The sections below relate to some of our projects undertaken in 2019 / 2020
Industry: Pharmaceuticals
3 off Thermal control units (TCUs)
Key criteria: Accurate temperature control, repeatability, wide operating temperature range and high value product processing
Design Features: Semi-closed self pressurising TCUs
ATEX zone: Zone 2 IIB T4
The above thermal control units were designed, manufactured and commissioned for use in the pharmaceuticals industry by PTSC. Two of the TCUs provide heating and cooling for glass lined batch reactors and one provides the heating and cooling for a filter dryer. The TCUs are able to accurately control the temperature during the process heating and cooling profiles to ensure consistency and repeatability between batches of high value feedstocks.
In order to maximise the process productivity using the existing site services, PTSC designed an innovative “semi-closed self pressurising TCU” which automatically changes from an closed loop system during the heating phase to a open loop system in the low temperature cooling phase. This resulted in lower CAPEX and OPEX for the customer as well as reducing the site services demand which was limited.
Industry: Waste Processing and Recycling
Fixed plant hot oil system (350kW)
Key Criteria: Waste recovery, circular economy, productivity, very high temperature, future energy recovery capability and commissioning
We designed, manufactured and installed the heating and cooling system for an innovative waste recycling process which turns granulated waste plastic into construction materials. The process requires high temperature operation, controlled and rapid heating and cooling profiles, accuracy and repeatability.
The system shown in the photo above uses propane as the heat source, however, PTSC also supplied a smaller modularised unit which uses electric heating (100kW) allowing for a zero carbon heating and cooling system
Industry: Industrial Materials
2.8MW installed capacity thermal oil system for autoclaves
Key Criteria: Extreme temperature, plant layout and design, productivity and reliability
The above project for our client required firstly determining the energy requirements and heat flux in order to operate two off high pressure industrial autoclaves operating on short cycle batches. These autoclave being larger than our client had currently in operation but was planning to install based on a higher throughput potential, measuring some 15m long and 3.5m in diameter each unit had the potential to demand an averaged heating rate of 1.4MW across the sub 1 hour heating cycle with a maximum temperature rating of 300 DegC.
PTSC designed the system to include for 2.8MW of installed capacity with the option designed into the system to include for a 3rd heater to future proof the site.
Encompassing 18 month span from initial design concept to commissioning PTSC carried out the full scope of preliminary and detail design, material procurement, manufacture, project management, site construction and commissioning. The site whilst located in continental Europe the project was managed and executed by PTSC throughout.
Industry: Fine Chemicals
Thermal Control Units
Key Criteria: Accuracy, Repeatability, Productivity, Improving Service Limitations
Our client needed to scale up their existing highly complex and valuable speciality chemical process which was being undertaken within a 500ltr batch reactor to a new 3000ltr production volume capacity unit. However, ensuring that the same level of performance currently specified in the process SOP’s was maintained. In order to ensure that firstly the general process environment could be scaled up, PTSC undertook a full computational fluid dynamics (CFD) of the mixing parameters between the old retreat curve impeller mixer (RCI) and a new turbine type mixer being supplied with the scaled up reactor. PTSC carried out a thorough review of both reactors developing a detailed report on each, highlighting where significant variables may be expected in relation to heat transfer, solid suspension, blending and flow patterns. Once these parameters were established PTSC was able to begin the design process to establish the thermal system required and configure it to the limitations of the existing site services. This included introducing electric heating in order to reach the required upper temperature and a two stage cooling system to maximise performance, economy and provide cryogenic cooling capability. The TCU design operated on a low pressure closed loop principal in conjunction with the new reactor and achieved a services output temperature accuracy of <1 DegC. In parallel to this a PTSC reactor solvent condenser TCU was also supplied which operated at cryogenic temperatures.
The result of this was that the client was able to scale up utilising the same SOP parameters and increase the accuracy and control of the new process over that of the existing process.