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Vapor thermo- compressor Stills
Vapor thermo-compressorStills
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Stilmas is an industrial and engineering Company specialized in theresearch, design, development and construction of high technologyplants for the pharmaceutical, electronic, cosmetic and food processingindustries.The business scope is the design, the production, the assembly, the saleand installation of such plants, of special equipment and instruments,as well as the exploitation of alternative powers and energy savingachievements.The modern and exhaustive equipment, the dynamic organizationand the available financing means, allow the completion and extension of both activity and study in addition to a closer relationshipwith C.N.R. and the most important universities.
STILMAS
pure technology, pure water
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Main features of StilmasThermocompressor• 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.
Vapor thermocompressor StillsThe Mascarini Thermocompression Stills FA-HRS series and ThermoPharma Thermocompression Still BDseries produce distilled water for injectable use which meets the latest requirements of the InternationalPharmacopeias including USP, EP and JP.They are also widely employed in many other industries such as: Food, Film, Electronic and Fine ChemicalStandard models capacity:• Series FA-HRS: capacity from 50 to 4500 lts/h• Series BD: capacity from 100 to 24.000 lts/h
Look closely...
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a unique and original design
Operating principle
Feed water is pre-heated in three heat exchanger torecover the sensible heat of produced WFI, concentrateand Non Condensable Gases. The feed water is thensent to the still main body bottom, where it is pre-heatedto evaporation temperature by an external energy source - electric or steam. The evaporation takes placein 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 puresteam is then sucked by the compressor, and sent backto the same shell and tube heat exchanger, shell side.The slightly pressurized steam condenses at a highertemperature than the boiling water tube side, so transferring the latent heat.The condensed WFI is sent to the hydrostatic column fordegassing, and finally is pressurized by a sanitarypump, sent to the heat recovery system and then to battery limits.
FEED WATER QUALITYStilmas Thermocompressors Series FA-HRS and BD can be fed with deionised water or even softenedwater. Not withstanding the higher blow down rate in case of softened water feeding, this possibility is of extremeinterest 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 providethe suitable feed water to the Still.
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Main components designStilmas 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.
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Construction CharacteristicsThe plant is completely made in AISI 316L stainless steel. Standard finishing of the active surface is pickled andpassivated; mirror or electropolishing can be made on request. Product (WFI) contact parts are manufactured withsurface finishing 0.6 microns Ra mechanically polished, with piping orbitally welded with sanitary flanges andpharmaceutical grade Teflon gasket.The design and construction of the decontamination chamber, which is a totally empty column, ensure the bestinspectability. The absence in this area of welding dramatically reduce the risk of corrosion, for a very long expectedlife 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 mainevaporator), the pipes are expanded into the plates, avoiding any welding for a totally hygienic execution, and abetter resistance against dilatation stress.
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a full range of special devices
Stilmas S.p.A. has developed two alternative solutions for the steam compressor.
Mascarini Still Serie FA - HRSEquipped 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 BDEquipped 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 bedone by Customer’s technicians. Typical maintenance consists in bearings substitution every 8000 - 10.000working hours
COMPRESSORS TECHNOLOGY
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www.stilmas.com
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 mostcommon 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 ServicePackage, including Validation Protocol Preparation, Site Tests execution, Instruments calibration andValidation Reports organization.The Validation Activity is performed by a dedicated Validation Team.
Viale delle Industrie, 14 • 20090 Settala (Milan), ITALYPhone +39 02 9508061 • Fax +39 02 95770022
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