Focus on chemical process equipments

Products

Gas Storage Tank

Classification

Types

Orientation

Vertical Air Receiver, Horizontal Air Receiver

Pressure Rating

Low Pressure (0.1~1.6 MPa), Medium Pressure (1.6~10.0 MPa), High Pressure (>10.0 MPa)

Material

Carbon Steel, Stainless Steel, Composite Material

Application

Air Tank, Nitrogen Tank, Steam Accumulator, Process Gas Tank

4. Main Structure and Materials

Main Structure:

Shell: Pressure-bearing cylindrical body.
Heads: Welded at both ends (top andbottom for vertical tanks), typically elliptical or dished.
Supports: Legs for vertical tanks; saddle supports for horizontal tanks.
Manhole / Handhole: For internal inspection and maintenance access.
Inlet & Outlet Nozzles: Threaded or flanged connections.
Drainage Device: Automatic or manual drain valve for condensate removal.
Safety Attachment Ports: For installing safety valves, pressure gauges, level indicators, etc.

Materials:

Carbon Steel : General-purpose material suitable for most compressed air systems.
Stainless Steel : High corrosion resistance, used in food, pharmaceutical, and chemical industries.
Alloy Steel: Applied in high-temperature and high-pressure special conditions.

5. Main Technical Parameters

Parameter	Typical Range	Remarks
Nominal Volume	0.1 m³ ~ 100 m³	Customizable
Design Pressure	0.8 MPa ~ 10.0 MPa	Designed per ASME/GB/T 150
Operating Temperature	-20°C ~ 200°C	Depends on medium and material
Shell Material	C.S. / S.S.	Meets pressure vessel steel standards
Connection Size	DN15 ~ DN300	Flanged or threaded
Design Code	GB/T 150, TSG 21 / ASME	International standards available

6. Features and Advantages

Pressure Stabilization: The buffering capacity reduces compressor loading/unloading cycles and minimizes pressure fluctuations by over 30%.
Energy Efficiency: Reduces compressor start-stop frequency, extending equipment lifespan and lowering overall energy consumption by 5%~10%.
Efficient Condensate Removal: Utilizes cooling and gravity separation to remove approximately 60%~70% of liquid water.
Safety & Reliability:Manufactured in strict compliance with pressure vessel regulations; each unit undergoes non-destructive testing and hydrostatic testing.
Compact Design: Vertical tanks minimize floor space, simplifying installation and maintenance.

7. Applications

Industrial Manufacturing: Automotive, machinery, electronics, textile, glass, ceramics – providing power for pneumatic tools and systems.
Food & Pharmaceutical: Storage and buffering of clean compressed air meeting hygienic standards.
Energy & Chemical: Process gas stabilization, gas distribution stations, nitrogen purging.
Environmental & Water Treatment: Aeration systems, pneumatic valve control.
Construction & Mining: Power supply for pneumatic tools and shotcrete equipment.

8. Safety Accessories and Installation

Safety Accessories:

Accessory	Function
Safety Valve	Automatically releases pressure in overpressure conditions to prevent rupture.
Pressure Gauge	Displays real-time pressure; range should be 1.5–3 times the working pressure.
Drain Valve	Removes condensate regularly to prevent corrosion and capacity loss.
Bursting Disc	Auxiliary overpressure protection device.

Installation Requirements:

Foundation: Vertical tanks must be installed on a level concrete foundation with anchor bolts. Horizontal tanks require saddle supports fully contacting the foundation.
Environment: Install in a well-ventilated, dry area free from corrosive gases. Outdoor installation requires sunshade and rainproof measures.
Piping: A check valve should be installed before the inlet; dryers or filters are recommended after the outlet.
Clearance: Maintain a minimum of 0.5 m around the tank for operation and maintenance access.
Registration: After installation, register the vessel with the local special equipment supervision authority as required.

9. Maintenance and Precautions

Routine Maintenance:

Daily: Check pressure gauge readings; drain condensate manually or automatically 1–2 times.
Weekly: Inspect the safety valve for leakage; monitor for abnormal vibration or noise.
Monthly: Check all flange and valve seals; tighten any loose bolts.
Semi-annually: Calibrate the safety valve and pressure gauge.
Annually: Conduct an external inspection, measure wall thickness, and inspect the anti-corrosion coating.

Precautions:

Never operate the tank beyond its rated pressure. Safety valves must be tested periodically.
Do not weld, cut, or modify the tank structure without authorization.
In case of abnormal noise, severe leakage, or sudden pressure rise, shut down immediately and release internal pressure.
For tanks unused for more than one month, perform an internal inspection and purging before restarting.
Strictly adhere to local regulations such as the “Special Equipment Safety Supervision Regulation” and relevant operating procedures.

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Extraction Column

Two-Phase Flow

The heavy phase (denser liquid, either solvent or feed) enters from the top and flows downward by gravity.
The light phase (less dense liquid, either feed or solvent) enters from the bottom and flows upward due to buoyancy.
Countercurrent flow maximizes the concentration driving force along the column height.

Dispersion and Mass Transfer
Internal components (sieve plates, packing, rotating discs, pulsing devices, etc.) break one phase into small droplets, dispersing it uniformly in the continuous phase. This creates a large interfacial area (typically 500–2000 m²/m³). Mass transfer occurs as solutes diffuse from the feed phase into the extract phase driven by concentration gradients.

Phase Separation
After mass transfer, the two phases separate by gravity in the settling sections at the top and bottom. The light phase is discharged from the top (extract), and the heavy phase from the bottom (raffinate).

Mass transfer performance is typically expressed by Number of Transfer Units (NTU) and Height of Transfer Unit (HTU). A lower HTU value indicates better column efficiency.

3. Main Types and Classification

Based on internal structure and energy input mechanism, extraction towers are classified as follows:

Type	Structural Features	Dispersion Mechanism	Typical HTU (m)	Applications
Spray Column	No internals, nozzle dispersion	Gravity, low efficiency	3.0–6.0	Pre-extraction, low-severity duties
Sieve Plate Column	Multiple sieve plates, inter-plate settling	Orifice dispersion	0.8–2.0	Medium interfacial tension systems
Packed Column	Structured or random packing	Film mass transfer	0.5–1.5	Corrosive media, low interfacial tension
Rotating Disc Contactor (RDC)	Rotors and stators, mechanical agitation	Shear dispersion	0.4–1.2	High throughput, medium-to-high viscosity
Pulsed Column	Pulse generator (mechanical/pneumatic)	Periodic pulsation	0.5–1.2	Small stage height requirements
Reciprocating Plate Column (Karr Column)	Plate stack reciprocating motion	High shear, controlled dispersion	0.3–0.8	Emulsion-prone systems, small diameters

Hybrid designs such as pulsed sieve plate columns and pulsed packed columns combine features to further enhance performance.

4. Main Structure and Materials

4.1 Main Structural Components

Component	Function
Tower Shell	Vertical cylindrical pressure vessel providing mass transfer zone
Liquid Distributors	Ensure uniform distribution of both phases across the cross-section
Internals	Sieve plates, packing, rotor/stator sets, pulse plates, etc., for dispersion
Phase Separation Sections	Enlarged top and bottom sections for gravity separation
Feed Nozzles	Heavy phase inlet (top), light phase inlet (bottom)
Outlet Nozzles	Light phase outlet (top), heavy phase outlet (bottom)
Auxiliary Connections	Pressure/temperature ports, sight glasses, sampling ports, level gauge connections
Agitation/Drive System	Motor, gearbox, seals (for RDC, reciprocating plate columns)

4.2 Common Materials and Selection Criteria

Component	Materials	Typical Applications
Tower Shell	Carbon steel (Q245R, Q345R)	Non-corrosive organic systems
Tower Shell	Stainless steel (304, 316L, 904L)	Mild acids/bases, organic solvents
Tower Shell	Titanium (TA2)	Chloride-containing media, oxidizing acids
Tower Shell	PTFE-lined / Glass-lined	Strong corrosive acids/alkalis
Internals	316L, Hastelloy, Polypropylene	Selected based on corrosion resistance and temperature
Seals	PTFE, Viton, Graphite-filled	High temperature, solvent resistance

For systems containing solids, anti-clogging designs such as large-aperture sieve plates, open-channel packing, or dead-end-free agitators should be used.

5. Main Technical Parameters

The following table lists typical design and operating parameters. Actual values must be determined based on process design:

Parameter	Typical Range	Remarks
Column Diameter	DN150 – DN4000 mm	Smaller diameters (<300 mm) often use reciprocating or pulsed columns
Column Height	3 – 35 m	Depends on NTU and HTU
Height-to-Diameter Ratio	5:1 – 20:1	Affects flow stability
Operating Pressure	-0.095 – 4.0 MPa	Atmospheric to medium pressure
Operating Temperature	-30 – 250 ℃	Limited by material and solvent thermal stability
Throughput	0.2 – 500 m³/h	Single column capacity; can be scaled in parallel
Theoretical Stages	3 – 20	Based on separation requirements
HTU	0.3 – 2.5 m	Varies with column type and system properties
Dispersed Phase Holdup	5% – 45%	Affects mass transfer and flooding limits
Flooding Point	60% – 85% of limiting throughput	Operating margin required
Interfacial Tension Range	1 – 50 mN/m	Lower values risk emulsification; higher values hinder dispersion

Performance Comparison of Column Types:

Column Type	Throughput	Mass Transfer Efficiency	Turndown Ratio	Clogging Resistance	Capital Cost
Spray	Low	Low	Narrow	High	Low
Sieve Plate	Medium	Medium	Medium	Medium	Medium
Packed	Medium	Medium–High	Medium	Low	Medium
RDC	High	High	Wide	Medium	High
Pulsed	Medium	High	Medium	Medium	Medium–High
Reciprocating Plate	Medium	High	Wide	High	Medium–High

6. Features and Advantages

High Mass Transfer Efficiency
Optimized internals and energy input (e.g., high-efficiency packing, RDC, pulsation) can achieve HTU values as low as 0.3–0.6 m, significantly reducing column height and capital investment.
Wide Operating Range
Stable operation between 30% and 110% of design capacity accommodates process fluctuations.
Strong Adaptability
Capable of handling high-viscosity (up to 500 cP), emulsion-prone, solids-containing, corrosive, and heat-sensitive materials. Column type and materials can be tailored accordingly.
Safe, Enclosed Operation
Fully enclosed design minimizes solvent loss and exposure, suitable for flammable, toxic, or hazardous media. Nitrogen blanketing can be integrated.
Continuous and Automated
Easily integrated with DCS for automatic interface control, flow ratio adjustment, and temperature/pressure interlocking, reducing manual intervention.
Compact Footprint
Compared to mixer-settler cascades, extraction towers reduce footprint by 50%–70%, making them ideal for retrofitting or space-constrained sites.

7. Application Areas

Industry	Typical Applications	Preferred Column Type
Petrochemical	BTX aromatics extraction, lube oil refining, phenol refining	RDC, Sieve Plate
Pharmaceutical	Antibiotic (penicillin, erythromycin) extraction, vitamin separation	Reciprocating Plate, Pulsed
Hydrometallurgy	Rare earth separation (La, Ce, Nd), copper, nickel, cobalt extraction	RDC, Pulsed
Nuclear	Nuclear fuel reprocessing (Purex process)	Pulsed Sieve Plate
Environmental	Phenolic wastewater treatment, organic solvent recovery, heavy metal removal	Packed, Sieve Plate
Fine Chemicals	Surfactants, fragrances, dyes, pesticide intermediates	Reciprocating Plate, RDC
Food Industry	Oil deacidification, caffeine decaffeination	Packed, Sieve Plate

8. Safety Accessories and Installation

8.1 Safety Accessories

Accessory	Function
Safety Valve / Rupture Disc	Overpressure protection, set pressure ≤ design pressure
Pressure Gauge (with snubber)	Real-time pressure monitoring
Dual Flange Level Gauge / Magnetic Level Gauge	Interface level monitoring to prevent phase carryover
Temperature Sensors (multi-point)	Monitor axial temperature profile
Explosion-Proof Sight Glasses	Visual observation of dispersion and interface
Emergency Relief Port	Rapid depressurization or emergency draining
Anti-Static Grounding	Prevent static buildup from organic solvents
Flammable/Toxic Gas Detector	Leak detection with DCS alarm

8.2 Installation Requirements

Foundation and Verticality

Column mounted on reinforced concrete foundation with sufficient load capacity.
Verticality deviation ≤ 1/1000, with no more than 5 mm deviation between measurement points.

Flange and Piping Connections

Flanges must be properly aligned; tightening torque per standards (e.g., HG/T 20613).
Expansion joints or flexible hoses installed to absorb thermal expansion and vibration.

Internal Component Installation

Liquid distributors leveled to ≤ 2 mm/m to ensure uniform flow.
Sieve plates and packing layers securely fixed to avoid bypassing.
For RDC, rotor-stator concentricity ≤ 0.5 mm, axial clearance per drawing.

Electrical and Instrumentation

Motors, pulse generators, and instrument cables must meet hazardous area requirements (Ex d IIB T4, etc.).
Control system shall include automatic interface regulation, flow ratio control, and alarm interlocks.

Pressure Testing and Commissioning

Hydrostatic test at 1.5× design pressure for 30 min after installation.
Clean and flush column, then perform water trial to check distribution, agitator operation, and level control stability.

9. Maintenance and Precautions

9.1 Routine Maintenance

Task	Frequency	Description
Visual Inspection	Daily	Check for leaks, corrosion, abnormal vibration
Process Parameters	Per shift	Record pressure, temperature, interface level
Sight Glass	Per shift	Observe dispersion quality and interface position
Agitation System (if applicable)	Weekly	Bearing temperature, lubrication, seal leakage
Sampling	Per process	Analyze extract and raffinate concentrations to assess efficiency
Internals Cleaning	6–12 months	Clean distributors, packing, sieve plates if fouled

9.2 Common Issues and Troubleshooting

Issue	Possible Causes	Corrective Actions
Reduced Efficiency	Fouled internals, maldistribution, poor dispersion	Clean distributors and internals; check nozzles/sieve holes
Flooding	Throughput exceed design, interface control failure	Reduce flow rates; adjust interface level; check feed ratio
Excessive Carryover	Insufficient settling time, interface fluctuation, emulsification	Increase settling zone; stabilize level control; add de-emulsifier
Pressure Fluctuation	Pulsing system failure, clogged lines, valve malfunction	Check pulse generator; clear pipelines; calibrate control valves
Agitator Noise	Worn bearings, bent shaft, excessive speed	Shut down; replace bearings; realign shaft; check speed

9.3 Safety Precautions

Never exceed design pressure or temperature. Operating pressure shall not exceed 90% of safety valve set pressure.
Startup sequence: Establish continuous phase (usually heavy phase) first, then introduce dispersed phase gradually to design flow.
Shutdown sequence: Stop dispersed phase feed first; maintain continuous phase flow for 15–30 minutes to flush out dispersed phase before stopping.
Maintenance preparation: Isolate power, drain contents, purge with nitrogen or water, and verify gas-free condition before entry.
Media change: Perform material compatibility tests before switching to new solvent systems to avoid corrosion, swelling, or chemical reactions.

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Mixing Tank

Macro-mixing: overall uniformity of materials in the tank

Micro-mixing: molecular-level contact to promote reactions

Solid suspension: preventing settling of solid particles

Liquid-liquid dispersion: forming emulsions from immiscible liquids

Gas-liquid dispersion: breaking gas into fine bubbles, increasing interfacial area

(3) Heat Transfer
For processes requiring heating or cooling, the tank can be equipped with jackets, coils, or external circulation heat exchangers. The agitator motion enhances contact between the material and heat transfer surfaces, improving heat transfer coefficients and temperature uniformity.

(4) Process Control
Online sensors (temperature, pH, dissolved oxygen, pressure, etc.) monitor tank conditions in real time. The control system automatically adjusts agitation speed, heating/cooling medium flow, feed rate, and other parameters to ensure process stability.

(5) Discharge
After completion of reaction or mixing, the material is discharged through the bottom outlet or by pump to the next process step.

Stirred tanks can operate in batch, semi-continuous, or continuous modes, depending on process requirements.

3. Main Types and Classification

Based on shape, agitator type, and application, stirred tanks are classified as follows:

Classification by Tank Shape

Type	Structural Features	Suitable Applications
Vertical Cylindrical	Straight shell with elliptical/dished/conical heads	Most common, suitable for most applications
Horizontal Cylindrical	Horizontal orientation, dished ends	Large volume, bottom discharge needed
Rectangular	Rectangular cross-section	Special processes, atmospheric pressure

Classification by Agitator Type

Type	Structural Features	Suitable Applications
Paddle Agitator	Flat or pitched blades, low speed	Low-viscosity mixing, solid suspension
Turbine Agitator	Straight, curved, or pitched blades, medium-high speed	Liquid-liquid dispersion, gas-liquid dispersion
Propeller Agitator	Propeller shape, high speed	Low viscosity, high circulation rate
Anchor/Frame Agitator	Close to wall, low speed	High viscosity, scraping
Helical Agitator	Spiral ribbon, low speed	High viscosity, pasty materials
Magnetic Agitator	Non-contact drive	Aseptic, high cleanliness

Classification by Seal Type

Type	Seal Method	Suitable Applications
Packing Seal	Packing gland compression	Low pressure, atmospheric, non-toxic media
Single Mechanical Seal	Rotating seal faces	Medium pressure, general media
Double Mechanical Seal	With seal fluid circulation	High pressure, toxic, flammable media
Magnetic Drive Seal	No shaft penetration	High cleanliness, absolute seal

Classification by Material

Type	Material	Suitable Applications
Stainless Steel Stirred Tank	304, 316L	Corrosive media, food, pharmaceutical
Carbon Steel Stirred Tank	Q235B, Q345R	Non-corrosive media
Glass-Lined Stirred Tank	Carbon steel + glass lining	Strong acids, bases, metal ion prevention
Titanium Stirred Tank	Titanium and titanium alloys	Strong corrosion, chloride-containing media
Plastic Stirred Tank	PP, PVDF	Low pressure, strong corrosion

4. Main Structure and Materials

4.1 Main Structural Components

Component	Function
Tank Body	Vertical or horizontal vessel, contains materials, withstands pressure
Heads	Top/bottom heads (elliptical/dished/conical), seal the tank
Agitator	Blades (paddle, turbine, anchor, etc.), achieve mixing
Agitator Shaft	Transmits torque, connects motor to agitator
Drive Unit	Motor, gearbox, coupling, provides power
Seal	Packing or mechanical seal, prevents leakage
Jacket/Coils	Heating or cooling medium channels
Insulation	Reduces heat loss, prevents burns
Feed Inlet	Entry point for liquid, solid, or gas materials
Discharge Outlet	Bottom or side discharge
Manhole/Handhole	Internal access for maintenance
Sight Glass	Observes tank interior
Thermowell	Temperature sensor installation
Pressure Gauge Port	Pressure gauge installation
Safety Valve Port	Overpressure protection
Supports	Supports tank, lug or leg type

4.2 Common Materials and Selection Criteria

Component	Common Materials	Applications
Tank Body	316L stainless steel	Corrosive media, pharmaceutical, food
Tank Body	Carbon steel + glass-lined	Strong acids, bases
Tank Body	Titanium	Strong corrosion, chloride
Agitator	316L stainless steel, titanium, glass-lined	Corrosion resistance
Shaft	316L stainless steel, carbon steel	Corrosion resistance, strength
Jacket	Carbon steel, stainless steel	Matching tank body
Seals	PTFE, fluororubber, graphite	Temperature resistance, corrosion resistance
Insulation Material	Rock wool, aluminum silicate fiber	Thermal insulation

For pharmaceutical and food industries, all wetted parts shall be 316L stainless steel with mirror-polished surfaces (Ra ≤ 0.4–0.8μm) to meet GMP requirements.

5. Main Technical Parameters

The following table lists typical design and operating parameters for stirred tanks. Actual values are determined by process requirements, material characteristics, and scale.

Parameter	Typical Range	Remarks
Nominal Volume	0.05–200 m³	Single unit
Design Pressure	-0.1–2.5 MPa	Tank/Jacket independent
Design Temperature	-40–300 °C	Depends on material
Agitation Speed	10–1000 rpm	High for propeller, low for anchor
Motor Power	0.25–200 kW	Based on volume and viscosity
Heat Transfer Area	0.5–50 m²	Jacket or coils
Agitator Type	Paddle, turbine, anchor, frame, etc.	Selected by material
Seal Type	Packing/single/double mechanical/magnetic	By pressure and media
Material	Carbon steel, stainless steel, glass-lined, titanium	By corrosivity
Operation Mode	Batch/semi-continuous/continuous	By process

Typical Specifications Reference

Model	Nominal Volume	Tank Diameter	Tank Height	Agitator Power	Applications
Small	50–500 L	DN400–DN800	600–1200 mm	0.55–3 kW	Laboratory, pilot
Medium	1–10 m³	DN1000–DN1800	1200–2500 mm	4–22 kW	Industrial production
Large	10–50 m³	DN2000–DN3200	2500–5000 mm	30–110 kW	Large-scale production
Extra Large	50–200 m³	DN3400–DN4500	5000–10000 mm	132–315 kW	Very large scale

6. Features and Advantages

Excellent Mixing Performance
By selecting the appropriate agitator type for different material properties, uniform mixing, dispersion, suspension, and emulsification of low- to high-viscosity materials can be achieved, with high mixing uniformity.

High Heat Transfer Efficiency
Jackets or coils combined with forced convection from the agitator significantly improve heat transfer coefficients, ensure uniform temperature distribution, and provide fast heating/cooling rates, suitable for temperature-sensitive reactions.

Flexible Operation
Adjustable agitation speed, controllable feed, discharge, heating, and cooling parameters allow batch, semi-continuous, and continuous operation modes, offering strong adaptability.

Reliable Sealing
Depending on process pressure and media characteristics, packing seals, mechanical seals, or magnetic drive seals can be selected to ensure leak-free operation, suitable for toxic, flammable, and explosive media.

Compact Structure, Easy Maintenance
Vertical design occupies minimal floor space. Manholes/handholes facilitate internal inspection and cleaning. The agitator is removable for easy maintenance.

High Automation
Can be integrated with PLC/DCS control systems for automatic regulation and interlock of temperature, pressure, speed, level, and other parameters, supporting data logging and remote monitoring.

Strong Adaptability
Capable of handling liquid, solid-liquid, gas-liquid, and liquid-liquid systems. Rich material selection (stainless steel, glass-lined, titanium, etc.) adapts to corrosive, high-temperature, aseptic, and other demanding conditions.

Meets Sanitary Standards
Food and pharmaceutical grade stirred tanks feature mirror-polished surfaces and dead-leg-free design, supporting CIP cleaning and SIP sterilization, meeting GMP and FDA requirements.

7. Application Areas

Industry	Typical Applications	Common Material	Agitator Type
Chemical	Chemical reactions, solvent mixing, polymerization, crystallization	316L, Glass-lined	Turbine, paddle
Pharmaceutical	Drug solution preparation, fermentation, reaction, crystallization	316L	Propeller, magnetic
Food	Syrup blending, dairy mixing, sauce stirring	304/316L	Paddle, anchor
Environmental	Wastewater treatment, chemical preparation, sludge mixing	316L, Carbon steel	Paddle, turbine
Coatings	Paint dispersion, pigment mixing, resin dissolution	316L, Carbon steel	Turbine, paddle
Metallurgical	Leaching, extraction, slurry agitation	Titanium, Duplex	Turbine, paddle
New Materials	Nanomaterial dispersion, precursor reaction	316L	Turbine, magnetic

8. Safety Accessories and Installation

8.1 Safety Accessories

Accessory	Function	Configuration Requirement
Safety Valve	Overpressure protection	Mandatory for pressure vessels
Pressure Gauge	Monitors tank pressure	Mandatory
Thermometer	Monitors material temperature	Mandatory
Level Gauge	Monitors liquid level	Recommended
Sight Glass	Observes tank interior	Recommended
Emergency Stop Button	Rapid shutdown in emergencies	Mandatory
Grounding Device	Anti-static	Mandatory for flammable media
Nitrogen Blanket System	Inert gas during shutdown or reaction	For heat-sensitive, flammable media
Explosion-Proof Motor	For hazardous areas	Based on explosion rating

8.2 Installation Requirements

Foundation Requirements

Stirred tank shall be installed on solid concrete foundations with load capacity at least twice the total weight when filled with liquid
Vertical tank verticality deviation ≤ 3 mm/m
Sufficient operating space shall be reserved around the tank

Agitator Installation

Agitator shaft verticality deviation ≤ 0.5 mm/m to ensure smooth rotation
Clearance between agitator and tank bottom/wall shall meet design requirements (anchor/frame: 5–15 mm)
Manual rotation check after installation to ensure no binding

Piping Connections

Feed, discharge, and jacket inlet/outlet lines shall have valves
Avoid stress transmission to the tank body during piping connection
Steam inlet shall have a steam trap

Electrical and Instrumentation

Motors and instrument cables shall meet explosion-proof requirements where applicable
Control system shall provide automatic regulation and interlock of speed, temperature, and pressure
Temperature and level signals shall be integrated into the control system

Insulation and Tracing

High-temperature media piping and equipment shall be insulated
Insulation surface temperature ≤ 50°C to prevent burns
Crystallization-prone media lines shall have tracing

Commissioning and Acceptance

Perform hydrostatic test at 1.5× design pressure for 30 minutes after installation
Conduct no-load trial to check agitator operation for smoothness and abnormal noise
Perform water trial to check sealing, heating/cooling system, discharge system
Conduct load trial to confirm mixing performance and heat transfer before handover

9. Maintenance and Precautions

9.1 Routine Maintenance

Task	Frequency	Description
Visual Inspection	Daily	Check for leaks, corrosion, abnormal vibration
Pressure, Temperature	Per shift	Record key parameters, compare with design values
Seals	Per shift	Check packing or mechanical seal for leakage
Agitation System	Daily	Check motor current, gearbox oil level, bearing temperature
Lubrication	Monthly	Lubricate gearbox and bearings
Cleaning	Per batch or periodically	Clean tank interior, agitator, baffles
Periodic Inspection	Every 3–6 years	Conduct periodic inspection per pressure vessel codes

9.2 Common Issues and Troubleshooting

Issue	Possible Causes	Corrective Actions
Poor Mixing	Wrong agitator type, low speed, material stratification	Replace agitator, increase speed, adjust feed sequence
High Current	High viscosity, agitator binding, bearing damage	Adjust process, shut down and inspect, replace bearings
Leakage	Seal wear, loose flange, corrosion perforation	Replace seal, tighten flange, repair
Temperature Runaway	Temperature control failure, insufficient heat transfer medium	Repair controller, check jacket/coils
Vibration, Noise	Bent shaft, loose impeller, bearing wear	Straighten shaft, tighten impeller, replace bearings
Seal Overheating	Packing too tight, dry running of mechanical seal	Adjust packing gland, check seal cooling

9.3 Safety Precautions

Operational Safety

Operators must be trained and familiar with equipment and procedures
Do not exceed design pressure, temperature, or speed
Confirm agitator rotates freely without binding before startup
Do not open manholes or inspection ports during operation

Maintenance Safety

Depressurize, drain material, and purge with nitrogen (if applicable) before maintenance
Follow confined space entry regulations when entering the tank
Use non-sparking tools in flammable areas
When servicing agitator, disconnect power and lock/tag out

Media Safety

For flammable media, ensure proper grounding and explosion-proof electrical equipment
Wear protective equipment when handling corrosive media
When handling high-temperature media, prevent burns

Emergency Response

In case of leakage, immediately stop material flow and initiate emergency procedures
In case of overpressure, immediately open safety valve to relieve pressure
In case of mechanical failure, perform emergency stop

Periodic Inspection

Pressure vessels shall be periodically inspected per codes
Safety valves and pressure gauges shall be calibrated periodically
Glass-lined tanks shall be regularly inspected for lining integrity

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Fixed Tubesheet Heat Exchanger

Type

Structural Features

Suitable Applications

Single Shell Pass, Single Tube Pass

Single shell pass, single tube pass

Small temperature difference, low flow rate

Single Shell Pass, Multiple Tube Passes

Single shell pass, 2/4/6 tube passes

Increasing tube side velocity

Multiple Shell Passes, Single Tube Pass

Multiple shell passes, single tube pass

Increasing shell side velocity

Multiple Shell Passes, Multiple Tube Passes

Multiple shell passes, multiple tube passes

High heat transfer efficiency

Classification by Thermal Compensation Method

Type	Structural Features	Suitable Applications
Without Expansion Joint	Rigid connection between shell and tubesheet	Temperature difference ≤30°C
With Expansion Joint	Bellows expansion joint on shell	Temperature difference 30–80°C
Thin Tubesheet Design	Reduced tubesheet thickness, good flexibility	Larger temperature differences

Classification by Material

Type	Material	Suitable Applications
Carbon Steel Fixed Tubesheet Heat Exchanger	Q345R, Q245R	Non-corrosive or mildly corrosive media
Stainless Steel Fixed Tubesheet Heat Exchanger	304, 316L, 904L	Corrosive media, food, pharmaceutical
Titanium Fixed Tubesheet Heat Exchanger	Titanium and titanium alloys	Strong corrosion, chloride-containing media
Duplex Steel Fixed Tubesheet Heat Exchanger	2205, 2507	High chloride, highly corrosive environments

Classification by Baffle Type

Type	Structural Features	Suitable Applications
Segmental Baffle	Most common, single or double segmental	General applications
Disc-and-Doughnut Baffle	Disc and ring arrangement	Low pressure drop requirements
Helical Baffle	Continuous helical flow path	High viscosity, fouling-prone materials

4. Main Structure and Materials

4.1 Main Structural Components

Component	Function
Shell	Cylindrical pressure vessel, contains tube bundle, forms shell side flow path
Tubesheet	Fixes both ends of heat exchange tubes, connects to shell and channel
Heat Exchange Tubes	Plain or enhanced tubes (finned, threaded), transfer heat
Baffles	Direct shell side fluid to flow across tube bundle, enhance heat transfer
Channel	Distributes tube side media, equipped with inlet/outlet nozzles
Expansion Joint	Compensates thermal stress from temperature difference between shell and tubes
Nozzles	Media inlet and outlet connections
Supports	Supports heat exchanger, saddle or lug type
Insulation	Reduces heat loss, prevents burns
Vent Valves	Releases air at top of shell and tube sides

4.2 Common Materials and Selection Criteria

Component	Common Materials	Applications
Shell	Q345R, Q245R	General applications
Shell	304, 316L stainless steel	Corrosive media
Heat Exchange Tubes	20# carbon steel	Non-corrosive media
Heat Exchange Tubes	304, 316L stainless steel	Corrosive media
Heat Exchange Tubes	Titanium, Hastelloy	Strongly corrosive media
Tubesheet	Carbon steel, stainless steel, clad plate	Matching tube material
Baffles	Carbon steel, stainless steel	Corrosion resistance
Expansion Joint	Stainless steel, carbon steel	Fatigue resistance
Seals	PTFE, spiral wound gasket, graphite	Temperature resistance, pressure resistance, corrosion resistance

5. Main Technical Parameters

The following table lists typical design and operating parameters for fixed tubesheet heat exchangers. Actual values are determined by process requirements, media characteristics, and heat transfer load.

Parameter	Typical Range	Remarks
Heat Transfer Area	1–2000 m²	Single unit
Design Pressure	-0.1–10.0 MPa	Tube side/Shell side independent
Design Temperature	-40–450 °C	Depends on material
Tube Specification	Φ19×2, Φ25×2.5, Φ32×3	Outer diameter × wall thickness
Tube Length	1.5–12 m	Standard lengths
Shell Diameter	DN200–DN2000 mm	Common sizes
Tube Passes	1, 2, 4, 6	Increasing flow velocity
Shell Passes	1, 2	Multiple shell passes require special design
Tube Side Velocity	0.5–3.0 m/s	Economic velocity
Shell Side Velocity	0.2–1.5 m/s	Affected by baffle configuration
Overall Heat Transfer Coefficient	100–3000 W/(m²·K)	Depends on media and structure
Fouling Resistance	0.0001–0.001 m²·K/W	Related to media cleanliness

Typical Specifications Reference

Model	Heat Transfer Area	Shell Diameter	Tube Specification	Tube Passes	Applications
Small	1–20 m²	DN200–DN400	Φ19×2	1/2	HVAC, pharmaceutical
Medium	20–100 m²	DN400–DN800	Φ25×2.5	2/4	Chemical, power
Large	100–500 m²	DN800–DN1400	Φ25×2.5	4/6	Petrochemical
Extra Large	500–2000 m²	DN1400–DN2000	Φ32×3	6	Large industry

6. Features and Advantages

Simple Structure, Low Manufacturing Cost
Fixed tubesheet heat exchangers have no floating head, packing, or other complex components. With fewer parts and mature manufacturing processes, manufacturing costs are 20%–30% lower than other types of shell-and-tube heat exchangers.

Reliable Sealing, Low Leakage Risk
Tubesheets are welded or flanged to the shell and channel, with few sealing surfaces and low leakage risk, particularly suitable for flammable, explosive, and toxic media.

High Heat Transfer Efficiency
Baffles direct shell side fluid to flow across the tube bundle transversely, creating turbulence, breaking the laminar boundary layer, and achieving a high heat transfer coefficient. Multiple tube passes can increase tube side velocity, further enhancing heat transfer.

Easy Maintenance
Compact structure with non-removable tube bundle, but maintenance can be performed by cleaning tube side and shell side. Expansion joints absorb thermal stress, reducing equipment failure.

Wide Range of Applications
Can handle various media including water, steam, oil, gas, and corrosive liquids. Rich material selection accommodates different corrosion resistance requirements.

Small Footprint
Flexible vertical or horizontal arrangement with compact structure, small footprint, suitable for space-constrained facilities.

Stable Operation
No moving parts, smooth operation, low noise, and long service life.

7. Application Areas

Industry	Typical Applications	Common Material	Operating Temp
Chemical	Reactor heating/cooling, solvent recovery, distillation tower reboiler/condenser	316L, Carbon steel	-20–300°C
Petroleum	Crude oil preheating, oil cooling, FCC units	Carbon steel, Duplex	50–350°C
Power	Cooling water systems, boiler feedwater preheating	Carbon steel, Stainless	20–200°C
Pharmaceutical	Drug solution heating/cooling, fermenter temperature control	316L	0–150°C
Food	Juice pasteurization, dairy heating, syrup cooling	304/316L	0–120°C
HVAC	Air conditioning heat exchange, district heating	Carbon steel	0–100°C
Refrigeration	Condensers, evaporators	Carbon steel, Copper	-20–50°C
Environmental	Waste heat recovery from wastewater, flue gas heat exchange	316L, Duplex	30–200°C

8. Safety Accessories and Installation

8.1 Safety Accessories

Accessory	Function	Configuration Requirement
Safety Valve	Overpressure protection	Mandatory for pressure vessels
Pressure Gauge	Monitors tube side/shell side pressure	Mandatory
Thermometer	Monitors inlet/outlet temperature	Mandatory
Vent Valve	Releases air at top of shell/tube sides	Mandatory
Drain Valve	Discharges bottom sediment	Recommended
Expansion Joint	Compensates thermal stress	Required for large temperature differences
Insulation	Reduces heat loss, prevents burns	For high-temperature media
Grounding Device	Anti-static	Mandatory for flammable media

8.2 Installation Requirements

Foundation Requirements

Heat exchanger shall be installed on solid concrete foundations with load capacity at least twice the total weight when filled with water
Horizontal heat exchangers with saddle supports: levelness deviation ≤ 3 mm/m
Vertical heat exchangers with lug supports: verticality deviation ≤ 3 mm/m

Piping Connections

Avoid stress transmission to the heat exchanger housing during piping connection
Install expansion joints on high-temperature piping to absorb thermal stress
Install valves and bypass lines on media inlet/outlet for switching and maintenance
Install steam traps on steam inlets

Electrical and Instrumentation

Pressure gauges and thermometers shall be installed in easily observable positions
Control system shall provide automatic regulation and interlock of temperature and pressure (if required)

Insulation and Tracing

High-temperature media piping and equipment shall be insulated
Insulation surface temperature ≤ 50°C to prevent burns
Crystallization-prone media lines shall have tracing

Commissioning and Acceptance

Perform hydrostatic test at 1.5× design pressure for 30 minutes after installation
Conduct leak test to check system leakage
Perform water trial to check heat exchange effect, pressure drop, temperature change
Conduct load trial to confirm heat transfer performance before handover

9. Maintenance and Precautions

9.1 Routine Maintenance

Task	Frequency	Description
Visual Inspection	Daily	Check for leaks, corrosion, abnormal vibration
Pressure, Temperature	Per shift	Record key parameters, compare with design values
Venting	Per shift	Open vent valves to release non-condensable gases
Draining	Daily	Discharge bottom sediment
Insulation	Monthly	Check for damage, detachment
Cleaning	As needed	Clean tube side and shell side based on fouling
Periodic Inspection	Every 3–6 years	Conduct periodic inspection per pressure vessel codes

9.2 Common Issues and Troubleshooting

Issue	Possible Causes	Corrective Actions
Reduced Heat Transfer Efficiency	Fouling, fluid short-circuiting, low flow rate	Clean heat exchanger, check baffles, adjust flow rate
Increased Pressure Drop	Fouling blockage, valve not fully open	Clean heat exchanger, check valves
Leakage	Loose flange, seal aging, corrosion perforation	Tighten flange, replace seal, repair or replace tube bundle
Excessive Temperature Difference	Flow mismatch, insufficient heat transfer area	Adjust flow rate, increase heat transfer area
Vibration, Noise	Excessive flow velocity, loose baffles	Adjust flow rate, repair baffles
Expansion Joint Damage	Excessive thermal stress, fatigue failure	Replace expansion joint, check operating parameters

9.3 Safety Precautions

Operational Safety

Operators must be trained and familiar with equipment and procedures
Do not exceed design pressure or temperature
Confirm vacuum system and cooling system integrity before startup
Gradually reduce temperature before shutdown to prevent thermal shock

Maintenance Safety

Depressurize, drain media, and purge with nitrogen (if applicable) before maintenance
Follow confined space entry regulations when entering equipment
Use non-sparking tools in flammable areas

Media Safety

For flammable media, ensure proper grounding and explosion-proof electrical equipment
Wear protective equipment when handling corrosive media
When handling high-temperature media, prevent burns

Emergency Response

In case of leakage, immediately stop media flow and initiate emergency procedures
In case of overpressure, immediately open safety valve to relieve pressure
In case of fire, immediately stop media flow and use fire extinguishers

Periodic Inspection

Pressure vessels shall be periodically inspected per codes
Safety valves and pressure gauges shall be calibrated periodically
Heat exchangers with severe corrosion shall have shortened inspection intervals

">1. OverviewA fixed tubesheet heat exchanger is the simplest and most widely used···

Bag Filter

Direct interception: particles larger than the pore size are captured

Inertial impaction: particles impact fibers due to inertia

Diffusion deposition: fine particles diffuse to fiber surfaces by Brownian motion

Electrostatic adsorption: charged particles are attracted to fiber surfaces

(3) Filtrate Discharge
Clear filtered liquid collects outside the bag and is discharged through the outlet to downstream processes or storage tanks.

(4) Residue Collection
As filtration proceeds, retained solids accumulate inside the bag, forming a filter cake. When the differential pressure reaches the set value or the bag is saturated, liquid feed is stopped and the bag is replaced. Residue is disposed of together with the old bag or recovered.

Bag filters are often designed with multiple bags in parallel to enable continuous operation (by switching to standby bags) or intermittent operation. Filtration precision depends on the bag’s pore size and material, with filtration efficiency reaching over 99%.

3. Main Types and Classification

Based on structural form, number of bags, and operation mode, bag filters are classified as follows:

Classification by Number of Bags

Type	Structural Features	Suitable Applications
Single Bag Filter	Single filter bag, simple structure, small size	Low flow, intermittent operation
Multi-Bag Filter	2–24 bags in parallel, large throughput	High flow, continuous operation
Twin Switching Filter	Two single-bag filters in parallel with switching valves	Continuous filtration, bag change without shutdown

Classification by Housing Material

Type	Material	Suitable Applications
Stainless Steel Bag Filter	304, 316L, 904L stainless steel	Corrosive media, food-grade, pharmaceutical-grade
Carbon Steel Bag Filter	Q235B, Q345R with anticorrosive coating	Non-corrosive or mildly corrosive media
Plastic Bag Filter	PP, PVC, PVDF	Highly corrosive media, low pressure

Classification by Connection Type

Type	Connection	Features
Flange Connection	Flanged inlet/outlet	Standard connection, reliable sealing
Threaded Connection	Threaded inlet/outlet	Small diameter, easy installation
Clamp Connection	Quick-clamp	Sanitary, easy to disassemble and clean

Classification by Bag Installation

Type	Structural Features	Suitable Applications
Top-Entry	Bag loaded from top, secured by compression ring	Standard design, convenient replacement
Side-Entry	Bag loaded from side	Space-limited installations
Basket Strainer	Stainless steel woven mesh basket	Coarse filtration, reusable

Classification by Residue Handling

Type	Handling Method	Features
Sealed Type	Bag replaced whole; residue disposed with bag	No leakage, suitable for hazardous media
Cleanable Type	Stainless steel basket; cleaned and reused	Environmentally friendly, economical

4. Main Structure and Materials

4.1 Main Structural Components

Component	Function
Housing	Pressure vessel, contains filter bags, withstands operating pressure
Filter Bag	Filtration element, retains solid particles
Support Basket	Perforated or wire mesh structure, supports filter bag, prevents collapse
Clamping Device	Compression ring, spring, or cover, secures bag, prevents bypass
Inlet/Outlet	Connections for liquid entry and discharge
Vent Valve	Releases trapped air at top to prevent air lock
Drain Valve	Discharges bottom sediment
Pressure Gauge	Monitors inlet and outlet pressure
Differential Pressure Gauge/Switch	Indicates bag clogging level for replacement
Support Legs	Supports filter, facilitates installation

4.2 Common Materials and Selection Criteria

Component	Common Materials	Applications
Housing	304, 316L stainless steel	Corrosive media, food, pharmaceutical
Housing	Q235B carbon steel + coating	Non-corrosive or mildly corrosive
Housing	PP, PVDF	Strong acids/bases, low temperature plastics
Filter Bag	Polypropylene (PP)	General water, acids, bases, solvents
Filter Bag	Polyester (PET)	Oil resistance, organic solvents
Filter Bag	Nylon (PA)	Wear resistance, alkali resistance
Filter Bag	Stainless steel mesh	High temperature, high viscosity, cleanable
Filter Bag	PTFE membrane	High temperature, strong corrosion
Support Basket	304, 316L stainless steel	Corrosion resistance, high strength
Seals	Silicone rubber, fluororubber, PTFE	Temperature resistance, corrosion resistance

For food and pharmaceutical industries, all wetted parts shall be 316L stainless steel with mirror-polished surfaces (Ra ≤ 0.6μm) to meet GMP requirements. Filter bags shall be made of food-contact approved materials.

5. Main Technical Parameters

The following table lists typical design and operating parameters for bag filters. Actual values are determined by process requirements, fluid characteristics, and filtration precision.

Parameter	Typical Range	Remarks
Design Pressure	0.6–2.5 MPa	Typically 0.6–1.6 MPa
Design Temperature	-20–200 °C	Depends on material
Filtration Precision	0.5–2000 μm	Commonly 1–200 μm
Number of Bags	1–24	Multi-bag parallel
Single Bag Area	0.1–0.5 m²	Standard bag ~0.2–0.25 m²
Single Bag Flow Rate	5–40 m³/h	Depends on viscosity and precision
Maximum Flow Rate	500 m³/h (multi-bag)	24 bags parallel
Inlet/Outlet Size	DN25–DN400	Flange, thread, clamp
Filtration Efficiency	90%–99.9%	Depends on precision and particle distribution
Initial Pressure Drop	5–30 kPa	Clean bag
Maximum Allowed ΔP	0.1–0.5 MPa	Replace bag when exceeded
Housing Material	Carbon steel, 304/316L SS, PP	Based on media

Typical Specifications Reference

Model	Bags	Filter Area	Flow Rate	Connection	Applications
Single Bag	1	0.25 m²	5–20 m³/h	DN50	Low flow, intermittent
Twin Switching	2 (switchable)	0.5 m²	10–40 m³/h	DN80	Continuous, online change
3-Bag	3	0.75 m²	15–60 m³/h	DN100	Medium flow
5-Bag	5	1.25 m²	25–100 m³/h	DN150	High flow
10-Bag	10	2.5 m²	50–200 m³/h	DN200	Large water treatment
20-Bag	20	5.0 m²	100–400 m³/h	DN300	Industrial high flow

6. Features and Advantages

High Filtration Precision
Filter bags use precision woven or non-woven materials with uniform pore size, offering a wide precision range (0.5–2000μm), suitable for coarse to high-precision filtration, with efficiency over 99%.

Large Throughput, Low Pressure Drop
Depth filtration structure provides high dirt-holding capacity, low initial pressure drop (≤30kPa), and low energy consumption for the same throughput, resulting in economical operation.

Simple Operation, Quick Bag Change
Bag replacement requires no tools; simply loosen the clamping device, remove the old bag, and install a new one. Single bag change takes less than 5 minutes, significantly reducing downtime.

Compact Structure, Low Investment
Vertical design occupies minimal floor space; flexible single or multi-bag configurations; capital cost much lower than other precision filtration equipment (such as cartridge filters, membrane filters).

Strong Adaptability
Capable of handling high-viscosity, corrosive, high-temperature, solids-containing materials. Wide material selection (PP, stainless steel, PTFE, etc.) meets requirements of food, pharmaceutical, chemical, and other industries.

Safe and Reliable
Enclosed operation, no leakage risk; equipped with differential pressure gauge, vent valve, drain valve for easy monitoring and maintenance; compliant with pressure vessel codes; explosion-proof design optional.

Wide Selection of Filter Bags
Various materials (PP, PET, nylon, PTFE, stainless steel mesh), precision, and sizes (standard #1, #2 bags) to meet different process needs.

7. Application Areas

Industry	Typical Applications	Common Material	Precision
Chemical	Solvent filtration, resin filtration, catalyst recovery, acid/base filtration	316L SS, PP	1–100 μm
Water Treatment	Pre-treatment, RO pre-protection, cooling water filtration	304 SS, PP	5–200 μm
Food	Beverage clarification, syrup filtration, edible oil polishing	304/316L SS	1–50 μm
Pharmaceutical	Drug solution filtration, API polishing, fermentation broth clarification	316L SS	0.5–20 μm
Coatings	Paint filtration, ink filtration, resin filtration	304 SS	10–100 μm
Electronics	High-purity chemical filtration, photoresist filtration	316L SS, PTFE	0.5–10 μm
Environmental	Wastewater pre-treatment, sludge dewatering pre-filtration	PP, carbon steel	50–500 μm
Petroleum	Oilfield injection water filtration, oil polishing	Carbon steel, 316L	5–200 μm
Metallurgy	Electroplating solution filtration, pickling solution filtration	PP, PVDF	1–50 μm

8. Safety Accessories and Installation

8.1 Safety Accessories

Accessory	Function	Configuration Requirement
Pressure Gauge	Monitors inlet/outlet pressure	Mandatory
Differential Pressure Gauge/Switch	Indicates bag clogging level	Recommended
Vent Valve	Releases trapped air at top	Mandatory
Drain Valve	Discharges bottom sediment	Recommended
Safety Valve	Overpressure protection	Mandatory for pressure vessels
Bleed Valve	Relieves pressure before maintenance	Recommended
Heating Jacket	Maintains medium temperature	For high viscosity/high temp applications
Grounding Device	Anti-static	Mandatory for flammable media

8.2 Installation Requirements

Foundation Requirements

Filter shall be installed on a solid level foundation with anchor bolts
Sufficient operating space (at least 1 meter) around for bag change and maintenance

Piping Connections

Install valves and bypass lines on inlet and outlet for switching and maintenance
Avoid stress transmission to the filter housing
Install shut-off valve on inlet for isolation during bag change

Vent and Drain

Vent valve shall be installed at the highest point; vent line routed to safe area
Drain valve at the lowest point for sediment discharge

Electrical and Instrumentation

Differential pressure switch signal shall be connected to control system with alarm setpoint
In hazardous areas, instruments shall meet explosion-proof requirements

Insulation and Tracing

For high-viscosity media, provide heating jacket or electric tracing
Use non-combustible insulation materials

Pressure Testing and Acceptance

Perform hydrostatic test at 1.5× design pressure for 30 minutes after installation
Conduct water trial to check sealing, vent function, pressure gauge readings
Perform load test to confirm filtration performance before handover

9. Maintenance and Precautions

9.1 Routine Maintenance

Task	Frequency	Description
Visual Inspection	Daily	Check for leaks, corrosion, abnormal vibration
Pressure/Differential Pressure	Per shift	Record pressures, observe ΔP changes
Venting	Per shift	Open vent valve to release air, prevent air lock
Draining	Daily	Discharge bottom sediment
Bag Replacement	When ΔP reaches setpoint or periodically	Replace with new bag, record replacement interval
Seal Inspection	Each bag change	Check O-ring for aging, damage
Housing Cleaning	As needed	Clean interior to remove deposits
Periodic Inspection	Annually	Pressure vessel inspection, instrument calibration

9.2 Common Issues and Troubleshooting

Issue	Possible Causes	Corrective Actions
High Differential Pressure	Bag clogged, high solids load	Replace bag, pre-filter
High Turbidity After Filtration	Bag damaged, seal leak, insufficient precision	Replace bag, replace seal, use higher precision
Low Flow Rate	Bag clogged, inlet valve not fully open	Replace bag, check valve
Housing Leakage	Loose flange, damaged seal, weld crack	Tighten flange, replace seal, weld repair
Air Lock	Vent valve not opened, rapid feed	Open vent valve, feed slowly
Bag Displacement	Clamping device loose, wrong bag size	Tighten clamp, install correct size bag

9.3 Safety Precautions

Operational Safety

Operators must be trained and familiar with equipment
Before bag change, close inlet/outlet valves, open vent to relieve pressure, confirm zero pressure
Do not operate under pressure (disassemble flanges, change bags)
Wear protective equipment when handling flammable, toxic media

Maintenance Safety

Depressurize and drain media before maintenance
Follow confined space entry regulations when entering large multi-bag filters
Use non-sparking tools in flammable areas
Obtain hot work permit before welding; remove combustibles

Media Safety

For corrosive media, ensure compatible materials; regularly inspect corrosion
For high-temperature media, provide insulation to prevent burns
For flammable media, ensure proper grounding to prevent static

Bag Replacement Precautions

Use bags of the same specifications to avoid bypass
Ensure bag is installed flat and properly seated
Dispose of used bags according to environmental regulations

Periodic Inspection

Pressure vessel type filters shall be periodically inspected per codes
Safety valves, pressure gauges calibrated regularly
Seals replaced periodically (typically every 6–12 months)

">1. OverviewA bag filter is a pressure-type filtration device that uses filter ba···

Three-phase Separator

Type

Structural Features

Suitable Applications

Horizontal Three-Phase Separator

Horizontal shell, gas-liquid separation section and oil-water settling section arranged axially

High throughput, high gas content, high gas-liquid ratio

Vertical Three-Phase Separator

Vertical shell, gas-liquid separation at top, oil-water separation at bottom

Small footprint, low gas content, high solids content

Spherical Three-Phase Separator

Spherical shell, uniform stress distribution

High-pressure applications, offshore platforms

Classification by Separation Stages

Type	Structural Features	Suitable Applications
Single-Stage Three-Phase Separator	Completes gas, oil, water separation in one stage	Conventional oil and gas processing
Multi-Stage Three-Phase Separator	Two or three stages in series for progressive separation	High separation requirements, fluctuating gas content

Classification by Internal Components Configuration

Type	Main Internals	Separation Mechanism
Gravity Three-Phase Separator	Inlet diverter, settling section, mist eliminator	Primarily gravity settling
Centrifugal Three-Phase Separator	Cyclone inlet, vortex tube	Primarily centrifugal separation, compact structure
Coalescing Three-Phase Separator	Coalescing plates, corrugated plates, packing	Enhanced oil droplet coalescence, improved separation efficiency

Classification by Material

Type	Material	Suitable Applications
Carbon Steel Three-Phase Separator	Q345R, Q245R	Non-corrosive media
Stainless Steel Three-Phase Separator	304, 316L, 904L	Corrosive media, sour service
Clad Plate Three-Phase Separator	Carbon steel + stainless steel clad	Corrosive media, high-pressure applications

4. Main Structure and Materials

4.1 Main Structural Components

Component	Function
Shell	Pressure-containing vessel, provides separation space
Inlet Diverter	Located at feed inlet, pre-separates gas phase, buffers fluid kinetic energy
Gas Section	Gas riser space, equipped with mist eliminator to remove liquid droplets
Settling Section	Oil-water gravity separation area, equipped with coalescing plates, corrugated plates to accelerate separation
Oil-Water Interface	Boundary layer between oil and water phases, equipped with interface detector
Mist Eliminator	Wire mesh or vane type, removes liquid droplets entrained in gas phase
Coalescing Plates/Corrugated Plates	Accelerate oil droplet coalescence, shorten settling time
Sand Drain/Blowdown Port	Bottom discharge for deposited solid impurities
Level Gauge	Monitors oil-water interface and liquid level
Pressure Gauge	Monitors operating pressure
Safety Valve	Overpressure protection
Nozzles	Feed inlet, gas outlet, oil outlet, water outlet, blowdown outlet

4.2 Common Materials and Selection Criteria

Component	Common Materials	Applications
Shell	Q345R, Q245R	Conventional oil and gas processing
Shell	316L stainless steel, duplex steel	H₂S, CO₂ corrosive media
Shell	Carbon steel + stainless steel clad	High-pressure corrosive applications
Internals	304, 316L stainless steel	Corrosion resistance, erosion resistance
Mist Eliminator	304, 316L stainless steel wire mesh	Corrosion resistance, high demisting efficiency
Coalescing Plates	304, 316L stainless steel, polypropylene	Corrosion resistance, oleophilic/hydrophobic
Seals	Fluororubber, graphite, PTFE	Temperature resistance, corrosion resistance
Level Gauge	Stainless steel housing	Pressure resistance, corrosion resistance
Nozzles/Flanges	Carbon steel, stainless steel	Matching shell material

For corrosive media containing H₂S, CO₂, etc., 316L stainless steel, duplex steel, or internal anti-corrosion coatings shall be used. For high-pressure applications, clad plate structures provide both corrosion resistance and cost-effectiveness.

5. Main Technical Parameters

The following table lists typical design and operating parameters for three-phase separators. Actual values are determined by processing media, throughput, and process requirements.

Parameter	Typical Range	Remarks
Liquid Processing Capacity	10–5000 m³/d	Depending on shell size and process
Gas Processing Capacity	1000–500000 Nm³/d	Depending on gas-liquid ratio
Operating Pressure	0.1–25.0 MPa	Atmospheric to high pressure
Operating Temperature	-40–200 °C	Based on fluid properties
Shell Diameter	DN500–DN4000 mm	Horizontal: typically DN800–DN3000
Shell Length	3–15 m	Horizontal separators
Residence Time	1–10 min	Liquid settling time
Oil-Water Separation Efficiency	95%–99.9%	Oil content in water ≤50–1000 mg/L
Gas-Liquid Separation Efficiency	99.5%–99.99%	Demisting efficiency
Oil-Water Interface Control Accuracy	±10–±50 mm	Depends on instrumentation and control valve
Pressure Drop	10–100 kPa	Gas-liquid separation section pressure drop
Material	Carbon steel, stainless steel, clad	Based on media corrosivity

Typical Specifications Reference

Specification	Shell Diameter	Shell Length	Liquid Capacity	Operating Pressure	Applications
DN800×3000	800 mm	3000 mm	50–200 m³/d	≤4.0 MPa	Small oil/gas stations
DN1200×4500	1200 mm	4500 mm	200–600 m³/d	≤6.4 MPa	Conventional oil/gas processing
DN1600×6000	1600 mm	6000 mm	500–1500 m³/d	≤10.0 MPa	Large-scale oil/gas processing
DN2200×8000	2200 mm	8000 mm	1000–3000 m³/d	≤15.0 MPa	High-pressure gas fields

6. Features and Advantages

High Separation Efficiency
Optimized internal components (inlet diverter, coalescing plates, mist eliminator) achieve efficient gas-oil-water separation. Oil-water separation efficiency reaches 95%–99.9%, with oil content in water ≤50 mg/L; gas-liquid separation efficiency exceeds 99.9%, with liquid carryover <0.01 m³/MMscm.

Strong Adaptability
Capable of handling complex media with fluctuating gas-liquid ratios, varying oil-water ratios, and containing sand or wax. Adapts to different operating conditions through parameter adjustment and internal component configuration.

Large Processing Capacity
Horizontal design provides sufficient gas-liquid separation space and oil-water settling time. Single unit capacity can reach 5000 m³/d liquid and 500000 Nm³/d gas, meeting large-scale production demands.

Stable Operation
Reliable interface control system and liquid level regulation devices achieve automatic and stable oil-water interface control, reducing manual intervention and ensuring long-term stable separation performance.

Compact Structure
Compared to traditional combinations of gravity settling tanks, oil removers, and gas-liquid separators, three-phase separators integrate multiple functions into one unit, occupying less space and reducing investment.

Easy Maintenance
Equipped with manways, blowdown ports, and cleaning ports for easy internal inspection and cleaning. Key internal components are removable and replaceable, extending equipment service life.

Safe and Reliable
Equipped with safety valves, pressure gauges, level gauges, and other safety accessories in compliance with pressure vessel codes, ensuring operational safety. Explosion-proof instrumentation options available for hazardous areas.

7. Application Areas

Industry	Typical Applications	Common Types
Oil & Gas Field Development	Wellhead oil-gas-water separation, crude oil dehydration, natural gas dehydration	Horizontal three-phase separator
Petrochemical	Refinery electric desalting water treatment, FCC slurry separation	Horizontal, vertical
Chemical Industry	Reaction product separation, solvent recovery, wastewater treatment	Horizontal, vertical
Environmental Engineering	Oily wastewater treatment, tank cleaning wastewater separation	Horizontal, coalescing type
Offshore Platforms	Offshore oil and gas field oil-water-gas separation	Horizontal, spherical
Shale Gas/Coalbed Methane	Gas field dewatering, produced water treatment	Horizontal, vertical
Biofuels	Biodiesel separation, oil dehydration	Vertical, coalescing type

8. Safety Accessories and Installation

8.1 Safety Accessories

Accessory	Function	Configuration Requirement
Safety Valve	Overpressure protection	Mandatory, periodic calibration
Pressure Gauge	Real-time operating pressure display	Mandatory
Thermometer	Monitor operating temperature	Recommended
Level Gauge	Monitor oil-water interface and liquid level	Mandatory
Interface Detector	Precise oil-water interface detection	Mandatory for automatic control
Blowdown Valve	Discharge bottom deposits	Mandatory
Manway/Handhole	Internal access for maintenance	Mandatory
Explosion-Proof Electrical	For hazardous areas	Based on explosion-proof rating
Grounding Device	Anti-static	Mandatory
Flame Arrester	Prevents flame propagation at gas outlet	For flammable gas applications

8.2 Installation Requirements

Foundation Requirements

Separator shall be installed on concrete foundations with load capacity at least twice the total weight when filled with water
Horizontal separators shall be equipped with saddle supports with embedded anchor bolts
Foundation levelness ≤ 5 mm/m

Levelness Requirements

Horizontal separator shell levelness deviation ≤ 3 mm/m to ensure uniform oil-water interface
Vertical separator verticality deviation ≤ 3 mm/m

Piping Connections

Feed piping shall be equipped with expansion bends or expansion joints to reduce fluid impact
Gas outlet piping shall be equipped with check valves to prevent backflow
Oil and water outlets shall be equipped with control valves for flow regulation
Blowdown piping shall be routed to safe areas

Instrument Installation

Level gauges and interface detectors shall be installed away from inlet fluid impact zones
Pressure gauges shall have isolation valves for easy replacement
Thermometers shall be inserted into fluid flow areas

Insulation and Tracing

Insulation and electric tracing shall be provided in cold climates to prevent medium solidification
Insulation materials shall be non-combustible

Pressure Testing and Acceptance

After installation, perform hydrostatic test (1.5× design pressure for 30 minutes)
Perform leak test to check system leakage
Commission interface control system to verify control accuracy
Confirm no leakage, no abnormalities before handover

9. Maintenance and Precautions

9.1 Routine Maintenance

Task	Frequency	Description
Visual Inspection	Daily	Check for leaks, corrosion, abnormal vibration
Pressure, Temperature	Per shift	Record operating parameters, compare with design values
Level/Interface	Per shift	Check level gauge and interface detector for normal display
Blowdown	Per shift or daily	Discharge bottom deposits, observe for abnormalities
Safety Valve	Monthly	Check for leaks, manual blowdown test
Pressure Gauge	Monthly	Check zero return, damage
Internals Inspection	Annually	Check inlet diverter, mist eliminator, coalescing plates for wear
Periodic Inspection	Every 3–6 years	Conduct periodic inspection per pressure vessel codes

9.2 Common Issues and Troubleshooting

Issue	Possible Causes	Corrective Actions
Gas Phase Carryover	Mist eliminator clogging, high gas velocity, high liquid level	Clean mist eliminator, reduce gas flow, lower liquid level
Oil Phase High Water Content	Insufficient residence time, interface control failure, coalescing plate damage	Increase residence time, repair interface detector, replace coalescing plates
Water Phase High Oil Content	Interface too high, poor oil-water separation	Adjust interface, check coalescing plates, add demulsifier
Increased Pressure Drop	Inlet diverter clogging, mist eliminator clogging	Clean inlet diverter, clean mist eliminator
Level Fluctuation	Control valve failure, unstable instrument signal	Repair control valve, calibrate instruments
Safety Valve Lifting	Overpressure, safety valve failure	Check system pressure, calibrate safety valve

9.3 Safety Precautions

Operational Safety

Operators must be trained and familiar with equipment operating procedures
Do not exceed design pressure or temperature
Regularly inspect safety accessories such as safety valves and pressure gauges
Open blowdown valves slowly to prevent splashing

Maintenance Safety

Depressurize, drain media, and purge with nitrogen before maintenance
Follow confined space entry regulations when entering vessels
Use explosion-proof tools to prevent sparks
Perform leak test after maintenance

Media Safety

Wear protective equipment when handling H₂S, flammable, or explosive media
Immediately shut off feed and activate emergency response in case of leakage
Discharge media to safe areas or treatment facilities

Freeze Protection

Inspect insulation and tracing systems during winter
Drain internal media during extended shutdowns

Periodic Inspection

Conduct periodic inspections per pressure vessel codes
Apply for inspection before expiration; never operate beyond inspection period
Repair defects such as corrosion or cracks promptly

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Scraped Film Evaporator

Type

Structural Features

Suitable Applications

Vertical Scraped Thin Film Evaporator

Vertical cylinder, material flows downward, axial scrapers

Most common, suitable for most materials

Horizontal Scraped Thin Film Evaporator

Horizontal cylinder, material moves axially, radial scrapers

High viscosity, fouling-prone materials, larger capacity

Conical Scraped Thin Film Evaporator

Conical cylinder, adjustable scraper angle

High viscosity, polymerizable materials, smooth discharge

Classification by Scraper Type

Type	Scraper Structure	Features
Hinged Scraper (Moving Scraper)	Scrapers hinged to rotor, pressed by centrifugal force	Suitable for high viscosity, fouling-prone materials, self-compensating wear
Fixed Scraper	Rigidly attached to rotor, fixed clearance	Suitable for low viscosity, clean materials, simple structure
Helical Scraper	Scrapers arranged in a spiral, also conveying function	Suitable for high viscosity, poor flowability materials

Classification by Scraper Material

Type	Material	Suitable Applications
Metal Scraper	Stainless steel, Hastelloy, titanium	General conditions, high temperature, wear resistance
Non-Metal Scraper	PTFE, PEEK, carbon fiber composite	Highly corrosive, food-grade, metal contamination prevention

Classification by Heating Method

Type	Heating Method	Suitable Applications
Jacket Heating	Steam or thermal oil in jacket	Most common, uniform heat transfer
Electric Heating	Electric heating elements directly on cylinder	Small units, no steam source
Thermal Oil Circulation	Circulating thermal oil from a heater	High-temperature applications (up to 300°C)

4. Main Structure and Materials

4.1 Main Structural Components

Component	Function
Cylinder	Cylindrical or conical pressure vessel, precision-machined inner surface, provides evaporation surface
Heating Jacket	Surrounds cylinder, contains heating medium (steam, thermal oil)
Rotor	Rotating shaft, carries scrapers, driven by motor and gearbox
Scrapers	Contact inner wall, form and renew the liquid film
Feed Distributor	Evenly distributes feed onto the inner wall
Vapor-Liquid Separator	Located at top, removes liquid droplets from secondary vapor
Condenser	Condenses secondary vapor, recovers solvent or distillate
Discharge Pump	Transfers concentrate; gear pump, screw pump, etc.
Vacuum System	Maintains vacuum; includes vacuum pump, condenser, buffer tank
Sealing Device	Mechanical seal or packing seal, prevents leakage
Insulation Layer	Reduces heat loss, prevents burns

4.2 Common Materials and Selection Criteria

Component	Common Materials	Applications
Cylinder	316L stainless steel	Corrosive media, pharmaceutical, food
Cylinder	Hastelloy (C-276, C-22)	Strong corrosion, high chloride
Cylinder	Titanium (TA2)	Strong oxidizing, chloride-containing media
Cylinder	Carbon steel + glass-lined	Strong acids/bases, metal ion prevention
Scrapers	316L stainless steel, PTFE, PEEK	Wear resistance, corrosion resistance
Rotor	316L stainless steel, duplex steel	High strength, corrosion resistance
Seals	PTFE, graphite, metal bellows	Temperature resistance, corrosion resistance, vacuum
Heating Jacket	Carbon steel, stainless steel	Matching cylinder material
Insulation Material	Rock wool, aluminum silicate fiber	Thermal insulation, high temperature resistance

For pharmaceutical and food industries, all wetted parts shall be 316L stainless steel with mirror-polished surfaces (Ra ≤ 0.4μm) to meet GMP and FDA requirements.

5. Main Technical Parameters

The following table lists typical design and operating parameters for scraped thin film evaporators. Actual values are determined by process requirements, material characteristics, and evaporation capacity.

Parameter	Typical Range	Remarks
Evaporation Area	0.5–60 m²	Single unit
Throughput	10–20000 kg/h	Depends on evaporation load and material
Operating Pressure (absolute)	1–1000 mbar	Vacuum operation
Operating Temperature	50–350 °C	Depends on heating medium
Scraper Speed	100–800 rpm	Adjustable based on material viscosity
Residence Time	5–60 seconds	Extremely short
Heat Transfer Coefficient	500–2000 W/(m²·K)	Much higher than traditional evaporators
Concentration Ratio	2–100 times	High concentration in single pass
Evaporation Temperature	50–250 °C	Related to vacuum level
Heating Medium	Steam (0.3–1.6 MPa), thermal oil	As required
Motor Power	1.5–75 kW	Based on evaporation area and viscosity

Typical Specifications Reference

Model	Evaporation Area	Throughput	Cylinder Diameter	Motor Power	Applications
Small	0.5–2 m²	10–200 kg/h	DN200–DN400	1.5–5.5 kW	Laboratory, pilot
Medium	3–10 m²	200–2000 kg/h	DN500–DN800	7.5–22 kW	Industrial production
Large	12–30 m²	2000–8000 kg/h	DN900–DN1200	30–55 kW	Large-scale production
Extra Large	35–60 m²	8000–20000 kg/h	DN1300–DN1600	75–90 kW	Very large scale

6. Features and Advantages

High Heat Transfer Efficiency
Forced film formation with scrapers creates an extremely thin film (0.5–2.0 mm) that is continuously renewed, achieving heat transfer coefficients of 500–2000 W/(m²·K), 3–10 times higher than traditional evaporators.

Extremely Short Residence Time
Material residence time is only 5–60 seconds, greatly reducing thermal degradation, polymerization, and discoloration of heat-sensitive materials, making it ideal for heat-sensitive, high-boiling, and easily decomposed materials.

Strong Adaptability
Capable of handling high-viscosity (up to 100000 cP), fouling-prone, foam-prone, and solids-containing materials, with wide adaptability to material properties.

High Concentration Ratio
Single pass can achieve high concentration (2–100 times), eliminating the need for multiple stages and reducing equipment investment.

Wide Operating Flexibility
Scraper speed, feed rate, vacuum level, and heating temperature are independently adjustable, adapting to different materials and production loads.

Continuous Operation, High Automation
Enables continuous feed and discharge, easily integrated with DCS for automatic control of temperature, pressure, flow rate, and speed, with interlock protection.

Excellent Product Quality
Low-temperature, short-time evaporation preserves heat-sensitive components, resulting in light color, high activity, and no burnt taste, meeting high-quality standards.

Easy Cleaning
The scraping action provides self-cleaning, minimizing fouling and simplifying cleaning.

7. Application Areas

Industry	Typical Applications	Common Material	Evaporation Temp
Chemical	High-boiling solvent recovery, polymer devolatilization, resin concentration	316L, Hastelloy	100–250°C
Pharmaceutical	Antibiotic concentration, herbal extract concentration, API solvent removal	316L	50–120°C
Food	Fruit juice concentration, honey dehydration, oil deacidification, dairy concentration	316L	50–100°C
Environmental	Waste liquid concentration, high-salinity wastewater evaporation, solvent recovery	316L, Titanium	80–150°C
New Materials	Polymer devolatilization, monomer removal, specialty resins	316L, Hastelloy	150–300°C
Fine Chemicals	Flavor purification, pesticide intermediate concentration, dye drying	316L	80–180°C
Biofermentation	Fermentation broth concentration, enzyme concentration	316L	40–80°C

8. Safety Accessories and Installation

8.1 Safety Accessories

Accessory	Function	Configuration Requirement
Safety Valve	Overpressure protection (jacket, evaporator chamber)	Mandatory for pressure vessels
Pressure Gauge	Monitors evaporator chamber and jacket pressure	Mandatory
Thermometer	Monitors material and heating medium temperature	Mandatory
Vacuum Gauge	Monitors system vacuum	Mandatory
Mechanical Seal Cooling System	Cools seal faces, extends life	Recommended
Bursting Disc	Emergency overpressure relief	For flammable/explosive media
Nitrogen Blanket System	Inert gas protection during shutdown, prevents oxidation	For heat-sensitive materials
Emergency Stop Button	Rapid shutdown in emergencies	Mandatory
Grounding Device	Anti-static	Mandatory for flammable media

8.2 Installation Requirements

Foundation Requirements

Equipment shall be installed on solid concrete foundations with load capacity at least twice the total weight when filled with water
Vertical unit verticality deviation ≤ 2 mm/m to ensure uniform scraper-to-wall clearance
Horizontal unit levelness deviation ≤ 2 mm/m

Piping Connections

Feed line shall have control valve and flow meter for feed rate control
Heating medium lines shall have valves and steam traps (for steam)
Vacuum piping shall be short and straight to minimize resistance and ensure vacuum
Discharge line shall have back-pressure valve or discharge pump to prevent siphoning

Electrical and Instrumentation

Motors, instrument cables shall meet explosion-proof requirements where applicable
Control system shall provide automatic regulation of temperature, pressure, speed, and feed rate
Mechanical seal cooling water supply shall be stable

Insulation and Tracing

Evaporator cylinder, jacket, and piping shall be insulated
Insulation surface temperature ≤ 50°C to prevent burns
High-viscosity material inlet and outlet piping shall have tracing

Commissioning and Acceptance

Perform hydrostatic test at 1.5× design pressure for 30 minutes after installation
Conduct vacuum test to check system sealing
Perform water trial to check scraper operation, heating system, discharge system
Conduct load trial to confirm evaporation performance, concentration ratio, and product quality before handover

9. Maintenance and Precautions

9.1 Routine Maintenance

Task	Frequency	Description
Visual Inspection	Daily	Check for leaks, corrosion, abnormal vibration
Pressure, Temperature, Vacuum	Per shift	Record key parameters, compare with design values
Mechanical Seal	Daily	Check cooling water flow, leakage
Scraper Wear	Monthly	Monitor by current and vibration; periodic shutdown inspection
Heating Medium	Monthly	Check steam trap, thermal oil level
Vacuum System	Daily	Check vacuum pump operation, cooling water
Lubrication	Monthly	Lubricate gearbox and bearings
Internal Cleaning	As needed	Clean based on material properties

9.2 Common Issues and Troubleshooting

Issue	Possible Causes	Corrective Actions
Reduced Evaporation Capacity	Low vacuum, low heating temperature, excessive feed	Check vacuum system, increase heating temperature, reduce feed
Insufficient Concentration	Low evaporation capacity, excessive feed	Increase vacuum, reduce feed
Poor Discharge	High viscosity, discharge pump failure, pipe blockage	Increase temperature, repair pump, clear pipe
Scraper Noise	Scraper wear, foreign object, improper clearance	Shut down, replace scrapers, remove foreign object, adjust clearance
Vacuum Drop	System leak, vacuum pump failure, condenser fouling	Leak test and repair, repair pump, clean condenser
Product Discoloration	High temperature, long residence time	Reduce heating temperature, increase feed or vacuum

9.3 Safety Precautions

Operational Safety

Operators must be trained and familiar with equipment and procedures
Do not exceed design pressure, temperature, or speed
Confirm scrapers rotate freely before startup
Empty material before shutdown to prevent drying and coking

Maintenance Safety

Depressurize, drain material, and purge with nitrogen before maintenance
Follow confined space entry regulations when entering equipment
Use non-sparking tools in flammable areas
Exercise caution when lifting heavy components during scraper/rotor removal

Media Safety

For flammable media, ensure proper grounding and explosion-proof electrical equipment
Wear protective equipment when handling corrosive media
For heat-sensitive materials, avoid prolonged high-temperature holdup

Emergency Response

In case of leakage, immediately stop feed and heating, and initiate emergency procedures
In case of overpressure, immediately open safety valve or vent
In case of mechanical failure, perform emergency stop

Periodic Inspection

Pressure vessels shall be periodically inspected per codes
Wear parts such as mechanical seals and scrapers shall be replaced periodically
Safety valves, pressure gauges, vacuum gauges shall be calibrated periodically

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Cooling Crystallizer

Type

Structural Features

Suitable Applications

Tank Cooling Crystallizer

Jacketed or coiled, agitated, simple structure

Small-medium scale, batch operation

Oslo Cooling Crystallizer

Central draft tube + circulation pump, slurry circulation

Large-scale continuous, uniform crystal size

Forced Circulation Cooling Crystallizer

External circulation cooler + crystallizer tank

High flow, fouling-prone materials

Scraped Surface Cooling Crystallizer

Internal scrapers prevent wall fouling

High viscosity, wall-fouling materials

Vacuum Cooling Crystallizer

Vacuum flash cooling

No cooling surface, heat-sensitive materials

Classification by Operation Mode

Type	Operation Characteristics	Suitable Applications
Batch Cooling Crystallizer	Batch operation, flexible	Small batches, multiple products
Continuous Cooling Crystallizer	Continuous feed and discharge	Large scale, single product
Semi-Continuous Crystallizer	Between batch and continuous	Medium scale

Classification by Cooling Method

Type	Cooling Method	Features
Jacket Cooling	Cooling medium through jacket	Simple structure, limited heat transfer area
Coil Cooling	Internal cooling coils	Large heat transfer area, suitable for small tanks
External Circulation Cooling	Slurry circulated through external heat exchanger	High heat transfer efficiency, easy cleaning
Vacuum Flash Cooling	Solvent vaporization under vacuum absorbs heat	No cooling surface, prevents wall fouling

Classification by Material

Type	Material	Suitable Applications
Stainless Steel Crystallizer	304, 316L stainless steel	Corrosive media, food, pharmaceutical
Titanium Crystallizer	Titanium and titanium alloys	Strong corrosion, chloride-containing media
Glass-Lined Crystallizer	Carbon steel + glass lining	Strong acids, bases, metal ion prevention
Carbon Steel Crystallizer	Q345R, Q245R	Non-corrosive or mildly corrosive

4. Main Structure and Materials

4.1 Main Structural Components

Component	Function
Crystallizer Vessel	Cylindrical or conical pressure vessel, provides crystallization space
Jacket/Coils	Contains cooling medium (cooling water, brine, glycol)
Agitator	Propeller, paddle, or turbine type, promotes mixing and heat transfer
Draft Tube (Oslo type)	Central draft tube, creates circulation flow path
Circulation Pump	Forced circulation, improves heat transfer efficiency
Cooler	Plate or shell-and-tube heat exchanger for external circulation
Shaft Seal	Mechanical seal or packing seal, prevents leakage
Feed Inlet	Solution or mother liquor entry
Discharge Outlet	Crystal slurry discharge
Thermowell	Temperature sensor installation
Sight Glass	Observes crystallization state
Sampling Port	Samples crystal size analysis

4.2 Common Materials and Selection Criteria

Component	Common Materials	Applications
Vessel	316L stainless steel	Corrosive media, pharmaceutical, food
Vessel	Glass-lined	Strong acids, bases, metal ion contamination prevention
Vessel	Titanium	Strong corrosion, chloride-containing media
Agitator	316L stainless steel, titanium, glass-lined	Corrosion resistance
Heat Exchanger	316L stainless steel, titanium	Corrosion resistance, good thermal conductivity
Circulation Pump	Stainless steel, titanium	Corrosion resistance, wear resistance
Shaft Seal	Mechanical seal, PTFE	Corrosion resistance, temperature resistance
Seals	Fluororubber, PTFE	Temperature resistance, corrosion resistance

For pharmaceutical and food industries, all wetted parts shall be 316L stainless steel with mirror-polished surfaces (Ra ≤ 0.4–0.6μm) to meet GMP requirements.

5. Main Technical Parameters

The following table lists typical design and operating parameters for cooling crystallizers. Actual values are determined by material characteristics, crystallization requirements, and production scale.

Parameter	Typical Range	Remarks
Effective Volume	0.1–100 m³	Single unit
Throughput	0.5–500 t/d	Depends on material and scale
Operating Temperature	-20–150 °C	Low temperature to ambient
Design Pressure	-0.1–1.0 MPa	Atmospheric or slight negative pressure
Cooling Rate	0.5–10 °C/h	Affects crystal size
Agitation Speed	20–200 rpm	Propeller lower, turbine higher
Average Crystal Size	100–2000 μm	Controllable range
Crystallization Yield	70%–95%	Depends on solubility curve
Cooling Medium	Cooling water, brine, glycol	-20–30°C
Heat Transfer Area	2–200 m²	Jacket + coils or external circulation
Motor Power	1.5–90 kW	Agitator + circulation pump

Typical Specifications Reference

Model	Effective Volume	Throughput	Vessel Diameter	Agitator Power	Applications
Small	0.1–1 m³	0.1–1 t/d	DN500–DN1000	1.5–5.5 kW	Laboratory, pilot
Medium	2–10 m³	1–10 t/d	DN1200–DN2000	7.5–22 kW	Industrial production
Large	12–30 m³	10–50 t/d	DN2200–DN3000	30–55 kW	Large-scale production
Extra Large	35–100 m³	50–500 t/d	DN3200–DN4000	75–110 kW	Very large scale

6. Features and Advantages

Uniform Crystal Size
By controlling cooling rate and agitation intensity, supersaturation is maintained within the metastable zone, avoiding spontaneous nucleation, resulting in uniform crystal growth, narrow size distribution, and high product quality.

High Purity
Cooling crystallization utilizes the temperature dependence of solubility without introducing other chemicals, producing high-purity products, especially suitable for high-purity product manufacturing.

Stable Operation
Optimized agitation and circulation systems ensure uniform temperature distribution, avoiding localized supercooling, providing stable and reliable operation.

Strong Adaptability
Capable of handling various materials including heat-sensitive, easily oxidized, and corrosive materials. Different materials and structural forms accommodate diverse process requirements.

Low Energy Consumption
Cooling crystallization does not require evaporation of large amounts of solvent, consuming significantly less energy than evaporative crystallization, resulting in low operating costs.

Continuous Production Capability
Oslo and forced circulation crystallizers enable continuous feed and discharge, suitable for large-scale industrial production.

Easy Cleaning
Smooth stainless steel surfaces and non-stick glass-lined surfaces facilitate CIP cleaning, meeting sanitary requirements.

High Automation
Easily integrated with DCS for automatic control of temperature, flow rate, and agitation speed, with interlock protection.

7. Application Areas

Industry	Typical Applications	Common Type	Crystallization Temp
Chemical	Sodium sulfate, potassium chloride, nitrates, ammonium sulfate	Oslo, Forced circulation	0–50°C
Pharmaceutical	API purification, antibiotic crystallization, vitamins	Tank, Glass-lined	-10–40°C
Food	Glucose, fructose, xylitol, citric acid	Stainless steel, Tank	20–60°C
Inorganic Salt	Magnesium sulfate, sodium carbonate, borax	Oslo, Carbon steel	10–50°C
Metallurgical	Nickel sulfate, cobalt sulfate, rare earth salts	Titanium, Forced circulation	0–80°C
Environmental	High-salinity wastewater salt recovery, desulfurization byproducts	Forced circulation, Titanium	5–40°C
Biochemical	Amino acids, organic acids	Stainless steel, Glass-lined	10–40°C

8. Safety Accessories and Installation

8.1 Safety Accessories

Accessory	Function	Configuration Requirement
Safety Valve	Overpressure protection	Mandatory for pressure vessels
Pressure Gauge	Monitors vessel pressure	Mandatory
Thermometer	Monitors material temperature	Mandatory
Level Gauge	Monitors vessel level	Mandatory
Sight Glass	Observes crystallization state	Recommended
Emergency Stop Button	Rapid shutdown in emergencies	Mandatory
Grounding Device	Anti-static	Mandatory for flammable media
Nitrogen Blanket System	Inert gas protection during shutdown	For heat-sensitive materials

8.2 Installation Requirements

Foundation Requirements

Equipment shall be installed on solid concrete foundations with load capacity at least twice the total weight when filled with water
Vessel verticality deviation ≤ 2 mm/m

Piping Connections

Cooling medium inlet and outlet shall have valves and thermometers
Feed line shall have control valve and flow meter
Discharge line shall have valve for control
Vacuum piping (if applicable) shall be short and straight

Electrical and Instrumentation

Motors, instrument cables shall meet explosion-proof requirements where applicable
Control system shall provide automatic regulation of temperature and agitation speed
Temperature and level signals shall be integrated into control system

Insulation and Tracing

Low-temperature crystallizers shall be insulated to prevent cold loss
Insulation surface temperature shall meet safety requirements

Commissioning and Acceptance

Perform hydrostatic test at 1.5× design pressure for 30 minutes after installation
Conduct water trial to check agitation system, cooling system, sealing
Conduct load trial to confirm crystallization performance and crystal size before handover

9. Maintenance and Precautions

9.1 Routine Maintenance

Task	Frequency	Description
Visual Inspection	Daily	Check for leaks, corrosion, abnormal vibration
Temperature, Pressure	Per shift	Record key parameters, compare with design values
Agitation System	Daily	Check operation, bearing temperature, seal leakage
Cooling System	Daily	Check cooling medium flow, temperature
Lubrication	Monthly	Lubricate agitator gearbox, circulation pump
Seals	Semi-annually	Check shaft seal, flange seal aging
Cleaning	Per batch or periodically	Clean vessel interior, agitator, coils from scaling

9.2 Common Issues and Troubleshooting

Issue	Possible Causes	Corrective Actions
Small Crystal Size	Excessive cooling rate, excessive agitation	Reduce cooling rate, adjust agitation speed
Severe Wall Scaling	Cooling surface supercooling, insufficient agitation	Increase cooling medium temperature, increase agitation
Low Yield	Insufficient cooling, short crystallization time	Lower final temperature, extend crystallization time
Agitator Noise	Bearing wear, impeller loosening	Replace bearings, tighten impeller
Leakage	Shaft seal wear, flange loosening	Replace shaft seal, tighten flange
Temperature Runaway	Cooling system failure, temperature controller failure	Check cooling system, repair temperature controller

9.3 Safety Precautions

Operational Safety

Operators must be trained and familiar with equipment and procedures
Do not exceed design pressure or temperature
Confirm agitator operation and cooling system integrity before startup
Drain material before shutdown to prevent crystallization blockage

Maintenance Safety

Depressurize, drain material, and purge with nitrogen (if applicable) before maintenance
Follow confined space entry regulations when entering equipment
Use non-sparking tools in flammable areas

Media Safety

For flammable media, ensure proper grounding and explosion-proof electrical equipment
Wear protective equipment when handling corrosive media
When handling low-temperature media, prevent frostbite

Emergency Response

In case of leakage, immediately stop feed and cooling, and initiate emergency procedures
In case of overpressure, immediately open safety valve to relieve pressure
In case of mechanical failure, perform emergency stop

Periodic Inspection

Pressure vessels shall be periodically inspected per codes
Safety valves, pressure gauges shall be calibrated periodically
Glass-lined equipment shall have lining integrity checked regularly

">1. OverviewA cooling crystallizer is a device that utilizes the decrease in solu···

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About Us

Wuxi Lancer Equipment Co., Ltd, is a high-tech enterprise specializing in designing and manufacturing pressure vessels and other chemical equipments that conform with GB,ASME,PED,AS,JIS,MOM,DOSH etc, including design, R&D, production, sales, installation, after-sales service, focuses on providing chemical equipments of high requirements and high qualities to petrochemical, coal chemical, fine ...

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The latest version ASME BPVC.VIII.1-2025 has been released

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The national standard GB/T 150-2024, "Pressure Vessels," was released on July 24, 2024, and will officially come into effect on February 1, 2025. This···