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Yulaibo Technology (Beijing) Co., Ltd
Thin film evaporation system
NegotiableUpdate on 05/07
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Overview
Thin film evaporation system is a separation and concentration equipment designed based on the principle of efficient heat and mass transfer. It forms a thin and uniform liquid film on the heating surface of the material to achieve rapid evaporation, separation, and purification. It is widely used in various industrial fields such as chemical, pharmaceutical, food, and environmental protection. This system, with its compact structure, gentle processing method, and wide material adaptability, has become an ideal choice for handling various thermosensitive, high viscosity, and easily crystallizable materials. It can effectively solve the pain points of low heat transfer efficiency, long material residence time, and easy scaling of traditional evaporation equipment, and help upgrade the energy-saving and refinement of production processes.
Product Details
Introduction to Thin Film Evaporation System Products
Thin film evaporation system is a separation and concentration equipment designed based on the principle of efficient heat and mass transfer. It forms a thin and uniform liquid film on the heating surface of the material to achieve rapid evaporation, separation, and purification. It is widely used in various industrial fields such as chemical, pharmaceutical, food, and environmental protection. This system, with its compact structure, gentle processing method, and wide material adaptability, has become an ideal choice for handling various thermosensitive, high viscosity, and easily crystallizable materials. It can effectively solve the pain points of low heat transfer efficiency, long material residence time, and easy scaling of traditional evaporation equipment, and help upgrade the energy-saving and refinement of production processes.
The system core is composed of multiple functional units that work together, with clear division of labor and smooth connection between each unit, ensuring the stability and efficiency of overall operation. The specific composition is as follows:
1. Feeding unit: As the material input end of the system, it is mainly responsible for the storage and stable transportation of the solution to be processed. The unit is equipped with dedicated liquid storage containers, which can store materials of different volumes according to production needs. At the same time, with precise conveying components, the material feeding speed can be smoothly controlled to avoid affecting the evaporation effect due to feeding fluctuations. The feeding unit is also equipped with a pre-treatment structure, which can perform preliminary filtration on the material to remove solid impurities and prevent impurities from entering subsequent units, causing equipment blockage or affecting product purity.
2. Evaporation unit: It is the core working area of the entire system, responsible for the key tasks of material liquid film formation and evaporation. The main body of the unit is a closed heating container, and the inner wall of the container is made of materials with excellent thermal conductivity. The outer side is equipped with a uniform heating structure, which can achieve stable heat transfer. There is a dedicated film-forming component inside the container. After the material enters, it is uniformly spread into a thin and turbulent liquid film under the action of gravity and machinery. The thickness of the liquid film can be flexibly adjusted according to the characteristics of the material to ensure sufficient contact between the material and the heating surface, thereby improving heat transfer efficiency.
3. Separation unit: closely connected to the evaporation unit, used to separate the secondary steam generated during the evaporation process from the unevaporated liquid phase material. The unit is equipped with an efficient separation structure that can quickly separate steam from droplets, avoiding steam carrying droplets and reducing product purity, while also minimizing material loss. The separated liquid phase material can be refluxed to the evaporation unit for further processing according to demand, or directly transported to the subsequent collection unit to achieve full utilization of resources.
4. Condensation unit: mainly responsible for condensing the separated secondary steam into liquid state for subsequent recovery or processing. The unit is equipped with an efficient condenser, which achieves rapid condensation of steam through sufficient contact between the cooling medium and steam. The condensed liquid can be transported to a storage container through a dedicated pipeline for solvent recovery or material purification. The condensation unit is also equipped with a temperature regulation structure, which can flexibly control the condensation temperature according to the characteristics of the steam, ensuring the stability of the condensation effect.
5. Vacuum unit: used to maintain the vacuum environment inside the system, reduce the boiling point of materials, achieve low-temperature evaporation, especially suitable for the processing of thermosensitive materials. The unit is composed of components such as vacuum pump and vacuum buffer tank, which can stably control the vacuum degree inside the system, reduce the residence time of materials in high temperature environment, avoid thermal decomposition, carbonization and other phenomena of materials, while improving evaporation efficiency and reducing energy consumption.
6. Control and Monitoring Unit: Responsible for the operation regulation and status monitoring of the entire system, equipped with intuitive display and operation interfaces, which can monitor key indicators such as temperature, pressure, feed rate, liquid level, etc. in real time within the system. Operators can set operating parameters through this unit to achieve automated operation of the system. At the same time, when there is an abnormality in the system, a prompt will be issued in a timely manner, which is convenient for operators to quickly investigate and handle, ensuring the continuity and safety of production.
The workflow of the thin film evaporation system is simple and efficient, and the entire process can be automated and continuously operated. The specific steps are as follows:
1. Material preparation: Inject the solution to be processed into the storage container of the feeding unit, remove impurities through a pre-treatment structure, and ensure that the material meets the processing requirements; At the same time, check the connection status of each unit in the system to confirm that the heating, cooling, vacuum and other systems are normal and error free.
2. System startup: Start the vacuum system through the control unit and evacuate the system to the set vacuum environment; Simultaneously activate the heating system to preheat the heating container of the evaporation unit until it reaches the set temperature; Start the cooling system to ensure that the condensing unit is in normal working condition.
3. Feeding and evaporation: The pre treated material is smoothly transported to the evaporation unit through the conveying component of the feeding unit; After the material enters, a uniform liquid film is formed along the inner wall of the heating container under the action of the film-forming component; The liquid film rapidly evaporates under heating, producing secondary steam that flows upward and enters the separation unit.
4. Separation and Condensation: The separation unit separates the secondary steam from the unevaporated liquid phase material. The unevaporated material flows back to the evaporation unit for further evaporation, while the secondary steam enters the condensation unit; In the condensation unit, steam comes into full contact with the cooling medium, condenses into a liquid state, and is then transported to a dedicated storage container.
5. Finished product collection and system shutdown: When the condensed liquid or evaporated concentrated material meets the set requirements, it is transported to the finished product storage container through a dedicated pipeline; After production is completed, shut down the feeding, heating, vacuum, and cooling systems in sequence, clean and maintain each unit to ensure stable operation of the equipment next time.
The core advantages of this system are reflected in its mild operation, wide adaptability, energy saving and high efficiency. The specific details are as follows:
1. Gentle treatment to protect material characteristics: The system adopts a vacuum low-temperature evaporation mode, which can effectively reduce the boiling point of materials. At the same time, the residence time of materials in the evaporation unit is short, only a few seconds to tens of seconds, which can reduce the thermal decomposition of thermosensitive materials, preserve the effective ingredients and original characteristics of materials, and is suitable for the treatment of thermosensitive materials such as antibiotics, vitamins, and fruit juice.
2. Wide material adaptability and flexible processing capacity: It can handle various materials with different characteristics, including solutions with high viscosity, easy crystallization, easy scaling, and easy foaming, without the need for frequent adjustment of equipment structure; At the same time, according to production needs, parameters such as feed rate and evaporation temperature can be flexibly adjusted to adapt to different processing capacities and product requirements, which can meet the research and development needs of small-scale laboratories and large-scale industrial production.
3. Energy saving and efficient, with controllable operating costs: Due to the thin liquid film and large heat transfer area, the heat transfer efficiency is much higher than traditional evaporation equipment, which can achieve rapid evaporation at lower temperature differences and reduce the consumption of high-temperature heat sources; At the same time, the equipment structure is compact, the supporting auxiliary equipment has a small volume, and the overall system energy consumption is low; In addition, the system is less prone to scaling and blockage, reducing the frequency of shutdown cleaning, lowering maintenance costs, and minimizing losses caused by production interruptions.
4. Easy to operate and stable in operation: The system adopts an automated control design, and operators only need to set relevant parameters to achieve continuous operation throughout the process, without the need for complex manual adjustments; Each unit adopts standardized component design, with a simple structure, easy maintenance, convenient replacement of vulnerable parts, and long-term stable operation, reducing the workload of operators.
5. Good separation effect and high product purity: The efficient separation structure of the separation unit can effectively avoid steam carrying liquid droplets, ensuring high purity of the condensed solvent or concentrated material. The solvent recovery purity can reach a high level and can be directly recycled, which not only improves product quality but also achieves resource recycling, in line with the concept of green production.
The application scenarios of thin film evaporation systems cover multiple industries, including: in the pharmaceutical industry, they are used for the concentration and purification of bioactive substances such as antibiotics, vitamins, amino acids, as well as the separation and treatment of pharmaceutical intermediates; In the food industry, it is used for the concentration of liquid foods such as fruit juice, syrup, dairy products, etc., to preserve the flavor and nutritional content of the food; In the chemical industry, it is used for concentration and solvent recovery of high-value chemicals, dye intermediates, etc; In the environmental protection industry, it is used for the treatment of saline wastewater and organic solvent wastewater, reducing the volume of waste liquid and lowering treatment costs.
working principle
Thin film evaporation
On the cylindrical inner surface of the heated evaporator, a rotating film scraping system scrapes the raw material into a uniform thin film. The scraping film system can create good turbulence effects on the liquid film, optimize heat and mass transfer processes, and greatly improve evaporation efficiency. The low boiling point components in the raw materials evaporate from the liquid film in a short period of time. The residence time of materials in the evaporator is very short. The evaporated light component gas is condensed in an external condenser. The concentrated heavy phase is continuously discharged from the bottom of the evaporator.
In thin film evaporators, high viscosity materials and materials that are prone to crystallization can be processed.
The operating pressure inside the thin film evaporator can be as low as 1mbar.
Advantages of thin film evaporation
>Continuous distillation process
>Short material retention time
>High evaporation rate
>Due to low operating pressure, the required heating temperature is low
>Can handle high boiling point and high viscosity materials
>Thin film evaporators can be connected to distillation columns with a certain theoretical number of trays
>The inner wall of the evaporator is not prone to scaling
Short-range distillation
>A short-range evaporator is a device that integrates a thin film evaporator and a condenser. The steam of light components is condensed on the condenser built into the short-range evaporator.
>The path between the evaporation surface and the condensation surface is very short, so the pressure drop in the gas phase is very low.
The advantages of short-range distillation
>Continuous distillation process
>High turbulence and high evaporation rate: The scraped film always maintains a high turbulence state, increasing the transfer of mass and heat
>Short dwell time: reduces the thermal stress of the product
>One step distillation: no need for circulation
>Forming a very thin liquid film on the inner wall of the evaporator: without the influence of static liquid level height
>No product coking: Due to the high turbulence of the thin film on the heated evaporator, the product will not remain on the surface of the evaporator
>Distillation of high viscosity products is possible: a specially designed scraper system is provided
>Low operating pressure: A low operating pressure can lower the boiling point of a substance, up to 0.001mbar (0.1Pa)
>The device design is very compact
Comparison Table of Different Distillation Methods
| Comparison of different distillation methods | Ordinary distillation | Thin film evaporation | Short-range/molecular distillation |
| The time during which the material is heated | Very long (in hours) | Very short (tens of seconds) | Very short (tens of seconds) |
| 真空度 | Generally (several to tens of mbar) | Very high (1mbar) | Very high (0.001mbar) |
| Required evaporation temperature | high | relatively low | very low |
| Separation of thermosensitive materials | not suitable | suitable | Very suitable |
| For the separation of materials that are prone to foaming | not suitable | Very suitable | suitable |
| Can continuous distillation be carried out | cannot | can | can |
| Concentration or separation of high viscosity samples | not suitable | Very suitable | suitable |
| Solvent removal efficiency | general | Very good (unlimited external condenser area) | Good |
TF40Thin film evaporation or MD52 molecular distillation system
| Distillation subject (choose 1 from 2) | TF40 Thin Film Evaporator Body | Zui has a high temperature resistance of 350 ℃, a scraping speed of 100-500rpm, an evaporation area of 0.04 ㎡, an evaporation capacity of 0.1-1.5L/h, a condensation area of 0.2 ㎡, Zui has a large material viscosity of 1000cp, and the contact material material is 3.3 high borosilicate glass&1.4571 (316Ti) stainless steel |
| Main body of MD52 molecular distillation apparatus | Zui has a high temperature resistance of 350 ℃, a scraping speed of 60-500rpm, an evaporation area of 0.052 ㎡, an evaporation capacity of 0.1-2L/h, a condensation area of 0.08 ㎡ (molecular distillation has low vapor pressure, high efficiency, and does not require a large condensation area), Zui has a high material viscosity of 5000cp, and the contact material material is 3.3 high borosilicate glass&1.4571 (316Ti) stainless steel | |
| Evaporator heating module (choose 1 from 4) | ITHERM-B1 circulating water bath | Zui High Temperature 100 ℃, Heating Power 1.5KW, Stability ± 0.05 ℃ |
| DD-BC4 circulating oil bath | Zui high temperature 200 ℃, heating power 2KW, stability ± 0.01 ℃ | |
| MS-BC4 circulating oil bath | Zui High Temperature 300 ℃, Heating Power 2KW, Stability ± 0.01 ℃ | |
| MX-BC4 circulating oil bath | Zui High Temperature 300 ℃, Heating Power 3KW, Stability ± 0.01 ℃ | |
| Condenser cooling module (choose 1 from 2) | CS3 cooling cycle generator | -20 to 100 ℃, cooling power 300W, with heating, flow rate 10L/min |
| FL300 Cooling Recirculator | -20 to 40 ℃, cooling power of 300W, lower noise, flow rate of 15L/min | |
| Vacuum module (choose 1 from 3) | SXD. 4 anti-corrosion diaphragm pump+vacuum gauge+vacuum regulating valve | The system has a low vacuum degree of up to 20mbar, corrosion resistance, and low noise |
| Cold hydrazine module+R-8D rotary vane vacuum pump+vacuum gauge+vacuum regulating valve | The system's lowest vacuum degree can reach 0.05mbar | |
| Cold hydrazine module+R-8D rotary vane vacuum pump+oil diffusion pump+vacuum gauge+vacuum regulating valve | The lowest vacuum degree of the system can reach 0.001mbar | |
| Feeding module (choose 1 from 2) | 500ml feeder, needle valve controls flow rate | The S-shaped circuit structure of the needle valve ensures system vacuum under continuous distillation conditions and allows for real-time addition of materials |
| 1000ml feeding tank+high-precision gear pump+one-way feeding valve continuous feeding kit | - | |
| Discharge module (choose 1 from 2) | Triple splitter+250ml collection bottle 2+4000ml collection bottle 1 | Clear fractions can be collected under two conditions without releasing vacuum |
| High precision gear pump continuous discharge kit for heavy and light components | The discharge speed is continuously adjustable, and the discharge accuracy is 0.1Hz |
Product application areas
| Oils and Foodstuffs >Separate free fatty acids from edible oil and fish oil >Removing insecticides from edible oil and fish oil >Purification of sterols >Concentrated monoglyceride >EPA and DHA in concentrated fish oil esters >Concentrated tocopherol >Concentrated carotene >Removing insecticides from lanolin >Improvement of Lanolin Color | Petrochemical products >Separation of Microcrystalline Wax from Vacuum Residue of Crude Oil >Refined synthetic and petrochemical wax >Coal chemical industry >Cutting of different grades of Fischer Tropsch synthetic wax |
| polymer >Purification and concentration of monomers for polymers >Purification and concentration of polymers >Removing solvents and monomers from polymers | |
| Chemical, agrochemical, and pharmaceutical products >1,4-Butanediol (BDO) refining >Polyethylene glycol (PTMEG) refining >Purification of polyformaldehyde >Purification and refinement of lactic acid >Purification and Distillation of Caprolactam >Concentrate and purify dimeric fatty acids >Removing volatile components from organosilicon and organosilicon resins >Concentrated insecticides, fungicides, herbicides >Concentrate and purify glycerol >Fractionation and removal of low boiling point components from natural wax >Free removal from isocyanate prepolymers (such as HDI, MDI) >Remove solvent >Deodorization and removal of pesticide residues >Improvement of Lanolin Color >Purification of Acrylic Acid and Acrylic Esters >Distillation and refining of pharmaceutical intermediates >Purification of active ingredients in traditional Chinese medicine extracts >Purification of CBD | Essence and spices >Purified tobacco extract >Purification of essential oils for tobacco use >Removing terpenes and concentrating essential oils >Purifying aromatic substances in essence >Concentrated Lemon Flavor >Concentrated pepper and chili extract |
| Recycling and reusing >Recycling and refining waste lubricating oil, brake oil, glycerin, and transformer oil >Recycling and processing of pharmaceutical process mother liquor >Recycling organic intermediates |
