Vapor thermocompressor Stills
STILMAS Stilmas is an industrial and engineering Company specialized in the research, design, development and construction of high technology plants for the pharmaceutical, electronic, cosmetic and food processing industries. The business scope is the design, the production, the assembly, the sale and installation of such plants, of special equipment and instruments, as well as the exploitation of alternative powers and energy saving achievements. The modern and exhaustive equipment, the dynamic organization and the available financing means, allow the completion and extension of both activity and study in addition to a closer relationship with C.N.R. and the most important universities. pure technology, pure water
Vapor thermocompressor Stills The Mascarini Thermocompression Stills FA-HRS series and ThermoPharma Thermocompression Still BD series produce distilled water for injectable use which meets the latest requirements of the International Pharmacopeias including USP, EP and JP. They are also widely employed in many other industries such as: Food, Film, Electronic and Fine Chemical Standard models capacity: Series FA-HRS: capacity from 50 to 4500 lts/h Series BD: capacity from 100 to 24.000 lts/h Main features of Stilmas Thermocompressor Possibility to produce cold distillate water at 25 C or hot distilled water at 85 C. No need of cooling water. High energetic performances due to a careful design of the compressors and to an optimized configuration of the heat recovery system. Highly efficient non condensable gases removal due to the hydrostatic column system installed downstream the still. Design of the compressors to guarantee the quality of the steam / distillate. Possibility to fed the unit with softened water. Distilled water produced pressurized, not requiring any pressurizing system. Fast response: in stand by conditions the distillate is produced in 10 minutes. Atmospheric pressure operation: no need of pressure vessel certification. Reduced and easy maintenance: due to a careful selection of compressor technology, low/medium rotational speed. Detail of evaporator tubes Look closely...
FEED WATER QUALITY Stilmas Thermocompressors Series FA-HRS and BD can be fed with deionised water or even softened water. Not withstanding the higher blow down rate in case of softened water feeding, this possibility is of extreme interest in running cost reduction (due to softened water lower production cost compared to deionized water), as well as extremely simplifying the configuration of the pre-treatment section: a simple softener can provide the suitable feed water to the Still. Operating principle Feed water is pre-heated in three heat exchanger to recover the sensible heat of produced WFI, concentrate and Non Condensable Gases. The feed water is then sent to the still main body bottom, where it is pre-heated to evaporation temperature by an external energy source - electric or steam. The evaporation takes place in a vertical shell and tube heat exchanger (tube side) which is an integral part of the still body. The produced steam is flowing into the evaporation column (dome) where the decontamination (droplet and - consequently - endotoxyn reduction) occurs. The pure steam is then sucked by the compressor, and sent back to the same shell and tube heat exchanger, shell side. The slightly pressurized steam condenses at a higher temperature than the boiling water tube side, so transferring the latent heat. The condensed WFI is sent to the hydrostatic column for degassing, and finally is pressurized by a sanitary pump, sent to the heat recovery system and then to battery limits. Thermocompression steel - detail of hydrostatic column a unique and original design
Main components design Stilmas Thermocompressors FA-HRS and BD series include: A set of preheaters to heat feed water. Such configuration guarantees very high energetic performances, simultaneously allowing the production of hot or cold distillate. Vertical evaporator / condenser, shell and tube type, granting a very high efficiency in heat transfer. Evaporation column: design is characterized by large diameter which allows for gravitational separation of the water droplets from the steam. Hydrostatic column of careful design for the separation of the non condensable gases from the generated distillate. The column is installed downstream the still, ensuring high NCG removal and, consequently, very low WFI conductivity. Thermocompressor still FA-HRS serie, 1000 lts/h capacity
Construction Characteristics The plant is completely made in AISI 316L stainless steel. Standard finishing of the active surface is pickled and passivated; mirror or electropolishing can be made on request. Product (WFI) contact parts are manufactured with surface finishing 0.6 microns Ra mechanically polished, with piping orbitally welded with sanitary flanges and pharmaceutical grade Teflon gasket. The design and construction of the decontamination chamber, which is a totally empty column, ensure the best inspectability. The absence in this area of welding dramatically reduce the risk of corrosion, for a very long expected life of the equipment. Heat exchangers: the preheater in contact with Non Condesable Gases is shell and tube DTS type; the other pre-heaters are plate type (Shell and tube DTS as options). In shell and tube heat exchangers (including the main evaporator), the pipes are expanded into the plates, avoiding any welding for a totally hygienic execution, and a better resistance against dilatation stress. Thermocompressor still BD serie, 500 lts/h capacity
COMPRESSORS TECHNOLOGY Stilmas S.p.A. has developed two alternative solutions for the steam compressor. Mascarini Still Serie FA - HRS Equipped with rotary piston volumetric compressor. Constructed in a bronze alloy, nickel plated (chemical deposition FDA approved) to form a passive surface inert to the aggression of the ultrapure steam. No contaminants can be released for corrosion. from the moving part of the compressor to the steam. Low rotational speed (less than 700 rpm), implying low noise and a simple mechanical execution. Limited and easy maintenance. Transmission between the two rotors by two gears placed in a separated gearbox, preventing any oil contamination. ThermoPharma Still Series BD Equipped with side channel blower. Material of construction: aluminium for body and rotor, nickel plated (chemical deposition FDA approved) to form a passive surface inert to the aggression of the ultrapure steam, AISI 316L for the shaft. Rotor installed on two external bearings with mechanical seals FDA approved. Low/Medium rotational speed (less than 2000 rpm), implying low noise and a simple mechanical execution. Limited and easy maintenance. Both the compressors types are characterised by an extremely limited and easy maintenance which can be done by Customer s technicians. Typical maintenance consists in bearings substitution every 8000-10.000 working hours a full range of special devices
AUTOMATION Stilmas pure water production plants are equipped with a PLC controller and HUMAN machine interface. A wide range of configurations are available based on the use of widely applied brands of PLC models. All the PLC controllers have the possibility to be connected with a factory supervisory system via the most common communication system. Software is developed according to the latest GAMP. Complete SCADA system CFR 21 - Part 11 Compliant is available on request. DOCUMENTATION AND VALIDATION The Documentation Package supplied by Stilmas for its Plants is conceived and organized to be in compliance with: to provide documented evidence of the Project Life-cycle, from the design phase up to the final Site Acceptance Test runs. to collect all the necessary information as needed to consistently feed and support the Validation Activity. With regards to the Validation Activity, Stilmas is able to provide a fully comprehensive Validation Service Package, including Validation Protocol Preparation, Site Tests execution, Instruments calibration and Validation Reports organization. The Validation Activity is performed by a dedicated Validation Team. Viale delle Industrie, 14 20090 Settala (Milan), ITALY Phone +39 02 9508061 Fax +39 02 95770022 stilmas@stilmas.com www.stilmas.com