Custom Low Pressure Crystallizer Fabrication

Roben, Mfg, Inc. is a leading provider of custom low pressure crystallizer fabrication services, specializing in the design, engineering, and manufacturing of tailor-made crystallization equipment for applications involving reduced pressure or vacuum conditions. With our expertise, state-of-the-art facilities, and commitment to quality and performance, we deliver custom low pressure crystallizer solutions that meet the unique requirements of our clients.

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Why Choose Custom Low Pressure Crystallizer Fabrication?

Custom low pressure crystallizer fabrication offers several advantages over standard equipment for applications that involve reduced pressure or vacuum conditions

  1. Tailored to Specific Process Requirements: Custom low pressure crystallizers are designed and fabricated to meet the unique process conditions, product specifications, and operational needs of each client, ensuring optimal performance and efficiency at reduced pressures.
  2. Enhanced Mass and Heat Transfer: By operating at reduced pressures, custom low pressure crystallizers can promote faster evaporation rates, increased supersaturation, and improved mass and heat transfer, leading to more efficient crystallization processes.
  3. Gentle Product Handling: Low pressure crystallization allows for the processing of heat-sensitive or delicate materials, as the reduced pressure enables crystallization at lower temperatures, minimizing the risk of product degradation or damage.
  4. Improved Product Purity: By operating under vacuum conditions, custom low pressure crystallizers can minimize the presence of dissolved gases or air entrainment, resulting in higher product purity and reduced contamination.
  5. Energy Efficiency: Low pressure crystallization can be more energy-efficient than conventional crystallization processes, as it requires less heating and cooling, and can utilize waste heat or low-grade energy sources.

Custom Low Pressure Crystallizer Fabrication Capabilities

At Roben, Mfg, Inc., we offer a comprehensive range of custom low pressure crystallizer fabrication capabilities to suit the diverse needs of our clients

  1. Vacuum System Design and Integration: We design and integrate custom vacuum systems, including vacuum pumps, ejectors, condensers, and control valves, to achieve and maintain the desired low pressure conditions in the crystallizer.
  2. Vapor-Liquid Separation: Our custom low pressure crystallizers incorporate advanced vapor-liquid separation techniques, such as cyclones, demisters, and packed beds, to efficiently separate the crystallized solids from the vapor phase and prevent entrainment.
  3. Heating and Cooling Systems: We offer a variety of heating and cooling options for low pressure crystallizers, including jacketed vessels, internal coils, external heat exchangers, and vacuum evaporators, to precisely control the temperature profile and supersaturation levels.
  4. Agitation and Mixing: Our low pressure crystallizers can be equipped with custom agitation and mixing systems, such as impellers, baffles, and recirculation loops, to ensure uniform suspension of crystals, promote secondary nucleation, and prevent agglomeration.
  5. Instrumentation and Process Control: We integrate advanced instrumentation and control systems, including pressure transmitters, temperature sensors, level indicators, and PLC-based controllers, to monitor and regulate the low pressure crystallization process for optimal performance and consistency.

Custom Low Pressure Crystallizer Types

Roben, Mfg, Inc. fabricates a wide range of custom low pressure crystallizer types to suit various industries and applications

  • Vacuum Crystallizers
  • Falling Film Crystallizers
  • Rising Film Crystallizers
  • Forced Circulation Crystallizers
  • Draft Tube Baffle Crystallizers
  • Agitated Thin Film Crystallizers
  • Wiped Film Crystallizers
  • Rotary Vacuum Crystallizers
  • Fluidized Bed Crystallizers
  • Continuous Vacuum Crystallizers
  • Multi-Stage Vacuum Crystallizers
  • Vapor Recompression Crystallizers
  • Desalination Crystallizers

Custom Low Pressure Crystallizer Applications

Our custom low pressure crystallizers are designed and fabricated to serve a wide range of industries and applications that involve reduced pressure or vacuum conditions, including

  • Pharmaceuticals and Fine Chemicals
  • Food and Beverage Processing
  • Sugar and Sweetener Production
  • Salt and Mineral Crystallization
  • Wastewater Treatment and Zero Liquid Discharge (ZLD)
  • Desalination and Brine Concentration
  • Chemical Processing and Purification
  • Agrochemicals and Fertilizers
  • Bioprocessing and Fermentation
  • Nutraceuticals and Natural Extracts
  • Polymers and Plastics
  • Pigments and Dyes
  • Metals and Alloys Refining
  • Petroleum and Petrochemicals

Custom Low Pressure Crystallizer Fabrication Process

At Roben, Mfg, Inc., we follow a systematic and thorough approach to custom low pressure crystallizer fabrication to ensure the highest level of quality and performance

  1. Process Analysis and Vacuum System Design: Our team of process engineers and vacuum specialists works closely with clients to understand their specific requirements and process conditions. We perform detailed analysis and modeling to design the optimal vacuum system and low pressure crystallizer configuration.
  2. Material Selection and Corrosion Resistance: Based on the process requirements and fluid properties, we select the most suitable materials for the low pressure crystallizer, considering factors such as chemical compatibility, corrosion resistance, thermal stability, and mechanical strength. We also offer a range of surface treatments and coatings to enhance the durability and performance of the crystallizer.
  3. Detailed Engineering and 3D Modeling: Our experienced designers and engineers create detailed 3D models, fabrication drawings, and specifications for the custom low pressure crystallizer, incorporating all the necessary vacuum components, heating/cooling systems, agitation mechanisms, and instrumentation. We use advanced simulation tools to validate the design and optimize its performance.
  4. Precision Fabrication and Assembly: Our skilled fabricators and welders use state-of-the-art equipment and techniques to manufacture the low pressure crystallizer components with the highest level of precision and quality. We employ rigorous quality control procedures, including dimensional inspection, non-destructive testing (NDT), and vacuum leak testing, to ensure the integrity and performance of the crystallizer.
  5. Factory Acceptance Testing (FAT): The custom low pressure crystallizer undergoes extensive factory acceptance testing to verify its functionality, performance, and compliance with the specified requirements. This includes vacuum pull-down tests, pressure hold tests, temperature control tests, and simulated process runs. All test results and quality control documents are provided to the client for review and approval.
  6. Installation and Commissioning Support: Our team of experienced field engineers and technicians provides on-site installation, commissioning, and startup support to ensure the proper integration and operation of the custom low pressure crystallizer in the client’s facility. We also offer training and technical support to the client’s personnel to ensure the safe and efficient use of the equipment.

Standards and Certifications for Low Pressure Crystallizers

Our custom low pressure crystallizers are designed and fabricated in accordance with the relevant industry standards and certifications for vacuum equipment and pressure vessels, including

  • ASME Boiler and Pressure Vessel Code (BPVC) Section VIII
  • ASME Bioprocessing Equipment (BPE) Standard
  • ASME Pressure Equipment Directive (PED)
  • NACE MR0175 / ISO 15156 for Sour Service
  • ATEX Directive for Equipment in Explosive Atmospheres
  • FDA Current Good Manufacturing Practices (cGMP)
  • USDA Dairy Grading Branch
  • 3-A Sanitary Standards
  • EHEDG (European Hygienic Engineering & Design Group)
  • ISO 9001 for Quality Management Systems
  • ISO 14001 for Environmental Management Systems
  • OHSAS 18001 for Occupational Health and Safety Management Systems

For more information about our custom low pressure crystallizer fabrication services or to discuss your specific requirements, please contact Roben, Mfg, Inc. today. Our experienced team is ready to assist you in designing and fabricating the most suitable and efficient low pressure crystallization equipment for your application.

Custom Low Pressure Crystallizer Fabrication FAQs

What are the typical operating pressures for custom low pressure crystallizers?

Custom low pressure crystallizers can be designed and fabricated to operate at a wide range of reduced pressures or vacuum levels, depending on the specific application and process requirements. The operating pressures can range from slightly below atmospheric pressure (e.g., 0.8-0.9 bar) to deep vacuum conditions (e.g., 1-10 mbar or lower).

The selection of the appropriate operating pressure for a low pressure crystallizer depends on various factors, such as

  • The vapor-liquid equilibrium (VLE) and solubility characteristics of the system
  • The desired evaporation rate and crystallization kinetics
  • The boiling point and thermal stability of the solvent and solute
  • The presence of dissolved gases or air entrainment
  • The available vacuum generation and heat transfer equipment
  • The energy consumption and operating costs

Our team of process engineers and vacuum specialists works closely with clients to determine the optimal operating pressure range for their custom low pressure crystallizer, considering the specific process requirements, product specifications, and economic feasibility.

How do you ensure the efficiency and reliability of the vacuum system in custom low pressure crystallizers?

Ensuring the efficiency and reliability of the vacuum system is critical for the successful operation of custom low pressure crystallizers. At Roben, Mfg, Inc., we employ several strategies to optimize the performance and dependability of the vacuum system

  • Proper sizing and selection of vacuum pumps, ejectors, and condensers based on the process requirements, operating pressure, and gas load
  • Use of redundant or backup vacuum pumps to maintain the vacuum level in case of equipment failure or maintenance downtime
  • Installation of vacuum control valves, pressure relief devices, and isolation valves to protect the system from overpressure, backflow, or contamination
  • Incorporation of filtration and purification devices, such as knock-out pots, demister pads, and activated carbon beds, to remove entrained liquids, particulates, or volatile organic compounds (VOCs) from the vacuum stream
  • Implementation of advanced instrumentation and control systems, including pressure transmitters, temperature sensors, and PLC-based controllers, to monitor and regulate the vacuum system in real-time
  • Regular maintenance, inspection, and calibration of the vacuum equipment, including leak testing, oil changes, and performance checks, to ensure optimal efficiency and reliability
Can you customize low pressure crystallizers for corrosive or hazardous processes?

Yes, at Roben, Mfg, Inc., we have extensive experience in designing and fabricating custom low pressure crystallizers for corrosive and hazardous processes. We understand the unique challenges and safety requirements associated with handling aggressive or toxic fluids under vacuum conditions, and we take special precautions to ensure the compatibility, durability, and safety of the crystallizer.

Some of the strategies we employ for corrosive or hazardous low pressure crystallization processes include

  • Selection of corrosion-resistant materials, such as stainless steel, nickel alloys, titanium, or graphite, based on the specific process chemistry and fluid properties
  • Application of protective coatings or linings, such as PTFE, PFA, or glass, to prevent direct contact between the corrosive fluid and the crystallizer surface
  • Incorporation of secondary containment, leak detection, and emergency shutdown systems to mitigate the consequences of potential leaks or failures
  • Use of sealed or magnetic drive agitators, double mechanical seals, and vapor recovery systems to minimize the release of hazardous vapors or liquids
  • Implementation of proper ventilation, gas detection, and personal protective equipment (PPE) to ensure the safety of operators and maintenance personnel
  • Compliance with relevant safety standards and regulations, such as ATEX, IECEx, and NFPA, for equipment in hazardous areas
What are the typical lead times for custom low pressure crystallizer fabrication?

The lead times for custom low pressure crystallizer fabrication can vary depending on the size, complexity, and specific requirements of the equipment. In general, the lead times can range from several months to a year, depending on the scope of the project and the current workload of our manufacturing facility.

The key stages of the fabrication process that impact the lead time include

  • Initial consultation and process analysis: 1-2 weeks
  • Vacuum system design and material selection: 2-4 weeks
  • Detailed engineering and 3D modeling: 4-8 weeks
  • Procurement of materials and components: 4-12 weeks
  • Fabrication and assembly: 8-24 weeks
  • Factory acceptance testing (FAT): 2-4 weeks
  • Shipping and installation: 2-4 weeks

At Roben, Mfg, Inc., we work closely with our clients to establish realistic project timelines and keep them informed of the progress at every stage of the fabrication process. We also strive to optimize our production schedules and supply chain management to minimize lead times and ensure on-time delivery of the custom low pressure crystallizer.

How do you support the maintenance and troubleshooting of custom low pressure crystallizers?

At Roben, Mfg, Inc., we are committed to providing comprehensive support for the maintenance and troubleshooting of our custom low pressure crystallizers throughout their entire lifecycle. Our support services include

  • Detailed operating and maintenance manuals that provide clear instructions and guidelines for the proper care and use of the crystallizer, including safety precautions, startup and shutdown procedures, and routine maintenance tasks
  • On-site or remote technical support from our experienced engineers and technicians, who can assist with troubleshooting, process optimization, and performance monitoring
  • Spare parts management and inventory services to ensure the timely availability of critical components, such as vacuum pumps, seals, gaskets, and instrumentation, and minimize downtime in case of maintenance or repairs
  • Preventive maintenance and calibration services, either on-site or at our facility, to keep the low pressure crystallizer and its vacuum system in optimal condition and prevent potential issues before they occur
  • Upgrades and retrofits to incorporate the latest technologies and improve the performance, efficiency, and safety of the crystallizer, such as advanced process control, energy recovery, or solids handling systems
  • Training and certification programs for the client’s operators, maintenance personnel, and engineers, to ensure the safe and efficient operation of the low pressure crystallizer and its vacuum system

In addition, we offer customized service contracts and warranty programs tailored to the specific needs and requirements of each client, ensuring a long-term partnership and support throughout the entire lifecycle of the custom low pressure crystallizer.

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