2 Design and Mode of Operation of the Unit

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Gary Parker
5 years ago
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$Pos: 15 /010 Universalmodule/ Abschnittswechsel @ 0\mod_1202124514062_0.$

1 Pos: 15 /010 Universalmodule/ 418 Freeze-Dryer Epsilon 2-12D Pos: 16 /200 Christ/310 GT-BA Produktion (PROJEKTE)/(-en) Epsilon 2-12 D (Intervet, NL)/ Aufbau (E The freeze-dryer is designed according to the Christ double chamber system where the ice condenser (B) is located directly below the drying chamber (A) (see design-scheme below). Cross-sectional view of the double chamber system (design scheme) The advantage lies in the large opening that provides the ideal cross section for discharge of water vapour to the ice condenser. Due to short distances for the water vapour the freeze-dryer offers highly efficient and economic operation. A reduced pressure difference between ice condenser and drying chamber allows to dry temperature sensitive materials close to their melting point. This allows shortest drying times. Furthermore this design has the benefit of easy access to the drying chamber and the ice condenser (with the shelves moved to the ceiling of the drying chamber) through the hinged full-size loading door. Thus no additional openings and gaskets are needed in order to perform service and maintenance work. The Christ double chamber system allows an extremely compact layout of the freeze-dryer. The hydraulic piston rod (1) for the actuation of the intermediate valve (2) between the drying chamber and the ice condenser chamber as well as for moving the shelves (3) to facilitate loading/ unloading and for sealing product vials is installed below a dome in the centre of the ice condenser chamber bottom. The ice condenser coil (4) is installed inside the separate ice condenser chamber to collect the vapour released from the product during drying. Characteristics of the CHRIST double chamber system: Convenient access to the ice condenser through the loading door Easy cleaning of drying and ice condenser chamber Minimization of gaskets to facilitate service and maintenance works 13

Optimized water vapour transport from the product on the shelves to the ice condenser coil due to the large cross-section between drying chamber and ice condenser chamber High efficiency and economic

2 Optimized water vapour transport from the product on the shelves to the ice condenser coil due to the large cross-section between drying chamber and ice condenser chamber High efficiency and economic operation of the unit due to short distances for the water vapour The reduced pressure difference between the ice condenser chamber and the drying chamber allows drying sensitive as well as low eutectic substances Easy validation in order to meet all national and international regulations The freeze-dryer is designed as stand alone unit with separated switch cabinet (16) for easy transportation and to match with the room layout at site. To reduce assembly work at the location of use and to simplify moving at site the double chamber together with all the machinery is installed in a single compact steel profile rack. The front panel at the loading side is made of ground stainless steel. Removable corrosion-resistant steel sheet doors cover the side walls. A removable perforated steel sheet with cutouts for accessing controls covers the rear side. The front panel and the side covers are fitted with acoustic insulation to reduce the noise level in the area of the operating personnel to 70. In order to provide full SCADA functionality at the front panel of the freezedryer the SCADA PC (host) is installed in a switch box (15) inside the steel rack and connected to the SIMATIC S7-300 PLC inside the separated switch cabinet (16) via Ethernet LAN. The SCADA PC is operated via a touch screen monitor (17) that is integrated into the front panel (HMI I). A second PC (remote, customer provided) can be connected to a network switch inside the switch cabinet via Ethernet LAN and thus permits host operation and monitoring via remote control. Freeze-dryer design drawing (partially assembled) front side 14

3 The drying chamber is equipped with a full-size see-through loading door (5) for convenient loading/ unloading. It is hinged on the right by means of two solid stainless steel hinges. The contact pressure for pre-sealing the door is achieved via two toggle fasteners on the left. Freeze-dryer design drawing (partially assembled) right side 15

Freeze-dryer design drawing (partially assembled) left side Major components of the freeze-dryer: (6) Rotary vane vacuum pump with exhaust filter (oil mist separator) and automatic oil recirculation

admission (injection, bleeding) (9) 2 vacuum sensors (Pirani and MKS) at the drying chamber and 2 vacuum sensors (Pirani and MKS) at the ice condenser chamber (10) Heat exchanger with an electrical

4 Freeze-dryer design drawing (partially assembled) left side Major components of the freeze-dryer: (6) Rotary vane vacuum pump with exhaust filter (oil mist separator) and automatic oil recirculation (7) Pressure control valve installed in the suction pipe of the vacuum pump to regulate the chamber vacuum (8) Proportional vacuum valve for high precision vacuum control by regulated air/ gas admission (injection, bleeding) (9) 2 vacuum sensors (Pirani and MKS) at the drying chamber and 2 vacuum sensors (Pirani and MKS) at the ice condenser chamber (10) Heat exchanger with an electrical heating element installed in order to heat the shelves and with built-in cooling coils connected to the refrigeration machines to cool the shelves via the circulated heat transfer medium (11) Heat transfer medium circulation pump (12) 2 two-stage refrigeration machines for ice condenser cooling as well as for shelf temperature control in combination with the electrical heating elements 16 (13) Hydraulic unit to actuate the intermediate valve (2) between the drying chamber and the ice condenser chamber and to move the shelves up and down

5 Pos: 17 /010 Universalmodule/ 418 Pos: 18 /010 Universalmodule/ 105 Freeze-Dryer Epsilon 2-12D (14) Condensate drain valve (15) Switch box containing the SCADA PC (host) and the transducers of the sensors. (16) Switch cabinet containing components of the load circuit and the control circuit including the control system (PLC) (17) Operating panel with SCADA touch screen. (18) 24 channel data recorder (paperless) for SCADA independent data acquisition and storage (19) Motor driven shelf locking mechanism, that in combination with the hydraulic shelf movement system enables sealing of product vials on a single shelf during drying (20) Humidity monitoring port next to the intermediate valve. Allows monitoring of the main water vapour stream towards the ice condenser by means of an Adixen LYOTRACK (not included in the scope of delivery) 17

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