Distillation units Recovery of solvents, solvent based products and heavily contaminated Waste water D.W.RENZMANN Apparatebau signals of these cells provide important process information and permit GmbH is a medium-sized company a fully automated distillation process. headquartered in the German State RENZMANN distillation units are used wherever heavily contaminaof Rhineland-Palatinate, near the ted media must be separated into their solid and liquid componenNahe River that has given its name ts. Such media include, for instance, contaminated solvents used in to a famous wine growing region. the chemical industry, e.g. by ink, paint and varnish manufacturers. RENZMANN has been developing RENZMANN‘s flagship products in this area are the ROTOmaX diand manufacturing industrial washing stillation units, which offer maximum efficiency in the treatment and machines and distillation units for more recovery of solvents, solvent-based products and heavily contathan 40 years and serves customers in minated waste water. Distillation is a fully automated process that the printing industry and in the ink, paint does not require supervision. The only waste produced is a small and varnish industry. The company‘s quantity of highly viscous residue that can be disposed of inexpencore competency is the removal of stub- sively, while nearly all of the solvent or water is recovered and may born residues and the distillation of the be reused. The high recovery rate, the supply of clean washing flammable organic solvents and alkaline agent with minimal transport requirements for the highly reduced media used in industrial washing ma- quantity of dischargeable residue are important factors that contribute to active environmental protection. chines. ROTOmaX units have a steam-heated boiler floor that ensures In addition to developing, designing, ma- efficient heating, optimal heat transfer, and a consistently high nufacturing and selling machines and heat output irrespective of the filling level. An ATEX-certified equipment, the company also offers its rotating scraper system discharges the residue and effectively customers consulting and other services. cleans the heating surface on the boiler floor. The filling level is monitored by external load cells, eliminating the need for leRENZMANN focuses on vel sensors inside the boiler that might become sticky through contact with the solvent. – safety at work and the protection In addition to separating the liquid and solid components of variof equipment operators, ous media, ROTOmaX units can be equipped with a fractionating – environmental protection, column for the downstream separation of liquids into their various – profitable solutions, and components. – high availability and durability Another very interesting core competency of D.W.RENZMANN of equipment. is a special, proven method for debinding mass-produced items D.W.RENZMANN is certified according as part of the metal injection molding process. What makes to the European ATEX directive and RENZMANN‘s debinding technology special is the fact that it does leads the market in the aforementioned not produce emissions and is therefore especially eco-friendly. segments. The company has an ATEXcertified quality assurance system and In summing up, D.W. RENZMANN offers the following consistently implements all relevant products and services: legal requirements. D.W.RENZMANN • Treatment and recovery systems for contaminated solvents, water-based cleaners and flushing water supplies category 1 equipment with a type examination according to ATEX • Washing machines for paint mixing containers, transport containers, barrels, buckets etc. and thereby protects customers from any liability due to unsuitable or pro- • Debinding systems for customers specializing in metal injection molding hibited equipment, irrespective of the solvent used. • Customized solutions for cleaning and treatment/recovery tasks • Maintenance, spare part supply and safety inspections State-of-the-art equipment includes • Consulting services for complete workspace solutions, selection of load cells that weigh the medium in washing agents based on economic and ecological aspects, comthe distillation boiler; combined with munication with authorities and preparation of documents to comply an intelligent control system, the with guidelines and regulations. 2 Functional principle of RENZMANN – ROTO- / ROTOmaX – distillation units The solvent is heated in the cylindrical boiler of the distillation unit, begins to boil and to evaporate. The solvent vapors condense in the watercooled condenser and then flow into a distillate container. An agitator with rotating scrapers (rotor) prevents incrustations on the heating surfaces and ensures a good heat transfer and high distillation output. After the end of distillation, the rotor discharges the viscous, pasty residue through the discharge valve into a disposal container. A manual cleaning of the distillation boiler is not necessary. The boiling point of the solvent can be lowered by means of a vacuum unit (optional). This permits recovery even of high-boiling and heatsensitive substances (e.g. washing solvents containing nitrocellulose). 3 Type ROTO 4 Type ROTOmaX 9 Type ROTO 9-18 Closed solvent circuit distillation unit ROTO 9 ROTO 12 ROTO 18 filling volume ca. 140 l ca. 250 l ca. 400 l Type ROTOmaX 15-110 cooling water distillation unit ROTOmaX 15 ROTOmaX 20 ROTOmaX 30 ROTOmaX 50 ROTOmaX 75 ROTOmaX 110 filling volume ca. 50 l - 250 l ca. 50 l - 250 l ca. 70 l - 400 l ca. 130 l - 650 l ca. 200 l - 1000 l ca. 300 l - 1500 l vessel volume ca. 450 l ca. 450 l ca. 750 l ca. 1300 l ca. 2000 l ca. 3000 l distillation output * ca. 45-90 l/h ca. 60-120 l/h ca. 90-180 l/h ca. 150-300 l/h ca. 225-450 l/h ca. 330-660 l/h vessel volume ca. 300 l ca. 480 l ca. 700 l distillation output * ca. 30-60 l/h ca. 40-80 l/h ca. 60-100 l/h cooling water flow rate ** ca. 1,3 m³/h ca. 1,7 m³/h ca. 2,5 m³/h ca. 4,3 m³/h ca. 6,5 m³/h ca. 9,5 m³/h cooling water flow rate ** ca. 0,7 m³/h ca. 1 m³/h ca. 1,5 m³/h heating energy 15 kW 20 kW 30 kW 50 kW 75 kW 110 kW heating energy 9 kW 12 kW 18 kW weight ** 2200 kg 2300 kg 2500 kg 2700 kg 3100 kg 3300 kg weight ** 1300 kg 2200 kg 2500 kg WxHxD WxHxD WxHxD WxHxD WxHxD WxHxD plate processor dimensions mm *** WxHxD WxHxD WxHxD 1300x2650x1700 1450x3400x1800 1560x3900x2000 required space mm **** 3500x3200x3600 4000x3700x4500 4000x3900x5000 Shipping dimensions mm 1500x1600x2800 1600x2300x2000 1750x2450x2100 plate processor Distillation output depends on the solvent If water from the public supply system is used; depends on the water temperature and the boiling point of the solvent, closed cooling circuit without water consumption is possible *** Standard version without accessories, without solvent container **** Required space with 2 containers app. • Cylindrical, vacuum-tight distillation boiler • Insulated heating jacket, floor and lower jacket surface with thermal oil and integrated electric heating elements. The unit can also be connected to an on-site steam or thermal oil network • Water-cooled stainless steel condenser • Rotating scraper system (rotor), prevents incrustations on the heating surfaces and agitates the material to be distilled • Dirt-resistant discharge valve, operated manually or pneumatically • Unit on sturdy frame with stairs at the side and an observation platform (accessory for ROTO 9) • Discharge height adapted to disposal container and/or 200-l-barrel (on a pallet) (accessory for ROTO 9, 5 • Optional: adapted residue carriage (only with ROTO 9) • Sight glass and explosion-proof halogen lamp for observing the distillation process • Automatic filling stop by means of a vibration limit switch and a pneumatic ball valve in the filling line • Batch distillation or continuous distillation possible • ex proof control elements at distillation unit: for vacuum, filling, heating, rotation of scraper and EMERGENCY STOP • control cabinet with programmable logic control (PLC) with text display, input and/or display of chronology and separate times of the functions vacuum, filling, heating, scraper and distilling down required space mm **** 6000x3400x4000 6000x3400x4000 6000x3500x4500 6500x3600x4600 7000x3800x5200 7500x3900x5500 * ** Distillation output depends on the solvent If water from the public supply system is used; depends on the water temperature and the boiling point of the solvent, closed cooling circuit without water consumption is possible *** Standard version without accessories, without solvent container **** Required space with 2 containers app. vacuum unit ROTOmaX components: Accessories standard discharge height 650 mm). Other heights are possible. 1450x3000x1900 1450x3000x1900 1650x3100x2100 1950x3200x2600 2250x3300x2900 2550x3400x3200 Shipping dimensions mm 1700x2200x2000 1700x2200x2000 1800x2400x2300 2100x2600x2700 2400x2850x3000 2700x2900x3300 vessel- and container cleaning * ** ROTO components dimensions mm *** distillate container • Vacuum unit for lowering process temperatures, with either a liquid ring vacuum pump (for solvents with a flash point > 55 °C) or a liquid jet vacuum pump distillation unit • Cylindrical, vacuum-tight distillation boiler consisting of an insulated dome (stainless steel) with a heating floor (standard steel) flanged to the bottom waste solvent container printing press inline cleaning for printing press parts • Insulated, flat heating floor for heating with steam (10 bar, 185°C max), consisting of a double-walled plate, ensures an excellent heat transfer and full heating capacity regardless of the solvent level in the boiler external cleaning of printing press parts • Residue temperature control system for processing heat-sensitive substances • Distillation output monitor for automatic distillation stop when the output drops below a set limit Devices for a safe operation of the units • All electric and mechanical components are explosion-proofed in accordance with directive 94/9 EC (Atex 95), type-tested rotating scraper system. • Conformity with all relevant EU safety directives is certified with a declaration of conformity and documented by means of a CE label at the machine. • Timer for automatic distillation start • Seal plate or exhaust hood adapted to on-site disposal container, optionally with an air extraction system • Thermostatic valves if the unit is connected to an on-site cooling/ public water supply; separate cooling water devices with separate circuits are available as option. 6 • All parts of the machine that come into contact with solvent are solvent-resistant. • Monitoring of the distillate temperature and deactivation of the heating in case of an interruption of the cooling water supply etc. • Deactivation of the rotor by motor circuit breakers in case of an overload. • Residue temperature control system for heat-sensitive substances (accessory); the solvent temperature is measured, and when specified temperature limits are reached, the heating is switched off and the distillation vessel is flooded with water. • Draining of the used solvent container is detected by flow detector (accessory). • Automatic deactivation of distillation in the distilling-off phase (accessory for ROTO, standard in ROTOmaX) • Steam generator flanged to the heating floor, operated with electric power or with steam or thermal oil from an on-site network. Direct heating of the floor with steam or warm water is also possible. RENZMANN units for category 1 according to ATEX for Zone 0 on the inside Fulfillment of the „CRITERIA FOR THE SELECTION OF EQUIPMENT AND PROTECTIVE SYSTEMS“ according to the ATEX workplace directive 1999/92/EC (ATEX 137) • Water-cooled stainless steel condenser D.W.RENZMANN: uses a certified quality assurance system according to ATEX and consistently implements all relevant legal requirements. • Rotating scraper system (rotor), prevents incrustations on the heating floor, agitates the material to be distilled and keeps the discharge valve clean The operator: is required by ATEX 137 to use equipment of the correct category for the respective hazard zones, e.g. category 1 equipment for zone 0. • Dirt-resistant discharge valve, operated manually or pneumatically D.W.RENZMANN supplies category 1 distillation units with a type examination according to ATEX and thereby protects customers from any liability due to unsuitable or prohibited distillation units, irrespective of the solvent used. 7 Accessories: • Unit on sturdy frame with stairs at the side and an observation platform • Discharge height adapted to disposal container and/or 200-l-barrel (on a pallet). Other heights are possible. • Sight glass and explosion-proof halogen lamp for observing the distillation process • Automatic filling stops when a preset filling quantity is reached; the filling quantity is monitored by means of load cells that register the total weight of the distillation boiler; filling stops by means of a pneumatic ball valve in the filling line • Batch distillation or continuous distillation possible • Control of the heating temperature according to the boiling temperature • PLC system and display with readings on heating temperature, filling quantity, refilling quantity, residue quantity, distillate quantity, average distillation output and operating hours • Color monitor with graphic display • Vacuum unit for lowering process temperatures with a liquid jet vacuum pump • Residue temperature control system for processing heat-sensitive substances • Sealing plate or sealing hood adapted to on-site disposal container, optionally with an air extraction system • Enclosure of the discharge area, including a door; when combined with an air extraction system, this makes it possible to install the unit in an area not protected against explosions • Fully automated distillation with automatic residue monitoring in a disposal container monitored by load cells • Thermostatic valves if the unit is connected to an on-site cooling/ public water supply; separate cooling water devices with separate circuits are available as option. 8 Type ROTOmaX-W Prevention of waste water coming from cleaning processes We want you to benefit from our know-how: The ROTOmaX-W distillation unit The soiled agent that has been slightly concentrated in the prevaporizes soiled aqueous/alkali- evaporator is now sucked into the distillation boiler, in which a ne washing and rinsing agents. The vacuum has been generated. Due to the vacuum, the boiling temcondensed clean distillate is admitted perature in the distillation boiler is reduced to < 60°C. The temback into the rinsing water / washing perature difference of > 40°C between the boiler contents and the agent circuit of the cleaning process. steam (100°C) from the pre-evaporator makes the steam in the There is no waste water. The residue heating floor condense and transmit its energy to the contents of – greatly reduced and concentrated the distillation boiler. There, the washing agent is vaporized and compared to the used quantity of rin- concentrated to less than 5% of its original volume. sing water / washing agent – is disposed The pre-evaporator distillate that condensed in the heating floor is sucked into the condenser of the distillation unit and combines of as hazardous waste. The two-step distillation with a pre-eva- with the condensing vapors from the distillation boiler. The distilporator reduces the energy consumpti- late cools slightly in the condenser, runs to the vacuum unit and from there into a separate clean water container. on per liter of evaporated water by half. Approximately half of the soiled agent The loss of liquid in the pre-evaporator (half of which is caused is vaporized in the pre-evaporator under by evaporation, the other half by liquid being sucked into the dinormal pressure. The resulting steam stillation boiler) is compensated for automatically by continuous (100°C) contains the energy supplied in refilling. the pre-evaporator and is piped into the heating floor of the distillation unit. We determine the profitability of your project in terms of performance, staff requirements, investments costs and operating costs, taking into account all relevant laws, regulations and directives. We support you in planning the site of your new equipment, dealing with the authorities and obtaining the required approvals and connecting your equipment to existing or future exhaust air systems. In our lab, we provide distillation units for practical tests with your solvent or washing agent. All tests are documented electronically and the results are made available to you after the conclusion of the tests. We take customer service literally: we want to serve our customers. Our top priority is to ensure smooth proceedings on your premises. To eliminate potential problems from the start, we offer to have our staff check the conditions on site and determine the possibilities of connecting our products to existing equipment. RENZMANN engineers are trained and experienced experts that repair, install, commission and service our equipment worldwide. When spare parts are needed, we do our utmost to supply these parts as quickly as possible. Distillation unit ROTOmaX-W 20 ROTOmaX-W 30 ROTOmaX-W 50 ROTOmaX-W 75 ROTOmaX-W 110 Distillation output * 15-25 l/h * 30-40 l/h 45-65 l/h 70-95 l/h 100-140 l/h 80 % more output with pre-evaporator soiled water cooling water clean water cooling water heating residue pre-evaporator 10 distillation unit vacuum unit 11 D.W. Renzmann Apparatebau GmbH Industriestraße 1 D-55569 Monzingen Germany Phone: +49 (0)67 51 878-0 Fax: +49 (0)67 51 878-111 www.dw-renzmann.de info@dw-renzmann.de RIOBEER AG Cleaning Solutions Phone: +41 (0)56 6186464 Fax: +41 (0)56 6186418 www.riobeer.ch info@riobeer.ch UK 04/12 Schützenmattweg 33 CH-5610 Wohlen Switzerland