Are there vacuum reactor mixers that cover mixing as well as reaction processes and crystallisation?
Multifunctional vacuum reactor mixers combine mixing, reaction and crystallisation in a single closed apparatus. Depending on the design, drying, solvent recovery and filtration can also be integrated.
The multifunctionality rests on a temperature-controlled jacket, vacuum management and a suitable agitator geometry. Temperature, pressure, mass transfer and crystal formation can thereby be controlled in a targeted manner.
Such systems are used above all in the pharmaceutical, fine chemical and speciality chemical industries. They reduce product transfers, improve process reliability and facilitate a closed, GMP-capable mode of operation.
amixon® vacuum mixer-dryers and synthesis reactors: mixing, reacting, crystallising and drying in a single apparatus
Two designs for the one-pot process
The vertical mixer-dryer/reactor VMT and the cone mixer-dryer reactor AMT are of pressure-tight and vacuum-tight design. A vacuum down to 5 mbar abs. is possible. Both apparatus are fully temperature-controllable, for example with water, steam or thermal oil.
In the same apparatus, the processes of mixing, reacting, suspending, crystallising, de-agglomerating, coating, conditioning and vacuum contact drying can be combined. Process pressure, temperature, addition of substances and mixing intensity are freely adjustable. The systems are therefore also suitable for solid-state reactions and crystallising processes with precise temperature control.
Large heat exchange surfaces and short process times
A particular feature is the ability to control the temperature of the mixing tool. The shaft, arms and helix can also be temperature-controlled. Together with the double-walled mixing chamber, very large heat exchange surfaces thereby arise. This enables rapid heat input and removal at low product temperatures.
Cutting rotors with a mechanical seal accelerate mixing and drying and support de-agglomeration, for instance when passing through tough plastic phases. A temperature-controlled vapour filter retains fine dust. Solvents can be condensed and recovered. An inspection door in the Clever-Cut® design is available on request.
Dead-space-free, safe, hygienic
The mixing chamber and mixing tool are fully welded and ground. The mixing tool is mounted at the top only. A critical lower shaft passage is dispensed with. The ball segment valve has few dead spaces and is of vacuum-tight and pressure-tight design.
The mixing chamber can be designed for ATEX Zone 20. Inerting is possible. On request, FDA-compliant sterile reactor designs as well as designs in accordance with EHEDG and 3-A are available. Materials up to Alloy 59, Hastelloy-C22 and nickel can be used. The sizes range from 100 to 50,000 litres in 100-litre increments. Low fill levels of, for example, 15 per cent are also reliably possible.
The design is based on trials
Drying and reaction trials with the original product in the amixon® pilot plant provide the basis for the design. The trials take place within the intended temperature and pressure range. The trial results are extrapolated thermodynamically. The choice of apparatus and the dimensioning can thereby be established robustly, even for large vacuum mixer-dryers.
The plants are qualifiable and documented
For regulated environments, amixon® supplies qualifiable plants. Every apparatus is a one-off manufactured in accordance with the URS. Quality control takes place in-house without gaps. amixon® assists on request with DQ, IQ and OQ. Documentation and execution follow, on request, EU GMP and FDA 21 CFR Part 11.
On request, the apparatus also meets the relevant standards, for example EHEDG, the FDA hygiene guidelines, the 3-A Sanitary Standards, USDA, GMP, ATEX and ASME. The plant can be integrated into the operator's validation concept from engineering through to commissioning.