenance, spare parts

Contact Pfaudler today to learn more. 

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Technologies

EDLON® Pfluoro-Pfix™ Manway shields get damaged glass-lined vessels back on-line quickly

Pfaudler Glasteel™ vessels are the material of choice for the most demanding corrosive chemical processes based on excellent corrosion and temperature resistance properties.  They can, however, be susceptible to mechanical abuse or erosion over time which can damage glass in high use areas such as manways.

While re-glassing is often an option, it is not always a timely solution as the vessel needs to be pulled from operation for a period of time, causing unplanned and costly downtime.

Our engineering, technical services and aftermarket parts & services are ready to keep your chemical & pharmaceutical process systems operating smoothly by proposing a suitable repair method to avoid long downtimes.

Pfaudler can get you up and running quickly with our Edlon Pfluoro-Pfix™ repair shields. 

These repair shields offer the corrosion resistance of glass plus mechanical and thermal shock resistance, thereby providing an economical repair technique that can be performed in the field.  

Our repair shields are isostatically molded PTFE (polytetrafluoroethylene), providing nearly universally corrosion resistance up to 200°C over a wide range of chemistries.  

They are designed to prevent leakage and exterior to improve bonding.  

The molded PTFE has a uniform wall thickness, has a smooth surface finish and is available in a variety of sizes that are stocked on the shelf, ready for immediate dispatch and installation by one of our qualified service specialists.

Edlon also offers a variety of other accessories designed to provide fast and effective repairs for damaged glass-lined equipment to allow time to plan for an outage for reglassing.

Contact Pfaudler today to learn more. 

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Technologies

Robust enamel pH electrodes make economic sense

The Pfaudler glass-lined measurement technology offers decisive benefits in demanding applications where sensitive products are processed.

Online measuring systems have an important part to play in the automated monitoring and tight process control required in chemical processes. 
In addition to liquid analysis, our other instrument technologies include temperature, level detection and corrosion monitoring. 

Pfaudler can demonstrate as the use of glass electrodes has various disadvantages, such as short calibration intervals, potential glass breakage, high sensitivity to CIP/SIP and short life spans, to name but a few. These are compounded by tough demands on their mechanical strength. Glass-lined pH probes from Pfaudler have none of these disadvantages, while their robust construction and glass-lined surface guarantee reliable and more economical production.

A pH probe from Pfaudler comprises a steel probe body with a highly-resistant, anti-adhesive technical glass-lining to protect the surface in contact with the product. Probes can therefore be installed in piping and vessels where they are directly exposed to the flow, enabling constant online measurement in the main product stream. Moreover, the smooth surface the glass-lining gives the probe body protects it against corrosion and product build-up. Thanks to the pressurized electrolyte system, the probes can be installed in any position at the point of use. The safety against glass breakage in the product is a particular bonus in food and pharmaceutical production. 

Pfaudler glass-lined pH probes don’t require regular calibration.

pH measurement systems using glass electrodes have to be regularly removed from the process during CIP or for periodic recalibration – often requiring the use of sophisticated and expensive retractable assemblies. Thanks to their smooth surface, glass-lined pH probes are easy to clean and can remain in the system during CIP cleaning and sterilization. This is in stark contrast to conventional glass electrodes, which usually need to be recalibrated after each sterilization process, and replaced after just a few cycles. Moreover, the calibration values (e.g. slope) of calibrated measuring probes remain constant over the entire lifetime, i.e. the probe does not age. Regular recalibration is therefore unnecessary. The result is significantly higher plant availability, and therefore enhanced productivity and cost-effectiveness. 

Dry storage possible 

Glass probes normally have to be protected against drying out, because this would damage them. This is not a problem for glass-lined measurement probes, which can be stored dry for any length of time without problems. 

Pfaudler Services provide full life cycle support for all our technologies

Product and Application advice - With the wide range of chemistries and processes in the industry, selecting a suitable technology is complex and requires an in-depth understanding of applications and products.

Commissioning, maintenance and training – Our expert technicians provide commissioning and maintenance of complex systems, an essential requirement for ensuring that your  equipment works perfectly and smoothly.

To sum it up – glass-lined probes often pay off after just 1-2 years.

With their extremely smooth glass-lined surface, easy installation directly in the product stream, stable measurement characteristics and lack of sensitivity to CIP processes, glass-lined measurement probes are extremely low-maintenance and long-lasting. The initial investment pays off in just a few years.

You can now calculate online how long the investment in your application will take to pay off.

Check out our life-cycle cost calculator 


Contact Pfaudler today to learn more. 

 

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Services

Modular Bottom Outlet Valves - quick removal of the temperature sensor for re-validating purposes.

The bottom outlet valve on the glass-lined reactor and the valves in the piping are key components for the safe containment of corrosive and hazardous contents. Our high quality, reliable, corrosion resistant valves come with a range of options including pipe-line or equipment mounting, glass-lined or PFA wetted construction and over 4,000 configurations/options.

The calibration of PT 100 sensors in bottom outlet valves, which has to be performed in the course of revalidating process equipment, can often be a problem.  The valve may need to be removed from the reactor and taken to a workshop for disassembly.

With the Pfaudler Valve Series AMA/APA-BT removal of the PT 100 is simplified, the valve does not require removal from the reactor and requires no special tools due to the smart design of the connections between the opening mechanism and the valve stem on both the pneumatic and handwheel opening options.

All components have been designed to avoid the need of additional adjustment work after the reinstallation of the PT 100. And the valve is still absolutely tight of course.

Working with our experienced field service technicians, who understand the difficulties with working in the limited space beneath a reactor, Pfaudler product developers have come up with a design that allows the PT 100 to be easily removed and refitted in even the most restrictive of spaces beneath a reactor.

To enable users to easily upgrade to this new feature, a stocked conversion kit comprising of only a few parts, is available to retrofit to existing valves giving the option to remove the PT 100 sensor from the side. Again, the bottom outlet valve does not need to be removed from the reactor for this purpose. 

Thus, Pfaudler offers not only the most compact and light-weight glassteel bottom outlet valve available on the market, but also one of the most maintenance-friendly ones.

Due to the modular construction, options like diverse temperature measurement, glass testing probes and air actuator extensions etc. can be easily added or even done as an upgrade to existing valves.

The Pfaudler Service teams provide a tailored support for the outlet valve and the glass-lined reactor, keeping the equipment running efficiently, avoiding long downtimes and using appropriate repair methods when things need special attention.

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Contact Pfaudler today to learn more. 

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