Separation Systems

Build Separation Systems with Applied Catalysts

Navigating the intricate processes in chemical manufacturing requires efficient, precise, and reliable equipment. This is especially true when it comes to the pivotal role of separation systems.

These sophisticated devices are crucial in chemical manufacturing, designed to separate desired products from co-products and unreacted feedstock materials. At Applied Catalysts, we recognize this pivotal role and thus offer an extensive range of top-tier separation systems.

These systems, available as standalone applications or in harmony with reactor systems, cater to various industries, from pharmaceuticals to food and beverage and even biomolecular applications.

When to Use Separation Systems

Separation Systems are integral to a variety of industries that involve the processing of complex chemical mixtures.

These industries require precision, efficiency, and reliability in their processing equipment.

Here are some scenarios when separation systems become indispensable:

Pharmaceutical Production: The creation of medicinal products often involves complex chemical reactions. Separation systems are used to isolate the desired active pharmaceutical ingredients from by-products and unreacted feedstock.

Specialty & Fine Chemicals: In manufacturing specialty and fine chemicals, it is vital to achieve high purity levels. Separation systems enable the segregation of desired chemicals from unwanted substances, ensuring the quality of the final product.

Food & Beverage: Ensuring the safety and quality of food and beverage products often involves removing impurities or separating mixtures into their individual components. A separation system can help achieve this efficiently and hygienically.

Biomolecular Applications: In biotechnology and life sciences, separation systems are crucial for extracting valuable biologically derived compounds from complex mixtures, such as specialty chemicals that are most economically derived from bio-organisms.

Industrial Chemicals & Basic Materials: Molecules are basic materials necessary for almost everything in modern life. More valuable molecules & materials need to be separated from substances of less value. For the production of Specialty Chemicals, Fine Chemicals, and Commodity Chemicals separations are a necessary part of the process. After a chemical reaction occurs, the resulting mixture often contains both the desired product and a variety of by-products. Separation systems are essential for isolating the desired product and removing or recycling unreacted feedstock and separating co-products to obtain desired purities.

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Benefits of Separation Systems

Utilizing advanced separation systems brings a multitude of benefits to various manufacturing processes. These benefits can impact not only the quality of the end product but also the efficiency of the production process and the overall sustainability of operations. Here are the key advantages of implementing separation systems:

Improved Product Purity

Separation systems enable the extraction of high-purity end products by effectively removing co-products and unreacted feedstock. This results in higher product quality, which is especially crucial in pharmaceuticals, fine chemicals, and food & beverage industries.

Efficient Resource Utilization

By separating unreacted feedstock from the end product, these materials can be recycled back into manufacturing. This leads to significant savings in raw materials and overall operational costs.

Energy Efficiency

Modern separation systems, like the ones provided by Applied Catalysts, are designed to optimize energy usage. For instance, energy-efficient distillation columns minimize the energy required for heating and cooling processes.

Scalability & Flexibility

Our separation systems can be delivered as fully modular production units or as technology packages, offering flexibility based on your operational needs. This modularity allows for easy expansion or modification as your business grows or as market demands change.

Performance Guarantee

At Applied Catalysts, we stand behind the performance of our separation systems. We provide Process Performance Guarantees, reinforcing our commitment to delivering reliable and efficient solutions that meet your requirements.

Broad Applicability

Separation systems play a key role in pharmaceuticals, specialty & fine chemicals, food & beverage, or biomolecular applications. The versatility of these systems makes them a valuable asset in a wide range of industries.

Distillation Columns

These devices are used to separate mixtures based on the different boiling points of their components. We offer reactive and unreactive distillation columns, catering to a broad spectrum of separation needs.

Filtration & Pervaporation Systems

Filtration is a common method for separating solid particles from a liquid or gas. Pervaporation, on the other hand, is a membrane process used for the separation of liquid mixtures, particularly when traditional distillation methods are ineffective.

Evaporative Crystallization Systems

These separate substances based on their different solubilities. In a crystallization process, a solution is first formed as liquid evaporates to form a super-saturated liquid that induces nucleation and the formation of crystals. These crystals are subsequently filtered from the remaining solution.

Fractional Crystallization Systems

These separate substances based on their different freezing points (aka temperatures of fusion). In a fractional crystallization process, one substance “freezes” onto a cold surface, while the other substance, still in the liquid phase, flows past the first substance to freeze on the cold surface. After the substances separate, the surface with the ‘frozen’ crystal is reheated, and the purified substance flows into a collection tank.

Liquid - Liquid Extraction Systems

Also known as solvent extraction, this process separates components based on their relative solubilities in two different immiscible liquids. It is usually used to separate desired substances from impurities or to recover valuable components.

Absorption & Stripping Systems

Absorption involves transferring a component from a gas phase to a liquid phase or on to a solid absorbant material such as a resin bead or activated carbon granual. This process normally removes unwanted components from the gas or liquid. Stripping is the reverse process, used to remove a solute from a liquid to a gas stream.

Examples of Separation Equipment We Provide

Separation equipment can take on various forms depending on the specific requirements of the process. Applied Catalysts provides an array of high-quality separation equipment, tailored to meet the diverse needs of multiple industries.

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Why Applied Catalysts for Separation System Builds

Choosing Applied Catalysts for your separation system needs offers numerous benefits. We bring to the table an exceptional blend of technology, expertise, and commitment to customer success. Here’s why Applied Catalysts should be your trusted partner:

Versatility

Our wide range of separation systems caters to diverse applications in pharmaceuticals, specialty & fine chemicals, food & beverage, and biomolecular applications. We offer standalone applications or systems integrated with reactors, delivering solutions that best meet your needs.

High-Quality Equipment

Our separation equipment is designed with precision, using state-of-the-art technology and built to the highest standards of quality. This ensures reliable and efficient performance.

Process Performance Guarantees

We have full confidence in our products and provide Process Performance Guarantees. We are committed to delivering systems that perform optimally in line with your specific process requirements.

Flexible Delivery

Our separation systems can be delivered as fully modular production units or as technology packages for Engineering, Procurement, and Construction (EPC) companies. This flexibility allows us to cater to your unique needs and operational constraints.

Extensive Industry Knowledge

With years of experience and a team of experts, we bring extensive industry knowledge to your project. Our team works closely with you, offering advice and recommendations to ensure your separation system meets your exact requirements.

Uncompromised After-Sales Support

Our commitment to our clients extends beyond sales. We offer comprehensive after-sales support, including maintenance services and operational guidance to ensure your system operates at peak performance.

Our Process for Building Catalyst Batch Reactor Systems

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Discovery

Which chemistry do you want to run in the batch reactor system?

This will help us determine the type of equipment and materials needed for the reaction.

What are your volumes?

We’ll need to know the desired production volumes to determine the appropriate size and capacity of the batch reactor system.

What’s your timeline for implementation?

Understanding your timeline will ensure that the batch reactor system can be designed, manufactured, and delivered in a timely manner.

What utilities do you have available?

To ensure that the batch reactor system can be properly installed and operated, we’ll need to confirm available utilities, such as electrical power, water, and steam.

Share your current batch reactor system with us. We’ll ask for details about the current equipment and its performance to better understand your needs and requirements.

Identifying Milestones

Is the batch reactor technology already in-house?

We need to know if the client currently has a batch reactor system in place or if they will need to acquire a new one.

If not, we’ll run experiments.

If the client does not have an existing batch reactor system, we’ll recommend running experiments to determine the reaction conditions and establish a design basis for the new system.

Project proposal.

Once we have a design basis for the new system, we can produce a proposal. Based on the results of the experiments and the client’s requirements, Applied Catalysts will develop a design basis for the new batch reactor system and produce a proposal outlining the equipment, materials, and costs involved in the project.

What’s In the Project Proposal?

Our proposal outlines the scope, details, and costs involved in designing, manufacturing, and installing a batch reactor system.

The proposal includes an opportunity summary that provides a brief overview of the project, a process schematic that outlines the process flow and equipment configuration, the required utilities needed to operate the system, the required footprint area, and the required timeline for the project’s completion.

Additionally, the proposal includes a budgetary price, which can be either for the sale or rent of the equipment, that provides a cost estimate for the system’s design, manufacturing, delivery, installation, and ongoing support. All of these items are critical to ensuring that the client understands the scope and costs of the project and can make an informed decision about whether to move forward with the batch reactor system proposal.

Catalysts

Activated Carbon Monolith Catalysts (ACMC)

In addition to the ACMC monolith based catalysts, Applied Catalysts can provide particulate catalysts to solve the customers catalytic needs. Applied Catalysts will provide Industry Standard catalysts when available from a number of participating Catalyst Vendors in addition to proprietary catalysts manufactured by Applied Catalysts.

Granular Activated Carbon Catalysts (GACC)

In addition to the ACMC monolith based catalysts, Applied Catalysts can provide particulate catalysts to solve the customers catalytic needs. Applied Catalysts will provide Industry Standard catalysts when available from a number of participating Catalyst Vendors in addition to proprietary catalysts manufactured by Applied Catalysts.

Metal Oxide Catalysts (MOC)

In addition to the ACMC monolith based catalysts, Applied Catalysts can provide particulate catalysts to solve the customers catalytic needs. Applied Catalysts will provide Industry Standard catalysts when available from a number of participating Catalyst Vendors in addition to proprietary catalysts manufactured by Applied Catalysts.

Custom & Industry Catalysts

With a proven record of Custom Catalyst manufacturing services and a foundation of knowledgeable chemists and researchers, Applied Catalysts’ monolithic catalyst supports even the most challenging design and processing needs from manufacturing to development, ensuring high performance.

Systems

Modular Process Systems

Applied Catalysts offers catalyst development services based on heterogeneous catalysts. Combining our testing services with our catalyst development services accelerates project success and maximizes value creation for the customer.

Services

Catalyst Development

Applied Catalysts offers catalyst development services based on heterogeneous catalysts. Combining our testing services with our catalyst development services accelerates project success and maximizes value creation for the customer.

Catalyst Testing

Applied Catalysts offers catalytic process development services, including catalyst screening and process parameter optimization to yield high activity, selectivity and lifetime.

Process Development

Applied Catalysts offers catalytic process development services, including catalyst screening and process parameter optimization to yield high activity, selectivity and lifetime.

Catalyst & Chemical Sourcing

Applied Catalysts offers process flowsheets using Chemcad simulation software and systems scale-up by partnering with Engineering Firms and Systems Manufacturers.

Applications & Industries Served

Biorenewables

Applied Catalysts serves bio-renewable industries to develop, scale up and help commercialize bio-based products and processes. ACMC catalytic reactors can be used for bio-mass transformations, everal fine chemical products, including pharmaceuticals.

Fine Chemical Catalysts

Applied Catalysts is well-conversant with the market’s needs and works effortlessly to meet them as a leader in catalytic technology for fine chemical products. These fine chemicals include active pharmaceutical ingredients and biocides.

Hydrogenation

The hydrogenation process involves the addition of hydrogen to organic substrates. The functional groups being converted in the organic substrates can be olefinic to aliphatic groups, aromatic compounds to aliphatic compounds, nitro groups to amines, nitrile groups to amines, acids to aldehydes, and aldehydes and ketones to alcohols and ethers. Hydrogenation can also be used to remove sulfur, nitrogen, and chlorine content in molecules.

Oleochemicals

As a catalytic technology leader in oleochemistry serving several oleochemical industries, Applied Catalysts carbon catalysts offer the conversion of unsaturated fatty acids into saturated fatty acids due to their susceptibility to hydrogenation.

Oxidation to Chemicals

Activated carbon monolith catalysts can also be used to oxidize organic substrates to other chemicals. There are many oxidation reactions of interest, including transformations of bio-mass to chemicals.

Pharmaceuticals

The manufacture of pharmaceuticals often contains one or more catalytic hydrogenation steps. Monolith catalysts convert the functional group of a molecule selectively into a new one to produce the starting material for the next synthetic step. Applied Catalysts can provide ACMC monolith-based catalysts for continuous flow process chemistry, enhancing the sustainability and low cost of manufacturing pharmaceutical products.

Polymers

Applied Catalysts is looking to provide polymer hydrogenation catalysts, systems and services to rubber, elastomer, and other hydrogenated polymers. Applications include tires, synthetic fibers, fiberglass, and silicone heart valves.

Reductive Alkylation

As a provider of catalytic technology, Applied Catalysts provides metal catalysts used in the reductive alkylation process which involves the addition of alkyl groups to amines, and amines to carbonyl containing compounds.

Specialty Chemicals

Applied Catalysts serves several specialty chemical industries that deal with specialty chemicals, including adhesives and cosmetic additives. The catalytic reactors convert a reactant of a single or more chemical reactions into a product or multiple products.

Process-Performance Guaranteed
Separation Systems

We give our clients the peace of mind that they need to invest in our equipment, knowing that it will perform as intended and meet their production goals.

  • Rapid changeover from one chemistry to another
  • Just-in-time manufacturing
  • Seamless process scaleup

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Are You a Catalyst, Service or Systems Provider?

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For a quarter-century

Applied Catalysts

Has provided a broad array of catalysts,

along with development, testing and troubleshooting services, to enhance clean air and chemical process applications.