Solvent Dehydraton Equipment
Crafting Purity: Breakthrough Zeolite Membrane Pervaporation for Superior Solvent Recovery
What is Zeolite Membrane Pervaporation Dehydration Equipment?
Zeolite Membrane Pervaporation (PV) Dehydration Equipment represents cutting-edge technology in solvent dehydration, especially for industries like pharmaceuticals, chemicals, and electronics. By utilizing molecular sieve membranes, which are constructed by cross-linking molecular sieve grains, creating a structure that facilitates selective adsorption based on the size or polarity of molecules. The technology leverages a concentration difference or partial pressure difference to drive mass transfer, efficiently separating solvent mixtures.
This equipment harnesses the principles of preferential adsorption and molecular sieving, achieving unparalleled efficiency and environmental friendliness in solvent recovery and purification.
- Production Process Information-Based Design Solution
- Processing capacity: 50TPY to 60000TPY
- Applicable solvents: alcohols, lipids, ketones, ethers, and other organic solvents
- Primary water content from 30%~1% to finished product water content of 0.5%~0.01% or lower.
- Sealing meets German TA Luft and ISO15848 standards.
Why Use Zeolite Membrane for Dehydration of Organic Solvents?
Elevate Your Process Efficiency with the Elite Zeolite Membrane Pervaporation System
Energy Saving
- Integrated technology of energy saving and environmental protection process.
- Energy saving: 50% – 75% lower than the traditional separation method
- The compact design leads to minimal energy requirements for heating, condensation, and vacuum conditions.
Safe and Efficient
- Simple process and fully automatic control with DCS control integration.
- Recovery yield: ≥ 99%,
- Separation purity: ≥ 99.99%
- Membrane selectivity can be optimized by choosing suitable PV membranes for the targeted mixture.
Separation of Organics
- Resist azeotropy and avoid the recovery and pollution of any third component.
- Separation coefficient ≥ 10000
- Not constrained by vapor-liquid equilibrium, it can separate challenging mixtures such as constant boiling point or near boiling point mixtures and isomers.
Specialized Design
- Combination of calculation, finite element analysis and experiment.
- The membrane module has high pressure resistance, long service life and reasonable fluid structure.
- The process is straightforward, requires fewer treatments, and can be integrated with other processes or reactions.
Compact Structure
- Skid mounted standardized construction structure saves 4 / 5 space
- Reduces infrastructure investment.
Top Class Membrane Sealing Technology
- The graphite gasket material is FDA certified
- Resist organic solvent corrosion, high temperature and aging.
- It has a service life of more than 5 years.
Hundreds of Engineering Projects Reference In the World
- Dehydration target of tetrahydrofuran (THF) solution: moisture from 10% → 0.05%.
- Dehydration target of MTBE solution: moisture from 2% → 0.05%.
- Dehydration target of Acetone solution : moisture from 1.5% → 0.05%.
- Dehydration target of Mixed Solvents solution: moisture from 10% → 0.5%.
- Dehydration target of Anhydrous Ethanol solution: moisture from 5% → 0.5%.
- Dehydration target of Isopropyl alcohol solution: moisture from 10% → 0.1%.
- Dehydration target of mixed alcohol solution: moisture from 20%→0.5%.
- Dehydration target of Ethyl acetate solution: moisture from 15% →0.5%.
- Dehydration target of Toluene and ethyl ether solution: moisture from 1%→0.01%.
- Dehydration target of Acetonitrile solution: moisture from 50%→ 0.03%
Tetrahydrofuran dehydration ceramic membrane equipment.
Dehydration capacity: primary 6% to finished 0.2%.
Pervaporation operation cost: US$24.8/ton.
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Acetone dehydration and purifying ceramic membrane equipment
dehydration capacity: primary 7% to finished 0.4%.
Pervaporation operation cost: US$17.5/ton
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- Independent pervaporation separation equipment unit.
- dehydration capacity: primary 15% to finished 1%.
Pervaporation operation cost: US$27.3/ton
- 50000 tons of tetrahydrofuran pervaporation equipment
- dehydration capacity: from 8% to 0.2%; 14% to 0.5%; 7% to 0.5%; 5% to 0.5%
- Solvent: tetrahydrofuran (THF), Ethanol, mixed ester, acetone.
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Isopropyl alcohol dehydration and purifying membrane equipment
dehydration capacity: 15% →0.2%
Treatment capacity: 8.4ton per day
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- Ethanol, ethyl acetate dehydration and separation equipment unit
- Dehydration capacity: 8% →0.2%
- Pervaporation treatment capacity: 15ton per day
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MTBE dehydration equipment.
Dehydration capacity: 2% →0.1%
Treatment capacity: 6 ton/day.
Methyl acetate dehydration equipment
dehydration capacity: 2% →0.1%
treatment capacity: 5ton per day.
- Acetone dehydration equipment.
- dehydration capacity: 0.3% →0.03%
treatment capacity: 4tons per day.
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How Does the Dehydration of Solvent with Zeolite Membrane Pervaporation System Work?
The process begins by heating the raw solvent mixture, creating a partial pressure difference across the membrane. The membrane, with its intrinsic hydrophilic properties, preferentially allows water molecules to permeate while obstructing organic molecules. The water vapor then condenses on the permeate side, effectively dehydrating the solvent.
Thereby producing a pure, anhydrous solvent. This makes it an effective and energy-efficient alternative to traditional distillation methods for solvent dehydration and recovery.
- Solvent feedstock composition and membrane entry requirements analysis
feed without salt substance.
the conductivity of the raw material shall be less than 5 μs ·cm-1
No pigment, colloid, peroxides, or substances that polymerize during heating
- No residue after evaporation.
Ceramic tubular permeation vaporization membrane dehydration technology is a separation process that combines thermally driven distillation with membrane separation technology. The mixture of organic solvents and water is driven by the difference in partial pressure of the component vapors, and the separation process of the substances is achieved by the difference in the adsorption and diffusion rates of the components through the permeation vaporization membrane, as shown briefly in the figure.
Application Area
Zeolite membrane dehydration equipment can be used in a wide range of industries, including pharmaceuticals, fine chemical, petrolchemical, medical health care, food and beverage, environmental protection etc., to improve the efficiency and quality of solvent production and recovery processes.
What types of mixtures can be separated using Zeolite Membrane PV?
Pervaporation Zeolite Membrane Separation System is especially designed for the compound of azeotropes, constant boiling point mixtures, isomers, and poor thermal stability chemical compounds that cannot be solved by distillation columns, PH6·5-8·5, DD<5us/cm, no salt crystals, no viscous macromolecules,
Pervaporation membrane technology has distinct advantages in the removal of trace water in organic solvents and mixed solvents as well as the separation of a small amount of organic pollutants in wastewater.
1.Organic solvent dehydration
2.Online dehydration of the synthetic reaction
3.The separation of organics
4.The mixed solvents dehydration
5.Refined oil
The listed various solvents are applicable for dehydration and separation with pervaporation membrane technology.
Customization Service and Solution
We are proposing the process equipment based on your production process flow and practical requests.
Tailored Process Engineering for Optimal Performance.
Step 1: Technical Communication and Technical Clarification
At the outset, our team engages in detailed technical communication with your experts to gain a thorough understanding of your specific process requirements and operational challenges. This phase involves a meticulous technical clarification process, ensuring every aspect of your production needs is captured accurately.
- In-depth requirement analysis
- Process feasibility discussions
- Identification of key technical parameters
Step 2: Experimental Testing with Minimum Sample
To ensure that our solution aligns perfectly with your expectations, we conduct extensive experimental testing on a laboratory and pilot scale. This phase is crucial for:
- Validating process viability
- Process flow design and simulation
- Optimization of process parameters
Step 3: On-Site Survey with Engineering Team
Our engineering team conducts on-site surveys to grasp the intricacies of your operational environment. This step is vital for:
- Precise equipment selection
- Adapted design considerations
- Alignment with existing infrastructure
How We Get Optimized Solution?
Step 4: Solution Customization and Design Approval
Leveraging advanced 3D design technology, we customize the solution to fit your unique process needs. This stage involves:
- Tailored equipment design
- Iterative design improvements
- Client collaboration and design approval
Step 5: Contract and Agreement Signing
Post design approval, we formalize our engagement through a contract that details every aspect of the project delivery, ensuring:
- Clear project deliverables
- Transparent timeline and milestones
- Production quality commitments
Step 6: Equipment Fabrication, Installation, and Commissioning
With a focus on top-tier manufacturing and stringent quality control, our fabrication phase adheres to the highest industry standards. This stage encompasses:
- Precision engineering and manufacturing
- Robust quality control protocols
- Seamless installation and commissioning
Step 7: Production Inspection and Acceptance
Before the final handover, we conduct a comprehensive inspection and testing phase to ensure the equipment performs as intended. This step includes:
- Rigorous performance testing
- Client-involved inspection
- Delivery upon acceptance
Step 8: After-Sales Services and Guidance
Our commitment to your success extends beyond delivery upon request. We provide:
- Extensive after-sales support
- Operational training and guidance
- Long-term maintenance services
Key Factors Influencing the Longevity of Membrane Module Performance
The durability and performance of membrane modules are pivotal for the efficiency of pervaporation processes. Understanding the factors that can adversely affect membrane longevity is crucial for maintaining optimal operations. Here’s a comprehensive guide to the main factors that impact the service life of membrane modules:
Presence of Crystallizable Salts and Viscous Polymer Impurities
The molecular sieve membrane can be compromised by the presence of crystallizable salts and viscous polymer impurities in the feed material.
- Salt Crystallization: Salts like calcium and magnesium can react deleteriously with the membrane, leading to a marked reduction in membrane flux and even irreversible damage.
- Polymer Adhesion: Viscous polymer impurities can gradually accumulate on the membrane surface, impeding the processing capacity of the device.
To mitigate these issues, it’s imperative to pre-treat the feed material to remove such impurities before the pervaporation process.
Deviation of Feed Material pH from the Optimal Range
The pH level of the feed material is a critical parameter that needs to be maintained within a specific range (6.5-8.5) to ensure membrane integrity.
- Acidic or Alkaline Extremes: A pH value outside this range can drastically shorten the membrane’s lifespan. Strongly acidic environments, in particular, can cause rapid membrane degradation.
- Neutralization Protocol: Should the pH deviate from the optimal range, it’s essential to neutralize the feed by adding acid or base, followed by thorough mixing and re-distillation. Only feed materials with a confirmed pH within the acceptable range should be processed.
Excessive Water Content and High Operating Temperatures
The feed’s water content and the operating temperature are also pivotal factors:
- Moisture Limitation: The moisture content in the feed should not surpass 30%; excess water can be detrimental to membrane performance.
- Temperature Threshold: Operating temperatures should be carefully controlled and must not exceed 130 °C to prevent thermal degradation of the membrane.
Technical & Commercial Clarifications
FAQs
We are pleased to clarify all of your technical and commercial concerns.
How many membrane columns recommended?
The membrane columns are selected according to the inlet flow rate, each module with 96 tube-type membrane columns in the component. So the proper area of membrane components is calculated and selected according to the feed rate, feed water content, and final draw-out water content.
How ethanol vapor is cooled?
The feeding ethanol solution is preheated by preheater, and with circulation water condensing through a condenser, A secondary condenser can be added for further cooling of ethanol to a lower temperature with chilling water about 7 degrees Celsius.
How to prevent ethanol entrainment to vacuum system?
Ethanol flows outside of the membrane when water is absorbed into the membrane, and a vacuum condition in the membrane system will suck the water off the membrane. Only a small amount of ethanol will pass through the membrane tube in the solvent dehydration process from 90% to 99%. the ethanol recovery rate is above 99%.
whether membrane reaches a saturation limit with water if then how it is getting regenerated?
The membrane can be used all along the lifetime, normally 3-5 years. The membrane can’t be regenerated. Membrane service life is related to the saltness of raw material, polymer viscous substances, and other impurities, it is necessary to strictly control the feed liquid quality, unclean solvent will cause membrane damage.
How to maintain membrane in hot condition -only jacketing may not be sufficient?
According to our engineering project experience of nearly 100 sets of equipment, the jacket heating designs were always sufficient to meet the requirements.
Since the temp. is between100-130 C, how to prevent cold spots in vacuum it can be in vapor phase- vacuum what is the level of vacuum (mmHg?)?
Absolute pressure can be 2000pa=15mmHg
What is the capacity of your system designing system?
The processing capacity has been designed from 50 tons per year to 50000 tons per year according to customer practical requests.
Can Zeolite Membrane PV be integrated with existing processes?
Absolutely, it’s designed for easy integration with biological, chemical, or other membrane separation processes either with single membrane module or complete membrane components. With properly selected and engineered membrane module, it can be servicing for your process applications.
What is the feed and product quality of finished solvents?
The proposal is customized with the required Capacity, for solvent concentration and purification process.
The equipment is customized according to customer processing requirements. Our company has completed the equipment and supply with a maximum processing capacity of 8 m³/Hr, and the final water content of the solvent solution can reach 0.02%.
What does your after services include?
we provide online and on-site after-sales service on request from customers, including engineering, installation, start-up commissioning guidance, etc.
How long is your equipment quality guarantee?
The warranty period for the whole equipment is one year.
The warranty period for the membrane components, including the membrane tube, seal, and membrane shell are two years from the acceptance of the equipment.
Can we add PLC program into our DCS system?
The Control system can be integrated into the upper control system as per the user’s requirement, or access to the DCS system.
The control system adopts Siemens PLC and Schneider components. There is a DCS communication interface, which can remotely monitor the running state of the system and guarantee the operation safety, and unattended can be realized.
What are the maintenance requirements?
Maintenance is minimal due to the simplicity of the operation and the robustness of the membranes.
Keep the lubricate oil clean and middle liquid level on working condition.
Keep stable supplying of utility. The system will working smoothly on long term.
We will provide complete process instruction and operation guidance on starting and maintenance.
What are payment options?
We welcome your firm order with a payment term of 30% advance payment and 70% cleared before delivery. Also available with L/C at sight payment term.
Contact Greatwall Team
For deep discussion about zeolite membrane and PV&VP technology for solvent dehydration, please feel free to contact to us.
Greatwall is willing to communicate and share process engineering design with you for securing the best solution.
We are looking forward to developing more market and creating more values for all parties.
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