Unique Distillation Problems with Electrometallurgical Products

An American company approached PRI with a unique problem for which they had not been able to find a solution from other potential vendors. Their product is microscopic, magnetic particles that are suspended in a solvent. By passing a magnetic field through the blend of materials, the specific gravity (density) of the blend can be changed allowing them to perform many unique functions with the fluid.

To allow recoverability of the material in the field and to accurately control their processes, they had several distillation/recovery parameters that they needed to meet:

• The recovery equipment was needed immediately to integrate into an existing process.
• Excessive temperature would destroy the magnetic particles.
• The input stream to the recovery unit would be highly variable in composition and quantity.
• Specific gravity of the recovered particulate solution would be critical.
• The system should be automated to minimize operator interface.

PRI’s team of engineers set down with the client and created a testing program that would determine the distillation characteristics and the limits of temperature and vacuum that could be used without degrading the characteristics of the magnetic particulate. Blind samples were submitted to the client for testing to negate the possibility that preconceived ideas of what was required during distillation would not affect their judgment of the acceptability of the samples.

In most distillation applications the consistency of the residue left in the still is not critical. In this application it was critical that the recovered magnetic particles be suspended in an appropriate amount of solvent to give a tightly controlled density of the recovered product. Measuring the density of a hot solution, under vacuum, while the process was running, provided PRI engineering with a unique challenge. Their solution fulfilled all the requirements of the client and gave them a measurement system that was more accurate than expected, thus giving them more control over the processes where the fluid was to be used.

For fast installation in the field, all the tanks, distillation unit, vacuum system, measuring equipment, and control panels were built into a single integrated package that was enclosed to create a self contained Class 1, Division 2 area. The unit was put onto a "fast track" production schedule to be able to ship as quickly as possible. Long lead time items were purchased before engineering was completed and production, engineering and purchasing all closely coordinated their activities to be able to reduce the manufacturing time to a minimum. When completed ahead of schedule, the 8,500 pound unit shipped by air to Europe where it was immediately installed. A PRI Field Service Technician was on site to verify the correct installation of the unit, commission the unit and to train the employees on the proper operation. It was quickly apparent that the system would meet the requirements of processing up to 2,600 gallons per day and achieving the quality desired.

Progressive Recovery was uniquely able to help this customer because we are a ‘full service" vendor. We draw on the experience of our mechanical, electrical and chemical engineers to create product concepts and problem solving approaches. We can validate these concepts in our test lab and determine the proper operating parameters before engineering designs the product. Our production department starts with flat steel stock to fabricate all of our vessels and other equipment while the electrical panel shop creates the proper controls and makes sure they meet the appropriate codes. Thorough testing of a unit before it leaves our facility minimizes problems in the field during the commissioning process.

If this is the type of capability and responsiveness that you are looking for in a vendor, give us a call. We will be happy to talk to you about your application and see if we can help solve your process problems.