Background Information:
Catalysts are substances that increase the rate of a chemical reaction without altering the overall standard Gibbs free energy change of the reaction. Alternatively, they can be defined as substances that accelerate chemical reactions without shifting the chemical equilibrium, and whose mass and chemical properties remain unchanged before and after the reaction.
It is estimated that catalysts are employed in over 90% of industrial processes, including chemical, petrochemical, biochemical, and pharmaceutical manufacturing, as well as environmental protection.A multinational company specializing in the manufacturing and trading of active pharmaceutical ingredients (APIs) and intermediates utilizes a process where solid and liquid phases react in the presence of a catalyst to form an acidic mixed solution. The liquid phase is clarified through filtration and recycled, while the solid-phase catalyst must be recovered and reused.The current process employs a two-stage filtration system comprising a plate filter and a bag filter. These filtration units require manual operation for cake discharge and cleaning between batches, leading to high labor and maintenance costs. Additionally, the company faces rising expenses for disposing of consumables such as used filter cloths and bags. The process also involves handling toxic and hazardous solvents, which pose potential health risks to personnel and environmental concerns.To enhance production efficiency, there is an urgent need for a more efficient filtration solution.
Solution:
Through communication with the company's process manager, we recommended a fully automatic candle filter device. The system uses PLC automatic control and is safe, efficient, and pollution-free. Its filter medium can be reused, saving a lot of consumables.
To verify the system's filtration effectiveness, a small sample test was conducted, achieving the desired results.
A systematic project renovation was then carried out. Due to the highly corrosive nature of the solution, the filter body was constructed from F40
stainless steel with a lining, the filter elements were constructed from PVDF and PTFE, explosion-proof electrical components were selected, and
compliance with GMP standards was ensured.
Result Feedback:
Fully automatic control significantly improves production efficiency;
Improves catalyst recovery efficiency and reduces material loss;
Eliminates human contact, improving product quality;
Fully enclosed design ensures safe production and eliminates odor spillage;
Pressure backflush drains dry catalyst, minimizing liquid loss and ensuring environmental friendliness;
Ensures operator health and minimizes environmental pollution;
No moving parts, resulting in low failure rates and low operating costs;
Food-grade certification and compliance with GMP standards.
