Chemical Processing Equipment

Working Principle

Operation of the wiped film evaporator (WFE) is both smooth and effective. Feed material is introduced at the top of the unit and spread uniformly over the heated inner shell surface by a rotating distribution plate. Specially engineered wipers continuously wipe the feed, create a thin film, and renew this thin film, ensuring efficient heat transfer even for viscous fluids — a defining characteristic of all thin film evaporation (TFE) technology. Wiper system ensures material residence time on Heated surface is short. The low-boiling component evaporates rapidly and passes through an entrainment separator. The entrainment separator knocks down liquid droplets; it minimizes liquid droplet carry-over. Vapors travel to an internal condenser and condense, uncondensed vapours then travel to an external condenser.

Placement of Internal Condenser ensures Vapour path is short & pressure drop is low. Such construction makes WFE into a Short Path Distillation Unit (SPDU) also known as Molecular Distillation Unit (MDU). In such construction vapours condense on the outside of the tubes and are discharged via the condensate outlet at the centre. , This makes the Short Path Distillation Unit (SPDU)/ Molecular Distillation Unit (MDU) technology the best choice for thermally sensitive materials. To name a few such chemicals as APIs, Cannabinoids, Dimer, Vitamin E / Tocopherol enrichment, and High-value oleoresins, Herbal / Natural extracts, etc.

The high-boiling residue flows along the shell wall under the action of gravity and wiper-assisted downward flow and is discharged from the Concentrate outlet. Different rotor designs are available to suit different feeds and their properties.

We can offer different configurations of Wiped Film Evaporators (WFEs) such as

a) Standard WFE with or without internal condenser

b) WFE with larger internal condenser

c) WFE with conical bottom and vapour outlet from top

d) WFE mounted on receivers

e) WFE with specially engineered rotor (different types of wiper systems - standard wipers, hinge type, swing type, metal blade, etc.)

Milestones

Features

• Low rotational speed
• No bottom bearing — simpler maintenance and reduced contamination risk
• Louvers/chevron rotor with interchangeable panels for ease of cleaning

Falling Film Evaporator (FFE)

The Falling Film Evaporator (FFE) is the preferred choice for the continuous, efficient concentration equipment for dilute feed streams, usually before WFE applications. As established falling film evaporator manufacturer, Dalal Engineering designs FFE systems that use steam, hot water, or hot oil as the heating medium, operating under either atmospheric or vacuum conditions. Feed liquid enters at the top of the vertical tube bundle; the feed distributor ensures uniform wetting of every tube, and the liquid descends as a thin falling film. Due to indirect heat from outside and vacuum from inside, evaporation starts, and vapours and the liquid films both travel downwards. Resulting in heat transfer coefficients significantly superior to those of conventional shell-and-tube or reactor-based evaporators. Usually a recirculation mode of operation is used and sometimes a once-through.

The FFE is ideal as a pre-concentration stage before the feed is transferred to a WFE for final concentration. This staged approach reduces the thermal load on the downstream thin film evaporator, optimizing energy consumption and improving overall system economics. (Lower capex and lower opex)

Total Solutions

Dalal Engineering supplies complete systems consisting of one or more Wiped Film Evaporators (WFE), Falling Film Evaporators (FFE), condensers, receivers for residue and concentrate, and vent condensers.

A pilot plant Wiped Film Evaporator (WFE) system is available at the Thane factory, where trials can be conducted to determine evaporation feasibility. Thereafter, WFE can be offered with process performance warranty.

Working Principle

The Supertor can crush, grind, homogenize & pump. An angular disc rotates in a cylindrical housing. Notched teeth in the Rotor disc meshes with teeth of Stator to effect disintegration & crushing - thus resulting movement generates thrust & shear causing acceleration of medium in both – axial & radial direction, resulting in intense mixing with pumping of the material.

Supertor Applications

Supertor is successfully is used in application such as high speed dispersers or batch emulsification / mixing, the Supertor operates continuously in Circulation or some times inline, reducing cycle times and enabling integration into automated process lines. It is equally effective as an inline homogenizer for emulsification of immiscible liquids and as an emulsification machine for producing stable emulsions at scale. The machine also supports wet micronization and particle micronization workflows, where surface-area enlargement through grain-size reduction is required to accelerate dissolution or reaction rates.

• Mixing Fluids of various viscosities
• Dispersing of pigments to produce colour
• Rapid homogenisation and slurry formation from wet cake
• Processing of pulp and black liquor in the paper Industry
• Mixing & crushing of liquid and paste like waste materials
• Surface enlargement through reduction in grain size for the dissolving process to reduce the dissolving time
• Crushing of coke particles in thick tar in coking plant ancillaries
• Increasing productivity and through put of spray dryers
• Rapid reslurry of filter cakes for efficient washing , also increasing reaction rate
• Waste cut treatment in the manufacture of fibre cement
• Diverse extractions for manufacturing essences
• Mixing & homogenising of spice extracts
• Prevention of choking and clogging of pipelines
• Clay & Silica application
• Starch manufacture
• Rapid dissolution of difficult-to-dissolve solids
• Maceration