The pharmaceutical and chemical reaction kettle will continuously discharge organic waste gas during the operation stages such as feed replacement, reaction pressure relief, vacuum pumping, and discharge. The components of the waste gas are mostly dichloromethane, ethyl acetate, acetone, alcohols, ketones, and other commonly used organic solvents in pharmaceutical production. The exhaust gas from the reactor belongs to typical intermittent pulse emissions, and each time the pressure is released, an instantaneous high concentration of oil and gas is generated. The gas flow carries a large number of solvent droplets and aerosols, and some solvent media have halogenated corrosion characteristics. The reaction kettle area belongs to Class A explosion-proof high-risk area. If the exhaust gas is directly discharged, it will cause a large amount of expensive pharmaceutical solvents to evaporate and lose, which will increase the cost of raw materials; On the other hand, flammable vapors are prone to accumulate in the workshop, posing a risk of explosion. At the same time, unorganized emissions can cause VOCs to exceed the standard, which cannot meet the environmental control requirements of the pharmaceutical industry.
Traditional waste gas treatment equipment is difficult to adapt to the dual requirements of explosion prevention and resource utilization in pharmaceutical reaction vessels. The incineration process comes with an open flame source and is strictly prohibited from being used in Class A explosion-proof workshop areas. It also directly burns recyclable solvents, resulting in serious resource waste. The combustion of halogenated components can also generate toxic and corrosive by-products, leading to high energy consumption and operation costs.activated charcoalThe adsorption equipment is prone to rapid saturation in the face of instantaneous high concentration exhaust gas impact from the reaction kettle, and there is a risk of thermal self ignition in the adsorption bed. It can only transfer pollutants and cannot recover solvents. The operation continues to generate hazardous solid waste, and consumables are frequently replaced. A single condensing equipment lacks a complete explosion-proof interlocking system, resulting in unstable recovery efficiency when operating conditions fluctuate, incomplete treatment of low concentration residual exhaust gas, and difficulty in matching the production characteristics of intermittent pressure relief in reaction vessels.
The explosion-proof solvent resource utilization equipment adopts a fully physical process of compression condensation membrane coupling, with no open flames or chemical reactions throughout the process, and does not produce secondary pollutants. It is specially developed for pharmaceutical and chemical reaction kettle waste gas conditions. The exhaust gas generated by the pressure relief of the reaction kettle is collected through a closed negative pressure pipeline and sent to a buffering and stabilizing unit to absorb the pressure and air flow impact caused by instantaneous pressure relief, smooth the intake fluctuation, and protect core precision components such as compressors, heat exchangers, and membrane components from damage caused by pulse airflow. The exhaust gas enters the multi-stage pretreatment module to remove solvent droplets, fine aerosols, and free water carried by the airflow layer by layer, reducing the probability of equipment corrosion, scaling, and blockage failures, and ensuring stable operation of the equipment under frequent start stop intermittent conditions.
The pretreated exhaust gas is compressed and pressurized to increase the partial pressure of organic vapor, create conditions for solvent liquefaction and recovery, and is sent to a multi-stage gradient condensation unit, where it is cooled and cooled in stages according to the boiling point range of different solvents, and most of the organic solvents are directly liquefied and precipitated to complete the recovery of the solvent body. After condensation, the remaining low-concentration tail gas enters the polymer membrane separation unit, relying on the permeability of the membrane material to selectively enrich the organic components, the purified tail gas meets the emission standard, and the concentrated high-concentration organic gas flow is recycled to the front end of the equipment to further improve the comprehensive recovery rate of the mixed solvent. The recovered liquid solvent is purified by water separation and precision filtration, the quality meets the reuse standard of pharmaceutical production, and can be returned to the reactor process for recycling, reducing the purchase of fresh solvent, reducing the cost of hazardous waste disposal, and realizing waste gas treatment and solvent resource recovery.
The whole set of equipment is designed and manufactured in strict accordance with Class A chemical explosion-proof standards. Motors, instruments, solenoid valves, etc. all adopt explosion-proof specifications. Pipelines and components in contact with corrosive media are made of special anti-corrosion materials. The system is equipped with over-temperature, over-pressure, combustible gas concentration linkage interlock protection and emergency venting bypass. Once the working condition of the reactor changes abruptly, the pressure relief protection can be automatically implemented to avoid the potential safety hazard caused by instantaneous high concentration exhaust gas. The intelligent frequency conversion automatic control system can dynamically adjust the operating load of the equipment according to the intermittent exhaust characteristics of the reactor, automatically standby at low load when no exhaust gas enters, reduce energy consumption, and support 24-hour unattended and stable operation. The equipment adopts a skid-mounted integrated structure. After the factory completes the whole machine assembly, pressure test and explosion-proof debugging, the factory leaves the factory, and the on-site docking pipeline can be put into use. The construction period is short, and the production line is supported not to stop production. According to the reactor volume, pressure relief frequency, waste gas composition, peak air volume and workshop explosion-proof partition custom process configuration, widely used in raw materials, pharmaceutical intermediates production enterprises reactor waste gas resource recovery project.
Mr. Li 13526990215
Hotline
