Sistema di riscaldamento di raffreddamento del reattore per la fabbrica farmaceutica

Integrated temperature control unit for reactors in pharmaceutical production

The supporting temperature control equipment mainly includes:

Reactor Jacket Temperature Control System: The temperature of the material in the reactor is adjusted by circulating heating or cooling medium (usually water or oil) through the jacket of the reactor. This system needs to be integrated with high-efficiency heat exchangers, accurate temperature sensors and automatic control systems to achieve fast response and precise control.

TCU (Temperature Control Unit): TCU is an independent unit specially designed for precise temperature control, commonly used in reactors that require high-precision temperature control. It usually contains heaters, coolers, pumps, controllers and temperature sensors, and can provide temperature control from very low to high temperatures.

Chillers and Heaters: Chillers are used for cooling during the reaction process to remove the heat generated by the reaction and keep the reactor working at a suitable low temperature. The heater is used to heat the reaction medium to ensure that the temperature can quickly reach the set value in the reaction step that requires heating.

Multi-stage Temperature Control System: For complex reaction processes, multi-stage temperature control may be required, that is, different temperature control strategies are adopted at different stages. This requires the temperature control equipment to have flexible temperature range switching and rapid response capabilities.

Automatic Control System: including PID controller, PLC system or more advanced SCADA system, which can automatically adjust the heating or cooling output according to the preset temperature curve, maintain the stability and accuracy of the temperature, and record and store temperature data for easy tracking and auditing.

Safety and Alarm System: integrated temperature, pressure, flow and other sensors, as well as safety protection measures such as overheating, overpressure, leakage, etc., to ensure that it can respond immediately and take measures in abnormal situations to protect the safety of equipment and personnel.

500L reactor distributed temperature control unit system

Large reactor workshops require a distributed control system (DCS) for temperature control units mainly to achieve the following key goals to ensure production efficiency, safety and product quality:

Controllo accurato della temperatura: Chemical reactions in reactors are extremely sensitive to temperature, and accurate temperature control is the key to ensuring the smooth progress of reactions and product quality. The temperature control unit distributed system can implement independent and precise temperature control for each reactor, ensure stable reaction conditions, reduce batch differences, and improve product quality.

Efficient management: Large workshops often have multiple reactors running at the same time, and each reactor may have different temperature control requirements. The distributed system can centrally monitor and manage the temperature control units of all reactors, simplify operations, improve management efficiency, and reduce manual intervention errors.

Controllo automatico: The DCS system provides automatic adjustment function, which can automatically adjust the heating or cooling output according to the preset process parameters and actual measurement feedback, achieve rapid temperature response and precise adjustment, and improve production efficiency and repeatability of reactions.

Safety monitoring: Reactor operation involves dangerous conditions such as high temperature and high pressure. The distributed system can monitor the working status of each reactor in real time, including key parameters such as temperature and pressure. Once it deviates from the safe range, it will immediately trigger an alarm or take automatic safety measures to reduce the risk of accidents.

Energy management: By optimizing the heating and cooling process, the distributed system can effectively manage energy use, reduce unnecessary energy consumption, reduce production costs, and also benefit environmental protection.

Data recording and analysis: The DCS system can record all data during the reaction process, provide detailed data support for process optimization, fault analysis, and quality traceability, and help companies continuously improve the production process.

The processes that use temperature control equipment in the pharmaceutical industry include:

1.Low temperature conditions required for biochemical reactions inside the reactor: low-temperature drug synthesis, etc

2.Rapid cooling of raw materials to prevent drug spoilage, low-temperature crystallization and extraction.

Generally speaking, temperature control in pharmaceutical production processes needs to consider the following aspects. Firstly, it is the temperature control of the raw materials. In the pharmaceutical process, the temperature of raw materials often needs to be heated or cooled to meet specific reaction conditions. For example, some reactions require high temperatures, while others require low temperature conditions. Therefore, it is necessary to control the temperature of raw materials according to specific process requirements during the production process. Temperature has a direct impact on the production process of active pharmaceutical ingredients. Excessive or insufficient temperature can lead to a decrease in drug quality and even affect the safety of drugs.

Next is the temperature control of the reactor. The reactor is the core equipment for conducting chemical reactions, and temperature control is crucial for the progress of the reaction. The temperature of the reactor, whether too high or too low, may have adverse effects on the yield, purity, and results of the reaction. To ensure the success of the reaction, it is necessary to control the temperature of the reactor according to specific reaction requirements.

The TCU temperature control unit utilizes existing thermal energy (such as steam, cooling water, etc.) and integrates it into a single fluid system or secondary circuit used to control the temperature of process equipment, relying on the existing infrastructure in the factory area. This completes the process of only one type of heat transfer fluid flowing into the jacket of the reaction vessel (instead of directly introducing steam, cooling water, etc.). Users can obtain a closed and repeatable temperature control over a wide temperature range, achieving temperature control of -120~300 ℃ with a wide temperature range and higher accuracy.

The TCU temperature control unit can achieve unified control of multiple kettles and meet the requirements of nearby layout, with instrument signals controlled by the TCU. The TCU is located near the equipment for easy operation and high adjustment accuracy. The instrument signals in the process unit area are all controlled by TCU, The TCU is located near the equipment. TCU is located in the workshop and can meet the explosion-proof requirements of the workshop.

The TCU temperature control unit has higher precision in controlling the reaction of materials inside the reactor. When stirred evenly, it can reach+1 ℃, which fully meets the special requirements for variety and temperature in the production of multifunctional raw materials. It can completely avoid the waste of cold and hot media and the instability of product quality caused by unstable temperature control.

The TCU temperature control unit can provide a broad and closed temperature control system, which can achieve temperature control of -120~300 ℃, and is completely suitable for the production of multifunctional and multi variety raw materials. And each TCU temperature control unit is an independent individual. Once a fault occurs, it will only have an impact on the corresponding reactor and will not pollute other reactors. It can minimize accident hazards and economic losses.