Collaboration blog between Venwiz and Topse Process Solutions Private Limited sharing valuable insights on solvent recovery systems
Solvent recovery systems play a crucial role in the chemical and pharmaceutical sectors. By helping recover and reuse solvents, these systems help minimize waste and environmental impact but also help save costs.
Whether you are new to the concept or looking to gain a deeper understanding, this blog will provide you with everything you need to know about solvent recovery systems.
What are solvent recovery systems?
A solvent recovery system is a method to extract the solvent from the solvent waste. You can use the recovered product in the production without causing any problems.
How does a solvent recovery system work?
A solvent recovery plant uses a multi-stage distillation process to reclaim the solvent from the waste stream. The process leverages the different boiling points of the solvents and contaminants. We boil the solution and condense the vapours into liquids in separate tanks.
- Feeding the System: Waste solvent is fed (either automatically or manually) into a heated chamber.
- Separation by Boiling Point: Each component boils at a specific temperature. For example, oils typically boil at higher temperatures than solvents.
- Condensation and Collection: The vaporized solvent travels to a cooled chamber, where it condenses back into a liquid form. This clean solvent is then ready for reuse or further processing.
Benefits
- Cost optimization: Solvent recovery systems offer significant cost savings by reducing the reliance on new solvents. The recovered solvent is recycled for use in the production process.
- Enhanced Operational efficiency: Solvent recovery systems improve production efficiency by ensuring a consistent supply of clean solvent, eliminating the need for frequent procurement and reducing downtime.
- Environmental impact: Solvent recovery helps reduce environmental pollution by reducing the solvent waste. By recovering solvents, businesses can prevent soil and groundwater contamination and help them comply with central and state pollution requirements.
- Potential for Improved Product Quality: In some cases, recovered solvents demonstrate superior quality compared to their commercial counterparts after purification. This enhanced quality can positively impact the final product, ensuring consistent performance and reliability.
Types of solvent recovery systems
Solvent recovery systems can be classified into:
- Batch System is the simplest type of solvent recovery system and works by heating batches of solvents and condensing the vapour back into liquid.
- Continuous System continuously feeds the waste solvent into the system and recovers the solvent.
Topse Process Solutions Private Limited specialises in the following solvent recovery systems:
Distillation system
The distillation system operates on batch and continuous operating modes and is ideal for regular solvents. Distillation systems are classified into:-
- ATM distillation
- High vacuum distillation
The distillation system has a single distillation column and is suitable for a multi-solvent recovery system.
Vacuum distillation is a preferred recovery method when the compounds have high boiling points or are prone to explosions. This technique enables separation at lower temperatures, preventing them from decomposing.
Distillation systems offer users quick changeover, high efficiency, and low contamination.
Membrane system
The membrane system is primarily used to remove water from solvent systems and can be further categorized into:
- Pervaporation Plant
- Vapor Permeation
It utilizes the physico-chemical interaction between the membrane and permeating molecules. Membranes are made from highly hydrophilic materials to enhance preferential absorption and diffusion of water molecules through a thin, dense membrane layer.
Hybrid system
As the name suggests these are systems that integrate distillation and membrane systems. This case study highlights the efficiency of hybrid systems.
| Parameter | Distillation Column | Hybrid System (Distillation Column with Pervaporation Membrane) |
| Feed Rate | 4200 liters per hour | 4200literse per hour |
| Reflux Ratio | 4-6 | 0.5-1.5 |
| Column Height | 15 m | 6 m |
| Column Diameter | 1400 mm | 700 m |
| Reboiler Duty | 2000 kw | 830 kw |
Factors to Consider When Choosing a Solvent Recovery System
When selecting a solvent recovery system for your plant, there are several factors you need to consider to ensure cost-effectiveness, performance, and regulatory compliance.
Here are some key considerations:
Industry regulations and compliance
India has strict regulatory requirements regarding solvent waste disposal and emissions. The system used must comply with these guidelines, ensuring safe and eco-friendly solvent recovery practices for your factory.
Energy efficiency and operating costs
With rising energy costs in India, evaluate the system’s energy consumption. Choose a system that is energy-efficient to minimise operating costs.
Compare cost
To determine the most cost-effective solvent recovery system for your plant, compare the initial cost of equipment, ongoing operational and maintenance costs, and potential cost savings by reusing the solvent. This analysis will help you calculate your purchase’s return on investment or (ROI).
Operational efficiency
Choose a system with easy maintenance and readily available spare parts. Assess the frequency of maintenance procedures for smooth operation. We recommend you use a system that provides a comprehensive operating manual and provides operator training for efficient and safe usage.
Input parameters required to supply solvent recovery systems
| Per Day Volume of the Stream (Liter) | The average daily flow rate of the liquid waste stream you want to process |
| Dissolved Solids | The concentration of dissolved solids (particles that cannot be separated by a filter) is measured in parts per million (ppm) within the liquid waste stream. |
| Suspended Solid (PPM) | The concentration of suspended solids (particles large enough to be separated by a filter) measured in parts per million (ppm) within the liquid waste stream. |
| Batch Kettle Capacity required (liter) | The desired capacity of the batch processing in litres, considering the volume of waste you generate per day. |
| Hours of operation per day | The typical number of hours per day your facility operates the process that generates the waste stream. |
| Utilities Available | Specify the utilities available at your facility, such as steam, compressed air, cooling water, and electricity. This information helps manufacturers recommend compatible systems. |
| Automation Requirement | Indicate your preference for the level of automation in the solvent recovery system. Options can range from manual to fully automated operation. |
Industries that use solvent recovery systems
Solvent recovery systems are widely used in the chemical and pharmaceutical industries. It is used to recover regular solvents like:
- Toluene
- Methanol
- THF (Tetrahydrofuran (THF)
- DMF (Dimethylformamide)
- Acetone
- Ethyl Acetate
- IPA (isopropyl alcohol)
- MCB Methylcyclohexane
Venwiz and Topse Process Solutions Private Limited a partnership in Solvent Recovery Systems
Venwiz is an online marketplace that brings together manufacturers with project vendors. We are the leading platform that will help you find partners for capex project requirements. We are proud to introduce Topse Process Solution Private Limited (TPSL) as a leading manufacturer of solvent recovery systems. TPSL provides turnkey solutions for process industries.
Topse Process Solution Private Limited.
TOPSE Process Solution Private Limited boasts over 120 engineers and advanced design software to deliver complete turnkey solutions with services encompassing the entire project lifecycle from initial design and engineering to final installation, commissioning, and training. This approach helps TPSL maintain strict quality standards. With an in-house pilot facility for trial and validation, TPSL has always strived to provide innovative solutions that work. View brochure here
Topse takes great pride in its in-house capabilities, handling all aspects of design, engineering, and manufacturing of various process equipment. They have a well-equipped 30,000 square-foot manufacturing facility with:-
- Machinery required to manufacture SS Reactors & Condensers
- Cutting and welding equipment
- Pressure testing
- Material polishing system
Besides solvent recovery systems, Topse Process Solution Private Limited also provides:
- Single Fluid Heating & Cooling System
- Membrane Separation System
Noteworthy projects
| Sr No | Client Name | Industry/Sector | Project description | Project Highlight |
| 1 | Reliance Life Sciences | Life Sciences | SRS Greenfield Project | Multi Solvent Recovery |
| 2 | Granules India | API | MPP Solvent Recovery | Product-Based Solvent Recovery |
| 3 | Deccan Fine Chemicals | PharmaIntermediates | Heating &Cooling Skid | High Temperature Skids |
Guest Author
Yogesh V has completed his B.E. in Electronics and Communication and Masters in Business Management, He brings over 12 years of experience in business development to the table. He has successfully managed international and domestic projects from conceptualization to completion. He is considered an invaluable resource for the company.
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