In the pharmaceutical and chemical production process, organic waste gas is continuously generated at stations such as reactor pressure relief, vacuum desolvation, distillation of non condensable gases, crystallization centrifugation, material transfer, and tank respiration. The main components of the waste gas are dichloromethane, ethyl acetate, acetone, and alcohol ketone organic solvents. The working conditions of pharmaceutical and chemical waste gas are complex, mostly intermittent pulse emissions, with large fluctuations in air volume and concentration. The airflow carries solvent droplets and aerosols, and some media have strong halogenated corrosion characteristics. If this type of exhaust gas is directly and unorganized discharged, it not only causes a large loss of high-value solvents and increases the cost of raw materials for enterprises, but also poses safety hazards due to the accumulation of flammable vapors in the workshop. At the same time, it is difficult to meet the strict VOCs environmental control requirements of the pharmaceutical industry.
The traditional waste gas treatment process has obvious shortcomings in complex working conditions in the pharmaceutical and chemical industries. The incineration process directly burns recyclable solvents, resulting in serious resource waste. The combustion of halogenated media can easily generate corrosive and toxic by-products, high equipment energy consumption, and high operation and maintenance costs.activated charcoalAdsorption only involves the transfer of pollutants and cannot achieve solvent resource recovery. Pulse type exhaust gas impact can easily cause rapid saturation and agglomeration of adsorption materials, posing a risk of heat accumulation and spontaneous combustion. The operation process continues to generate hazardous solid waste, and consumables are frequently replaced. The single condensation process is limited by the partial pressure of organic vapor, and when faced with fluctuating mixed exhaust gases, the solvent recovery efficiency is unstable, and the treatment of low concentration exhaust gases is not thorough, making it difficult to adapt to the continuous and multi batch production needs of pharmaceuticals.
The solvent condensation membrane separation device adopts a fully physical process of compression condensation membrane coupling, with no combustion or chemical reaction throughout the process, and does not produce secondary pollutants. It is suitable for the resource recovery of organic waste gas in pharmaceutical and chemical industries. The organic waste gas emitted from each production site is collected centrally through a closed negative pressure pipeline network and sent to a buffering and stabilizing unit to smooth out the pressure and gas pulse impact caused by intermittent exhaust, stabilize the intake conditions of the main engine, and reduce the impact damage of fluctuating airflow on core precision components such as compressors, heat exchangers, and membrane components. The exhaust gas enters the multi-stage pretreatment module, which gradually removes solvent droplets, fine aerosols, and free moisture inside the airflow, effectively reducing the probability of equipment corrosion, scaling, and blockage failures, and extending the operating life of the entire equipment.
After pre-treatment and purification, the exhaust gas is compressed and pressurized, the organic vapor partial pressure is raised, and the solvent liquefaction phase transition conditions are constructed. It is then sent to a multi-stage gradient condensation unit and cooled by different solvent boiling point differences. Most of the organic components are directly liquefied and precipitated, completing the recovery of the solvent main body. After condensation treatment, the remaining low concentration exhaust gas enters the polymer membrane separation unit and is enriched with organic components through the permeation selectivity of the membrane material. The purified exhaust gas meets the emission standards, and the concentrated high concentration organic gas flow is circulated back to the front end of the equipment for further improvement of the comprehensive recovery efficiency of the mixed solvent. The recovered liquid solvent undergoes water separation, precision filtration and purification treatment to meet the production reuse standards. It can be returned to the pharmaceutical workshop for recycling, reducing solvent procurement costs, reducing hazardous waste disposal, and simultaneously achieving waste gas treatment and material resource utilization benefits.
The equipment supports integrated configuration of pry and installation, and the factory completes assembly, pressure testing, and explosion-proof verification before the entire machine leaves the factory. On site, only the tail gas pipeline and utility interface need to be connected, with a small construction workload and a short renovation period. It can achieve non-stop renovation of the old factory area, which is suitable for new pharmaceutical and chemical projects, as well as upgrading and renovating the tail gas system of existing production lines. The whole machine is designed and selected according to the Class A explosion-proof standards for chemical engineering, and all electrical components meet the explosion-proof level. Components that come into contact with corrosive media are made of suitable anti-corrosion materials. The system is equipped with interlock protection for overheating, overpressure, and combustible gas detection, as well as emergency venting bypass, to calmly respond to various sudden abnormal working conditions and avoid on-site safety risks. Equipped with an intelligent frequency conversion self-control system, it can dynamically and adaptively adjust the operating load according to the exhaust gas volume and concentration, reduce ineffective energy consumption, and support long-term unmanned stable operation. The process configuration can be customized based on the composition of pharmaceutical waste gas, treatment air volume, and on-site site conditions, and is widely used in solvent recovery projects for organic waste gas in pharmaceutical and chemical industries such as raw materials and pharmaceutical intermediates.
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