Continuous flow production

Optimum conditions have been determined for the continuous-flow production of ergocalciferol by irradiation of ergosterol. ... 

Apart from for the continuous flow production units, there are also batch production units. In this case, the predetermined proportions of water, emulsifier and all the other chemicals for each batch are mixed with water in a separate tank before the aqueous solution is pumped into the colloid mill. The hourly output of this system is always lower than the output of the continuous flow system. 

Continuous manufacturing usually refers to products that are not discrete. The APICS Dictionary defines continuous flow (production) as Lotless production in which products flow continuously rather than being divided. However, sometimes individuals speak of continuous production in the context of mass production. When they speak of continuous production in this way, they are usually referring to shops with automated assembly lines. A common example of the assembly line is the automobile assembly plant. 

The advantages offered by this kind of technology are continuous flow production, high degree of flexibility both for the machine speed and the choice of profiles, possibility to choose the preferred direction, high resistance, and the possibility to use the process also for small transverse sections, both hollow and full. 

As microreaction technology becomes widely accepted, fine chemical and pharmaceutical companies frequently report the use of at least one continuous-flow step in their manufacturing campaigns and laboratory synthesis. Lonza Ltd in Visp, Switzerland, has developed at least 10 processes for continuous-flow production with micro- and other flow reactors. For an organolithium exchange reaction, up to... 

Continuous Flow Production Process whereby items are produced and moved from one processing step to the next, one piece at a time. Each process makes only the one piece that the next process needs, and the transfer batch size is one. Also called single-piece flow or one-piece flow. 

Flow Sheet. Most purge-swing appHcations use two fixed-bed adsorbers to provide a continuous flow of feed and product (Fig. 16). Single beds are used when the flow to be treated is intermittent or cycHc. Because the purge flow is invariably greater than that of adsorption, purge is carried out in the down-flow direction to prevent bed lifting, and adsorption is up-flow. 

Reaction times can be as short as 10 minutes in a continuous flow reactor (1). In a typical batch cycle, the slurry is heated to the reaction temperature and held for up to 24 hours, although hold times can be less than an hour for many processes. After reaction is complete, the material is cooled, either by batch cooling or by pumping the product slurry through a double-pipe heat exchanger. Once the temperature is reduced below approximately 100°C, the slurry can be released through a pressure letdown system to ambient pressure. The product is then recovered by filtration (qv). A series of wash steps may be required to remove any salts that are formed as by-products. The clean filter cake is then dried in a tray or tunnel dryer or reslurried with water and spray dried. 

Pasteurization may be carried out by batch- or continuous-flow processes. In the batch process, each particle of milk must be heated to at least 63°C and held continuously at this temperature for at least 30 min. In the continuous process, milk is heated to at least 72°C for at least 15 s ia what is known as high temperature—short time (HTST) pasteurization, the primary method used for fluid milk. For milk products having a fat content above that of milk or that contain added sweeteners, 66°C is requited for the batch process and 75°C for the HTST process. For either method, foUowiag pasteurization the product should be cooled quickly to <7.2° C. Time—temperature relationships have been estabHshed for other products including ice cream mix, which is heated to 78°C for 15 s, and eggnog, which must be pasteurized at 69°C for 30 min or 80°C for 25 s. 

High Temperature—Short Time Pasteurizers. The principal continuous-flow process is the high temperature—short time (HTST) method. The product is heated to at least 72°C and held at that temperature for not less than 15 s. Other features are similar to the batch hoi ding method. 

Continuous-Flow Stirred-Tank Reactor. In a continuous-flow stirred-tank reactor (CSTR), reactants and products are continuously added and withdrawn. In practice, mechanical or hydrauHc agitation is required to achieve uniform composition and temperature, a choice strongly influenced by process considerations, ie, multiple specialty product requirements and mechanical seal pressure limitations. The CSTR is the idealized opposite of the weU-stirred batch and tubular plug-flow reactors. Analysis of selected combinations of these reactor types can be useful in quantitatively evaluating more complex gas-, Hquid-, and soHd-flow behaviors. 

Electrodialysis. In electro dialysis (ED), the saline solution is placed between two membranes, one permeable to cations only and the other to anions only. A direct electrical current is passed across this system by means of two electrodes, causiag the cations ia the saline solution to move toward the cathode, and the anions to the anode. As shown ia Figure 15, the anions can only leave one compartment ia their travel to the anode, because a membrane separating them from the anode is permeable to them. Cations are both excluded from one compartment and concentrated ia the compartment toward the cathode. This reduces the salt concentration ia some compartments, and iacreases it ia others. Tens to hundreds of such compartments are stacked together ia practical ED plants, lea ding to the creation of alternating compartments of fresh and salt-concentrated water. ED is a continuous-flow process, where saline feed is continuously fed iato all compartments and the product water and concentrated brine flow out of alternate compartments. 

Nonicosahedral carboranes can be prepared from the icosahedral species by similar degradation procedures or by reactions between boranes such as B H q and B H with acetylenes. The degradative reactions for intermediate C2B H 2 species (n = 6-9) have been described in detail (119). The small closo-Qr Yi 2 species (n = 3-5 are obtained by the direct thermal reaction (500—600°C) of B H using acetylene in a continuous-flow system. The combined yields approach 70% and the product distribution is around 5 5 1 of 2,4-C2B3H2 [20693-69-0] to l,6-C2B Hg [20693-67-8] to 1,5-C2B3H3 [20693-66-7] (120). A similar reaction (eq. 60) employing base catalysts, such as 2 6-dimethylpyridine at ambient temperature gives nido-2 >-(Z, ... 

Air Drying Equipment. Tunnel kiln dryers (70) are long furnaces comprised of several zones of different temperature, humidity, and air flow through which the ware travels on a moving car or belt. These kilns afford continuous processing. Periodic kiln cross-circulation dryers (70) are box furnaces in which ware is stacked on permanent racks or on a car that can be shuttled in and out of the furnace. Fans or jets are used to circulate heat uniformly through the ware. The process is not continuous, but production rates can be enhanced by shuttling multiple cars. 

Production of potassium permanganate in the CIS is beheved to be from potassium manganate. Electrolysis of potassium manganate in a continuous-flow electrolytic cell with turbulent electrolyte flow and continuous crystallization has been reported (72). 

Continuous-flow Stirred Tank Reactor (CSTR) A reaction vessel in which the feed is continuously added, and the products continuously removed. The vessel (tank) is continuously stirred to maintain a uniform concentration within the vessel. 

Mixing of product and feed (backmixing) in laboratory continuous flow reactors can only be avoided at very high length-to-diameter (aspect) ratios. This was observed by Bodenstein and Wohlgast (1908). Besides noticing this, the authors also derived the mathematical expression for reaction rate for the case of complete mixing. 

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