Distillation units

Recovery of solvents, solvent based products and heavily contaminated Waste water

Functional principle of RENZMANN – ROTO- / ROTOmaX – distillation units

The solvent is heated in the cylindrical boiler of the distillation unit, be-gins to boil and to evaporate. The solvent vapors condense in the water-cooled condenser and then fl ow 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 re-sidue 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 heat-sensitive substances (e.g. washing solvents containing nitrocellulo-se).

D.W.RENZMANN Apparatebau GmbH is a medium-sized company headquartered in the German State of Rhineland-Palatinate, near the Nahe River that has given its name to a famous wine growing region. RENZMANN has been developing and manufacturing industrial washing machines and distillation units for more than 40 years and serves customers in the printing industry and in the ink, paint and varnish industry. The company‘s core competency is the removal of stub-born residues and the distillation of the fl ammable organic solvents and alkaline media used in industrial washing ma-chines.

In addition to developing, designing, ma-nufacturing and selling machines and equipment, the company also offers its customers consulting and other services. RENZMANN focuses on

– safety at work and the protection of equipment operators,

– environmental protection, – profi table solutions, and– high availability and durability

of equipment.

D.W.RENZMANN is certifi ed according to the European ATEX directive and leads the market in the aforementioned segments. The company has an ATEX-certifi ed quality assurance system and consistently implements all relevant legal requirements. D.W.RENZMANN supplies category 1 equipment with a type examination according to ATEX and thereby protects customers from any liability due to unsuitable or pro-hibited equipment, irrespective of the solvent used.

State-of-the-art equipment includes load cells that weigh the medium in the distillation boiler; combined with an intelligent control system, the

signals of these cells provide important process information and permit a fully automated distillation process.RENZMANN distillation units are used wherever heavily contamina-ted media must be separated into their solid and liquid componen-ts. Such media include, for instance, contaminated solvents used in the chemical industry, e.g. by ink, paint and varnish manufacturers. RENZMANN‘s fl agship products in this area are the ROTOmaX di-stillation units, which offer maximum effi ciency in the treatment and recovery of solvents, solvent-based products and heavily conta-minated waste water. Distillation is a fully automated process that does not require supervision. The only waste produced is a small quantity of highly viscous residue that can be disposed of inexpen-sively, while nearly all of the solvent or water is recovered and may be reused. The high recovery rate, the supply of clean washing agent with minimal transport requirements for the highly reduced quantity of dischargeable residue are important factors that con-tribute to active environmental protection.ROTOmaX units have a steam-heated boiler fl oor that ensures effi cient heating, optimal heat transfer, and a consistently high heat output irrespective of the fi lling level. An ATEX-certifi ed rotating scraper system discharges the residue and effectively cleans the heating surface on the boiler fl oor. The fi lling level is monitored by external load cells, eliminating the need for le-vel sensors inside the boiler that might become sticky through contact with the solvent. In addition to separating the liquid and solid components of vari-ous media, ROTOmaX units can be equipped with a fractionating column for the downstream separation of liquids into their various components. Another very interesting core competency of D.W.RENZMANN is a special, proven method for debinding mass-produced items as part of the metal injection molding process. What makes RENZMANN‘s debinding technology special is the fact that it does not produce emissions and is therefore especially eco-friendly. In summing up, D.W. RENZMANN offers the following products and services:• Treatment and recovery systems for contaminated solvents, water-based cleaners and fl ushing water

• Washing machines for paint mixing containers, transport containers, barrels, buckets etc.

• Debinding systems for customers specializing in metal injection molding

• Customized solutions for cleaning and treatment/recovery tasks• Maintenance, spare part supply and safety inspections• Consulting services for complete workspace solutions, selection of washing agents based on economic and ecological aspects, com-munication with authorities and preparation of documents to comply with guidelines and regulations.

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Type ROTO Type ROTOmaX

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RENZMANN units for category 1 according to ATEX for Zone 0 on the inside

Fulfi llment of the „CRITERIA FOR THE SELECTION OF EQUIPMENT AND PROTECTIVE SYSTEMS“ according to the ATEX workplace directive 1999/92/EC (ATEX 137)

D.W.RENZMANN:uses a certifi ed quality assurance system according to ATEX and consistently implements all relevant legal requirements.

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.

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.

Type ROTO 9-18 Type ROTOmaX 15-110

ROTO components

• Cylindrical, vacuum-tight distillation boiler

• Insulated heating jacket, fl oor and lower jacket surface with thermal oil and integrated electric heating ele- ments. The unit can also be con- nected to an on-site steam or thermal oil network

• Water-cooled stainless steel con- denser

• 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 dispo- sal container and/or 200-l-barrel (on a pallet) (accessory for ROTO 9,

ROTOmaX components:

• Cylindrical, vacuum-tight distillation boiler consisting of an insulated dome (stainless steel) with a heating fl oor (standard steel) fl anged to the bottom

• Insulated, fl at heating fl oor 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

• Steam generator fl anged to the hea- ting fl oor, operated with electric pow- er or with steam or thermal oil from an on-site network. Direct heating of the fl oor with steam or warm water is also possible.

• Water-cooled stainless steel con- denser

• Rotating scraper system (rotor), pre- vents incrustations on the heating fl oor, agitates the material to be distil- led and keeps the discharge valve clean

• Dirt-resistant discharge valve, opera- ted manually or pneumatically

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 certifi ed with a declaration of conformity and documented by means of a CE label at the machine.

• 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 specifi ed temperature limits are reached, the heating is switched off and the distillation vessel is fl ooded with water.

• Draining of the used solvent container is detected by fl ow detector (accessory).

• Automatic deactivation of distillation in the distilling-off phase (accessory for ROTO, standard in ROTOmaX)

Closed solvent circuit

standard discharge height 650 mm). Other heights are possible.

• Optional: adapted residue carriage (only with ROTO 9)

• Sight glass and explosion-proof halogen lamp for observing the distillation process

• Automatic fi lling stop by means of a vibration limit switch and a pneumatic ball valve in the fi lling line

• Batch distillation or continuous distillation possible

• ex proof control elements at distilla-tion unit: for vacuum, fi lling, 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, fi lling, heating, scraper and distilling down

Accessories

• Vacuum unit for lowering process temperatures, with either a liquid ring vacuum pump (for solvents with a fl ash point > 55 °C) or a liquid jet vacuum pump

• Residue temperature control sys- tem for processing heat-sensitive substances

• Distillation output monitor for auto- matic distillation stop when the output drops below a set limit

• Timer for automatic distillation start

• Seal plate or exhaust hood adapted to on-site disposal container, optio- nally 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.

• 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 distil- lation process

• Automatic fi lling stops when a preset fi lling quantity is reached; the fi lling quantity is monitored by means of load cells that register the total weight of the distillation boiler; fi lling stops by means of a pneumatic ball valve in the fi lling 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, fi lling quan- tity, refi lling quantity, residue quantity, distillate quantity, average distillation output and operating hours

Accessories:

• 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, option- ally 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 auto- matic 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.

plate processor

inline cleaning for printing press parts

vessel- and container cleaning

external cleaning of printing press parts

waste solvent containerdistillation unitdistillate container

vacuum unit

cooling water

plate processor

printing press

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distillation unit ROTOmaX 15 ROTOmaX 20 ROTOmaX 30 ROTOmaX 50 ROTOmaX 75 ROTOmaX 110

fi lling 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

cooling water fl ow 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

heating energy 15 kW 20 kW 30 kW 50 kW 75 kW 110 kW

weight ** 2200 kg 2300 kg 2500 kg 2700 kg 3100 kg 3300 kg

W x H x D W x H x D W x H x D W x H x D W x H x D W x H x D

dimensions mm *** 1450x3000x1900 1450x3000x1900 1650x3100x2100 1950x3200x2600 2250x3300x2900 2550x3400x3200

required space mm **** 6000x3400x4000 6000x3400x4000 6000x3500x4500 6500x3600x4600 7000x3800x5200 7500x3900x5500

Shipping dimensions mm 1700x2200x2000 1700x2200x2000 1800x2400x2300 2100x2600x2700 2400x2850x3000 2700x2900x3300

* 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.

distillation unit ROTO 9 ROTO 12 ROTO 18

fi lling volume ca. 140 l ca. 250 l ca. 400 l

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 fl ow rate ** ca. 0,7 m³/h ca. 1 m³/h ca. 1,5 m³/h

heating energy 9 kW 12 kW 18 kW

weight ** 1300 kg 2200 kg 2500 kg

W x H x D W x H x D W x H x D

dimensions mm *** 1300x2650x1700 1450x3400x1800 1560x3900x2000

required space mm **** 3500x3200x3600 4000x3700x4500 4000x3900x5000

Shipping dimensions mm 1500x1600x2800 1600x2300x2000 1750x2450x2100

* 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.

pre-evaporator

cooling water

distillation unit vacuum unit

cooling water

heating

clean water

soiled water

residue

Type ROTOmaX-W

The ROTOmaX-W distillation unit vaporizes soiled aqueous/alkali-ne washing and rinsing agents. The condensed clean distillate is admitted back into the rinsing water / washing agent circuit of the cleaning process. There is no waste water. The residue – greatly reduced and concentrated compared to the used quantity of rin-sing water / washing agent – is disposed of as hazardous waste. The two-step distillation with a pre-eva-porator reduces the energy consumpti-on per liter of evaporated water by half.Approximately half of the soiled agent is vaporized in the pre-evaporator under normal pressure. The resulting steam (100°C) contains the energy supplied in the pre-evaporator and is piped into the heating fl oor of the distillation unit.

We want you to benefi t from our know-how:

We determine the profi tability of your project in terms of performance, staff requirements, investments costs and operating costs, taking into ac-count 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 exis-ting or future exhaust air systems.

In our lab, we provide distillation units for practical tests with your sol-vent 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 connec-ting our products to existing equipment.

RENZMANN engineers are trained and experienced experts that re-pair, install, commission and service our equipment worldwide.

When spare parts are needed, we do our utmost to supply these parts as quickly as possible.

The soiled agent that has been slightly concentrated in the pre-evaporator is now sucked into the distillation boiler, in which avacuum has been generated. Due to the vacuum, the boiling tem-perature in the distillation boiler is reduced to < 60°C. The tem-perature difference of > 40°C between the boiler contents and thesteam (100°C) from the pre-evaporator makes the steam in the heating fl oor condense and transmit its energy to the contents of the distillation boiler. There, the washing agent is vaporized and concentrated to less than 5% of its original volume.The pre-evaporator distillate that condensed in the heating fl oor is sucked into the condenser of the distillation unit and combines with the condensing vapors from the distillation boiler. The distil-late cools slightly in the condenser, runs to the vacuum unit and from there into a separate clean water container.The loss of liquid in the pre-evaporator (half of which is caused by evaporation, the other half by liquid being sucked into the di-stillation boiler) is compensated for automatically by continuous refi lling.

Prevention of waste water coming from cleaning processes

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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

D.W. Renzmann Apparatebau GmbH

Industriestraße 1 D-55569 MonzingenGermany

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

Schützenmattweg 33CH-5610 WohlenSwitzerland

Phone: +41 (0)56 6186464 Fax: +41 (0)56 6186418

www.riobeer.ch info@riobeer.ch

UK

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