Industrial Pharmacy

EQUIPMENTS USED
IN MASS AND HEAT
TRANSFER IN
PHARMACEUTICAL
INDUSTRY
To: Ma’am Anum

Submitted by
Sherazar Amjad
Muhammad Mukhtar
Muhammad Mursaleen
Muhammad Jawad
Iqra Niazi
MASS AND HEAT TRANSFER EQUIPMENT
IN PHARMACEUTICAL INDUSTRIES
Mass transfer is the net movement of mass from one location, usually meaning stream, phase, fraction
or component, to another. Mass transfer occurs in many processes, such as absorption, evaporation,
drying, precipitation, membrane filtration, and distillation.

And Heat transfer is a discipline of thermal engineering that concerns the generation, use, conversion,
and exchange of thermal energy between physical systems. Heat transfer is classified into various
mechanisms, such as thermal conduction, thermal convection, thermal radiation, and transfer of
energy by phase changes.

Equipments used in Mass transfer:

For Distillation

Distillation is one of the most reliable, cost-effective methods of chemical separation and is a
crucial step or “unit operation” in a wide range of industrial processes. Thermal Kinetics provides
both “Modular” and “Field-erected” Distillation systems that support many industries.

Distillation is a separation processes involving both Heat and Mass transfer. While there are many
methods for separating chemical compounds, distillation has been proven to be the most reliable
and economical design for many applications.

Within the pharmaceutical industry, distillation is generally utilized to efficiently remove one or
more solvents or to exchange solvents in preparation for isolation of an active ingredient or
intermediate.

Distillation Columns

A Distillation Column is essentially used for the

distillation of liquid mixtures. This separates the
mixture into its component parts or fractions.

The Distillation Columns are used for varied

purposes, depending upon the desired liquid
holdup, capacity (flow rates) and pressure drop. To
meet the requirements of our esteemed clients,
these are available in diverse specifications and
designs.
Single Stage & Multiple Stage Separation Processes
Before delving into the specifics of the distillation process and design considerations, it is
important to first establish the difference between single and multiple stage separation processes
in general.

One single stage of separation is defined as evaporation or more specifically but not commonly
termed “Flash Distillation.” In this process one volatile component is removed in a solution by
heating and consequently boiling the solution. The more volatile component in the solution is
vaporized and removed from the process.
Multiple effect evaporation applies several stages of evaporation in the separation process. In
multiple effect evaporation the process is limited by the sequential process design. Distillation
employs the same multi-stage principle in countercurrent stages to allow for a more efficient
process minimizing waste from the system.
Graphical Method for Continuous Distillation: The McCabe-Thiele Diagram
Developed in 1925 and still used today, the McCabe-Thiele diagram evaluates the separation of
components in a binary system. This x-y diagram simplifies some variables to provide a quick,
high-level evaluation of a simple distillation based on established Vapor/Liquid Equilibrium (VLE)
data. While useful in providing a visual representation of the distillation process, this graphical
method is limited to analyzing two variables.

Modern Solutions

For more complicated distillation systems with three or more components, computer-based
simulation software is used in the design process. Two popular brands of software are Aspen and
ChemCad. The software programs allow designers to select an appropriate VLE model for the
mixture and generate accurate predictions and distillation stage calculations.

The more complex systems also may require pilot testing for final design validation. Thermal
Kinetics can help develop Pilot Testing Equipment unique to a given test system. These pilot runs
provide valuable data for statistical analysis and development of a more robust simulation model.
These customized solutions are invaluable for more complex systems that can otherwise be
difficult to validate.

The Distillation Design Process

Regardless of the specific models used, the overall design process follows a standard practice.
The general steps are as follows:

1. Evaluate the vapor-liquid equilibrium data

2. Calculate the necessary equilibrium stages

3. Determine tray hydraulics

 4. Select the appropriate tray or packing efficiencies

The use of hand calculation procedures is justified in cases when an engineer is tasked with: rough
system cost analysis, general valuation of operating variables, separations with coarse purity
requirements, designs for ideal and close-to-ideal systems.

Conversely, a rigorous design approach is used for several situations:

• Designing a system that deviates significantly from ideal behavior or the lack of good VLE
data

• High product purity requirements

• Highly precise cost estimate requirement

• Multicomponent distillation with a tight range of component boiling points

Thermal Kinetics will often advise the use of Pilot Testing in a variety of situations, especially
when a design carries a performance risk.
For Drying

Dryers are used to remove liquids or moisture from bulk solids, powders, parts, continuous
sheets or other liquids by evaporation or sublimation. Dryers can be broken up into two
main types: direct and indirect. Direct dryers convectively heat a product through direct
contact with heated air, gas or a combusted gas product. Indirect dryers conductively heat
a product through contact with a heated wall.

There are various types of Dryers used in Pharmaceutical Industries

▪ Fluid Bed Dryers

▪ Tray Dryer
▪ Belt Dryer
▪ Vacuum Tray Dryer
▪ Spray Dryer
▪ Rotary Dryer

Belt Dryer
Belt dryer is continuous drying equipment. Belt Dryer is widely used for chemical, food,
pharmaceutical industries. It is especially suitable for drying raw materials that are
good in breathability and in the shapes of piece, strip or granule. It is also possible to
dry the pasted raw material such as filter cake after shaped through granulator or
extruder.
▪ In the Belt dryer, the raw material to be treated is distributed on the conveyor belt
through right mechanism such as star distributor, swing belt, crusher or
granulator.
▪ The conveyer passes through the channel consisting of one or several heating
units, which are equipped with air heating and circle system. Each channel has
one or several damp discharge systems.
▪ When the conveyer passes through it, hot air will pass through the raw material
up and down. In this way the raw material can be dried evenly.
GRAPHITE MASS TRANSFER EQUIPMENT:
GAB Neumann offers a wide range of
graphite mass transfer equipment for the
most corrosive applications in the
pharmaceutical and the chemical
industries. Our product portfolio includes
absorbers, columns, quenches,
hydrochloric acid recovery units, sulfuric
acid dilution units and well as vacuum jet
pumps.

Materials
• Impervious graphite: GAB GPX1,
GPX1T or GPX2
• Shell, Pressure plates and
flanges: carbon steel or stainless
steel
• Tie rods, nuts, bolts, washers, and
springs: stainless steel
• Tanks, containers, and piping:
PTFE lined steel or Fiber
Reinforced Plastic
Key features
• Design pressure: -1 barg (full vacuum) to +10 barg (145 psig)
• Design temperature: -60 to +200°C (-76 to 392°F)
• Design: according to European PED, ASME code, Chinese Pressure
Vessel code and other national pressure vessel codes on request
Main applications:
• Absorption, washing or quenching of ultra-corrosive gases
• Recovery of spent acids
• Generation of dry hydrochloric acid
• Dilution of sulfuric acid
• Vacuum generation in ultra-corrosive environment
Servo-hydraulic press HV255.45
DESCRIPTION
This model introduces the fourth punch on the horizontal plane, in order to improve
the performance for multi forging stroke and the machine is prepared to 255×255 die
dimensions also, so you will be able to forge a wider range of parts than H205 series,
with a compact furnace for diameters up to 45mm, Neotecman presents a flexible all-
in-one forge system. This approach improves the energy consumption, and provides
to this series the chances to produces slightlest parts with the use of more cilynders
to decrease the weight. Moreover, Neotecman’s design is based in a double structure
for press and furnace, that includes the assembly of a robot to offer a multiple billet
positioning in the press, simetric billets, diferent orientations or multiple billets at the
same time.
PUNCHES - 4 horizontal + 1 vertical (option)
PRODUCTION (empty) - From 500 to 4.000 parts/hour
BAR DIAMETER - From 12 to 45 mm (From 0.47 to 1,77 in)
BAR LENGTH - To 4.000 mm (To 2.65 lb)
DIE DIMENSONS - 255 x 255 mm
Equipments used in Heat Transfer
Plate and frame heat exchanger
The concept behind a heat exchanger is the use of pipes or other containment vessels to heat
or cool one fluid by transferring heat between it and another fluid. In most cases, the
exchanger consists of a coiled pipe containing one fluid that passes through a chamber
containing another fluid. The walls of the pipe are usually made of metal, or another
substance with a high thermal conductivity, to facilitate the interchange, whereas the outer
casing of the larger chamber is made of a plastic or coated with thermal insulation, to
discourage heat from escaping from the exchanger.

Most of the heat exchangers used in industry are shell and tube, air cooled, or plate and frame.
Typically, plate and frame heat exchangers are used for liquid-liquid exchange at low to medium
pressures. However, gasket-free plate and frame heat exchangers can safely operate at high
temperatures and pressures. Plate and frame heat exchangers offer flexibility because plates can
be either added or compressed for each different situation.
Plate and frame heat exchangers are made of corrugated plates on a frame. This design creates
high turbulence and high wall shear stress, both of which lead to a high heat transfer coefficient
and a high fouling resistance. Fluids travel within the heat exchanger. The two streams flow
counter currently. The hot fluid flows down one plate while the cold fluid flows up the other
plate.

Gaskets ensure that the cold fluid and the hot fluid don’t mix. Alternatives to the traditional
gasket seal include brazing and laser welding.
The plates are stacked in an alternating manner to cause the counter current flow. Multiple plates
are clamped together and sealed at the edges. The design allows for the two fluids to flow in
alternate directions and not be mixed. However, heat can be transferred from one medium to
the other through the plates.
Because gasketed plate and frame exchangers are easy to clean, they are especially useful for
food and pharmaceutical processing, where high degrees of sanitation are required.
Insulating plate and frame heat exchangers
Heat exchangers must be adequately insulated to reduce heat losses. Because inspection and
maintenance of heat exchangers is routine, stay-in-place insulation is not practical. Generally,
heat exchanger experiences touch temperatures that differ from the ambient temperature,
valuable heat is likely radiating away. In the cases of larger heat exchangers or facilities with
multiple units, the amount of energy loss can be substantial.
Insulation coatings are a possible solution however it has to be reapplied each time maintenance
is performed which is costly & labor intensive. Custom fit removable and reusable insulation is
the most economic & efficient way to insulate heat exchangers allowing for easy on & off
application as maintenance is required.

Gasketed plate heat exchangers

In a gasketed plate heat exchanger, the plates are fitted with elastomeric gaskets which seal the
channels and direct the fluids into alternate channels. The plate pack is assembled between a
frame plate and a pressure plate, and compressed by tightening bolts fitted between these
plates. The channel plates and the pressure plate are suspended from an upper carrying bar and
located by a lower guiding bar, both of which are fixed to the support column. The physical
design of the gasketed plate heat exchanger allows easy cleaning, and modification of capacity
by the addition or removal of plates. Liquid/Liquid GPHE
Liquid/Liquid GPHE
This animation above shows the working principle of an Alfa Laval liquid/liquid 1-pass gasketed
plate-and-frame heat exchanger where the fluids run counter-currently through the heat
exchanger. The hot liquid (illustrated in red) normally enters through one of the upper
connections and leaves through the connection underneath. The cold liquid (illustrated in blue)
enters through one of the lower connections and leaves through the
connection above.

As the fluids pass through the heat exchanger, heat is transferred from the hot media to the cold
media. Counter current flow enables maximum heat recovery possibilities and very close
temperature approach can be achieved. Temperature cross is also possible, meaning that the hot
outlet can reach a lower temperature than the cold outlet. This can only be achieved to a limited
extent with tubular heat exchangers making plate-and-frame heat exchangers more thermally
efficient.

The fluids enter through the connections and portholes of the heat transfer plates. Specially
designed sealing gaskets located between the plates direct the fluids so that the hot and cold
fluids pass counter-currently in alternating channels. When the fluid enters between the plates,
it passes over the distribution area. Alfa Laval offers two types of distribution areas: our patented
CurveFlowTM and the chocolate pattern. The distribution area is one of the most important
features of a plate heat exchanger. Its main purpose is to ensure an even flow of fluid over the
entire plate while maximizing heat transfer efficiency and minimizing maldistribution and fouling.
In the animation you can see that the distribution area helps the fluids to quickly fill up the entire
cross section of the plates.

For very heat sensitive media, co-current flow is used in gasketed plate-and-frame heat
exchangers. The benefit with this design is that the coldest fluid meets the hottest fluid when
entering the heat exchanger, minimizing the risk of overheating or freezing sensitive media. In
the animation you can imagine that the hot fluid is reversed, so that both fluids are entering at
the bottom connections.

The animation shows the working principle of a conventional gasketed plate-and-frame heat
exchanger, but the same working principle is applicable also to specialized ranges such as our
Semi-welded and WideGap plate heat exchangers.

Alfa Laval has an extremely broad range of gasketed plate-and-frame heat exchangers which are
used in all types of industries. The number of sizes, plate and gasket materials and available
options are enormous.

The Spiral Heat Exchanger

In applications prone to high fouling, consider using a spiral heat exchanger. Its single-
channel
design minimizes fouling and erosion and helps ensure high flow velocities even with
heavy process slurries.
A spiral heat exchanger consists of two long flat plates wrapped around a mandrel or
center tube, creating two concentric sprial channels.
Heat exchanger fouling is a major source of maintenance costs and lost production time.
It has been estimated that fouling costs U.S. industry more than $5 billion annually. Over
time, as material builds up on the heat transfer surfaces of a typical heat exchanger, an
insulating layer is formed that reduces the heat transfer rate and increases pressure drop
through the exchanger. Eventually, the heat exchanger must be cleaned to restore the
heat transfer rates and pressure drops required by the process. With many traditional heat
exchanger designs, cleaning is

timeconsuming and costly, and it may need to be performed frequently. A spiral heat
exchanger can help processors avoid these problems.

A spiral heat exchanger is a useful alternative to shell and tube designs for many applications
prone to fouling and plugging problems. For more than 60 years, it has been used in difficult
services ranging from PVC slurry coolers to asphalt heaters. Its flow-channel geometry and
single-
channel design induce highly turbulent flow, so the compact exchanger can operate reliably with
low fouling rates even in heavy fouling, fibrous or slurry duties. It can be opened quickly and
easily for inspection, cleaning and maintenance.
In a spiral heat exchanger, the hot fluid flows into the center of the unit and spirals outward toward
the outer plates while at the same time, the cold fluid enters the periphery and spiral inward,
exiting at the center.

Welded Plate Heat Exchanger

Fully welded plate heat exchanger is a plate heat exchanger made of a series of
corrugated metal plates welded by laser or argon arc welding. The plate group and the
plate group are connected by welding with molding strips. Because there is no gasket
seal, it has higher temperature and pressure resistance. It can be applied to extreme
working conditions of high temperature and high pressure.
Fully welded plate heat exchangers are divided into non-detachable fully welded plate
heat exchangers, 2-sided detachable fully welded plate heat exchangers, 4-sided
detachable fully welded plate heat exchangers (Compbloc) and wide channel fully welded
plate heat exchangers

Tubular Heat Exchanger

Heating or cooling water for injection (WFI), purified water (PW), distilled water,
and products of biotechnology or pharmaceutical industry, as can be glucose,
emulsions and cosmetics, among others.
Other equipments are used also such as incubators, ovens, distillators etc...

References

Google Scholar

https://www.pharmaceuticalmachinery.in/

Thermopedia.com

Cower.com

Researchgate.net

Process-heating.com