Zen Adsorptions Pvt. Ltd.

Our Pilot-Scale Rising Film Evaporator (RFE) is specifically designed for concentration of heat-sensitive, low-viscosity liquids under controlled conditions. This equipment is ideal for process development, R&D trials, and small-scale production in industries such as pharmaceuticals, chemicals, food & beverage, and biotechnology.

• Vertical tubular evaporator design ensures efficient heat transfer

• Rising film mechanism allows thin film formation for gentle evaporation

• Steam or hot water jacketed heat exchanger for uniform heating

• Vapor-liquid separator at the top for efficient phase separation

• Feed and product tanks with integrated flow and level controls

• Skid-mounted compact structure for easy installation and mobility

• Customizable configurations for multi-effect or solvent recovery processes

• Automation-ready with temperature, pressure, and flow control instrumentation

• Solvent recovery

• Concentration of herbal extracts and APIs

• Wastewater minimization

• Evaporation of thermally sensitive solutions

The pilot-scale RFE is engineered for scalability, making it a valuable tool for bridging the gap between lab and full-scale industrial operations. We also offer trial services, process optimization support, and custom fabrication based on client-specific requirements.

Additional Information:

• Delivery Time: 8 Weeks

Our Pilot-Scale Rising Film Evaporator (RFE) is specifically designed for concentration of heat-sensitive, low-viscosity liquids under controlled conditions. This equipment is ideal for process development, R&D trials, and small-scale production in industries such as pharmaceuticals, chemicals, food & beverage, and biotechnology.

• Vertical tubular evaporator design ensures efficient heat transfer

• Rising film mechanism allows thin film formation for gentle evaporation

• Steam or hot water jacketed heat exchanger for uniform heating

• Vapor-liquid separator at the top for efficient phase separation

• Feed and product tanks with integrated flow and level controls

• Skid-mounted compact structure for easy installation and mobility

• Customizable configurations for multi-effect or solvent recovery processes

• Automation-ready with temperature, pressure, and flow control instrumentation

• Solvent recovery

• Concentration of herbal extracts and APIs

• Wastewater minimization

• Evaporation of thermally sensitive solutions

The pilot-scale RFE is engineered for scalability, making it a valuable tool for bridging the gap between lab and full-scale industrial operations. We also offer trial services, process optimization support, and custom fabrication based on client-specific requirements.

Additional Information:

• Delivery Time: 8 Weeks

An Agitated Thin Film Evaporator (ATFE), commonly referred to as a Wiped Film Evaporator (WFE), is a highly efficient rotary evaporation system designed for the controlled evaporation, concentration, or distillation of liquids. It is especially suitable for heat-sensitive, viscous, or fouling-prone materials.

• The core structure is a jacketed shell precisely machined for optimal heat transfer.
  
  

• The high-speed rotor with blades operates with minimal clearance from the shell.
  
  

• The liquid feed enters through a feed distributor and spreads into a thin film along the heated wall.
  
  

• The rotor continuously agitates the liquid film, promoting even distribution and maximizing contact with the heated surface.
  
  

• An integrally attached entrainment separator cleans the vapors, which flow counter-current to the liquid, improving separation efficiency and vapor quality.
  
  

• The process operates in a once-through mode without recirculation, reducing product degradation and minimizing hold-up.
  
  

1. Thin Film Formation:
   
   

   • Maximizes surface area for heat transfer, ensuring uniform heating.
     
     

2. Intense Agitation:
   
   

   • Prevents fouling, scaling, and local overheating.
     
     

   • Maintains turbulent flow even for highly viscous liquids.
     
     

   • Enhances heat transfer efficiency.
     
     

3. Short Residence Time:
   
   

   • The liquid spends only a few seconds in the heated zone, minimizing thermal degradation.
     
     

4. Low Product Hold-Up:
   
   

   • Reduces material loss and improves process control.
     
     

1. Pharmaceutical Industry:
   
   

   • Vacuum distillation of bulk drugs, intermediates, and fine chemicals.
     
     

2. Chemical Industry:
   
   

   • Distillation of glycols, used lubricating oils, fatty acids, and their derivatives.
     
     

   • Processing of rubber chemicals, amines, and esters.
     
     

3. Solvent Recovery:
   
   

   • Recovery of contaminated solvents and products from residues.
     
     

• Capacity range: 0.1 sq.m to 30 sq.m surface area.
  
  

• Operating temperature: 30°C to 300°C.
  
  

• Operating pressure: From full vacuum to 2 bar (g).
  
  

• Construction materials (MOC): SS304, SS316, Hastelloy for chemical compatibility.

Additional Information:

• Delivery Time: 8 weeks

Short-path distillation, also known as molecular distillation, is a specialized technique used for separating compounds under high vacuum conditions. In this process, the fluids operate in the free molecular flow regime, meaning that the mean free path of the molecules is comparable to the dimensions of the equipment.

• The SPDU features an internally mounted condenser, which plays a critical role in its operation.
  
  

• The vapors generated from the heated surface travel a very short distance directly to the condenser surface.
  
  

• This design eliminates significant pressure drop, allowing operation at extremely high vacuum levels, typically down to 0.001 mbar.
  
  

• The short path ensures minimal thermal degradation of heat-sensitive materials by reducing residence time to only a few seconds.
  
  

• Minimum liquid hold-up: Reduces processing time and material loss.
  
  

• Ideal for heat-sensitive materials: Prevents decomposition or degradation of delicate compounds.
  
  

• Excellent turn-down capability: Allows processing of variable feed rates without loss of efficiency.
  
  

• High evaporation rate: Optimizes throughput while maintaining product integrity.
  
  

• Operates at high vacuum (0.001 mbar): Facilitates distillation of high-boiling or thermally unstable compounds.
  
  

• Heating temperatures up to 400°C: Suitable for processing a wide range of materials.
  
  

• Short residence time: Typically a few seconds, which is beneficial for sensitive products.
  
  

1. Pharmaceutical Industry:
   
   

   • Concentration of bulk drug products and active pharmaceutical ingredients (APIs).
     
     

2. Chemical Industry:
   
   

   • Distillation of epoxy resins, esters, plasticizers, and stabilizers.
     
     

3. Nutraceutical Industry:
   
   

   • Purification and concentration of fatty acids, fish oil, omega-3 fatty acids, and glycerides.
     
     

4. Food Industry:
   
   

   • Purification of natural and synthetic vitamins.
     
     

5. Cosmetics and Personal Care:
   
   

   • Concentration and purification of natural and synthetic waxes.
     
     

6. Lubricants Industry:
   
   

   • Refining of spent lube oil.
     
     

• Capacity ranges from 0.01 sq.m to 40 sq.m surface area.
  
  

• Designed to operate over a wide temperature range: 30°C to 400°C.
  
  

• Designed to withstand pressures from full vacuum to 2 bar (g).
  
  

Construction materials include SS304, SS316, and Hastelloy, depending on the chemical compatibility and application needs.

Additional Information:

• Delivery Time: 8 Weeks

An Agitated Thin Film Evaporator (ATFE), commonly referred to as a Wiped Film Evaporator (WFE), is a highly efficient rotary evaporation system designed for the controlled evaporation, concentration, or distillation of liquids. It is especially suitable for heat-sensitive, viscous, or fouling-prone materials.

• The core structure is a jacketed shell precisely machined for optimal heat transfer.
  
  

• The high-speed rotor with blades operates with minimal clearance from the shell.
  
  

• The liquid feed enters through a feed distributor and spreads into a thin film along the heated wall.
  
  

• The rotor continuously agitates the liquid film, promoting even distribution and maximizing contact with the heated surface.
  
  

• An integrally attached entrainment separator cleans the vapors, which flow counter-current to the liquid, improving separation efficiency and vapor quality.
  
  

• The process operates in a once-through mode without recirculation, reducing product degradation and minimizing hold-up.
  
  

1. Thin Film Formation:
   
   

   • Maximizes surface area for heat transfer, ensuring uniform heating.
     
     

2. Intense Agitation:
   
   

   • Prevents fouling, scaling, and local overheating.
     
     

   • Maintains turbulent flow even for highly viscous liquids.
     
     

   • Enhances heat transfer efficiency.
     
     

3. Short Residence Time:
   
   

   • The liquid spends only a few seconds in the heated zone, minimizing thermal degradation.
     
     

4. Low Product Hold-Up:
   
   

   • Reduces material loss and improves process control.
     
     

1. Pharmaceutical Industry:
   
   

   • Vacuum distillation of bulk drugs, intermediates, and fine chemicals.
     
     

2. Chemical Industry:
   
   

   • Distillation of glycols, used lubricating oils, fatty acids, and their derivatives.
     
     

   • Processing of rubber chemicals, amines, and esters.
     
     

3. Solvent Recovery:
   
   

   • Recovery of contaminated solvents and products from residues.
     
     

• Capacity range: 0.1 sq.m to 30 sq.m surface area.
  
  

• Operating temperature: 30°C to 300°C.
  
  

• Operating pressure: From full vacuum to 2 bar (g).
  
  

• Construction materials (MOC): SS304, SS316, Hastelloy for chemical compatibility.

Additional Information:

• Delivery Time: 8 week

• Product developmentPilot plant trials can be used to test and develop a production process, and to evaluate scale-up issues.  
• Material handlingPilot plant trials can help identify material handling restrictions.  
• Process optimizationPilot plant trials can help optimize process conditions by analyzing products in real-time and conducting feed rate studies.  
• ValidationPilot plant trials can provide crucial test results and validation for full-scale implementation.  

Short-path distillation, also known as molecular distillation, is a specialized technique used for separating compounds under high vacuum conditions. In this process, the fluids operate in the free molecular flow regime, meaning that the mean free path of the molecules is comparable to the dimensions of the equipment.

• The SPDU features an internally mounted condenser, which plays a critical role in its operation.
  
  

• The vapors generated from the heated surface travel a very short distance directly to the condenser surface.
  
  

• This design eliminates significant pressure drop, allowing operation at extremely high vacuum levels, typically down to 0.001 mbar.
  
  

• The short path ensures minimal thermal degradation of heat-sensitive materials by reducing residence time to only a few seconds.
  
  

• Minimum liquid hold-up: Reduces processing time and material loss.
  
  

• Ideal for heat-sensitive materials: Prevents decomposition or degradation of delicate compounds.
  
  

• Excellent turn-down capability: Allows processing of variable feed rates without loss of efficiency.
  
  

• High evaporation rate: Optimizes throughput while maintaining product integrity.
  
  

• Operates at high vacuum (0.001 mbar): Facilitates distillation of high-boiling or thermally unstable compounds.
  
  

• Heating temperatures up to 400°C: Suitable for processing a wide range of materials.
  
  

• Short residence time: Typically a few seconds, which is beneficial for sensitive products.
  
  

1. Pharmaceutical Industry:
   
   

   • Concentration of bulk drug products and active pharmaceutical ingredients (APIs).
     
     

2. Chemical Industry:
   
   

   • Distillation of epoxy resins, esters, plasticizers, and stabilizers.
     
     

3. Nutraceutical Industry:
   
   

   • Purification and concentration of fatty acids, fish oil, omega-3 fatty acids, and glycerides.
     
     

4. Food Industry:
   
   

   • Purification of natural and synthetic vitamins.
     
     

5. Cosmetics and Personal Care:
   
   

   • Concentration and purification of natural and synthetic waxes.
     
     

6. Lubricants Industry:
   
   

   • Refining of spent lube oil.
     
     

• Capacity ranges from 0.01 sq.m to 40 sq.m surface area.
  
  

• Designed to operate over a wide temperature range: 30°C to 400°C.
  
  

• Designed to withstand pressures from full vacuum to 2 bar (g).
  
  

Additional Information:

• Delivery Time: 2 weeks

An Asymmetric Rotating Disc Contactor (ARDC) Column is a highly efficient system used for continuous counter-current liquid-liquid extraction. It is specifically designed to separate components from a liquid feed by using an immiscible solvent with a preferential affinity for the desired components.

• The liquid feed enters the ARDC column and comes into repeated contact with the immiscible solvent.
  
  

• Due to the counter-current flow arrangement, the fresh solvent moves opposite to the liquid feed, maximizing contact time and mass transfer.
  
  

• The rotating discs create intense mixing and promote efficient phase contact without back mixing, enhancing separation.
  
  

• The system provides three to six equivalent theoretical stages of separation by using a series of mixers and settlers.
  
  

• At the outlet, two separate streams emerge:
  
  

  • Extract: Enriched in the desired component.
    
    

  • Raffinate (spent feed): Contains minimal amounts of the desired component.
    
    

• Residence time: 15 to 120 minutes, depending on process requirements.
  
  

• No back mixing: Ensures high separation efficiency and product purity.
  
  

• Reduced power, space, and solvent consumption: Efficient design reduces operational costs.
  
  

• Continuous operation enables large-scale and steady production.
  
  

• Capable of handling high-boiling products.
  
  

• Theoretical separation stages: Up to four stages for effective separation.
  
  

1. Separation of Close Boiling Point Liquids:
   
   

   • Helps in separating components that are difficult to separate by distillation due to similar boiling points.
     
     

2. Purification of Fine Chemicals & Pharmaceuticals:
   
   

   • Extraction of active pharmaceutical ingredients (APIs) and fine chemicals from reaction mixtures or intermediates.
     
     

3. Wastewater Treatment:
   
   

   • Reduces COD (Chemical Oxygen Demand) and BOD (Biological Oxygen Demand) by extracting harmful organic compounds.
     
     

4. Breaking Azeotropes:
   
   

   • Separates azeotropic mixtures that are hard to separate by conventional distillation.
     
     

5. pH Adjustment via Washing:
   
   

   • Allows for pH modifications of solutions by liquid-liquid washing techniques.
     
     

6. Aromatic Extraction:
   
   

   • Extraction of aromatic compounds from complex mixtures.
     
     

• Capacity: Columns up to 2000 mm diameter.
  
  

• Operating temperature range: 10°C to 100°C.
  
  

• Designed to withstand pressure up to 2 bar (g).
  
  

• Construction materials (MOC): SS304, SS316, Hastelloy depending on chemical compatibility

Pilot Annular Centrifugal Extraction (ACE) Trials are conducted to evaluate and optimize liquid-liquid extraction processes using annular centrifugal contactors. These pilot-scale experiments provide critical data for scale-up, process validation, and solvent optimization in various chemical, pharmaceutical, and nuclear applications.

In the ACE process, two immiscible liquid phases (feed and solvent) are introduced into a rapidly rotating annular mixing zone. Centrifugal force ensures intense and uniform mixing of the liquids, significantly enhancing mass transfer. The rotation also promotes efficient phase separation in the same unit, eliminating the need for large settlers.

During pilot trials:

1. Feed and solvent are continuously introduced at controlled flow rates.
   
   

2. The rotor speed and phase ratio are optimized for maximum extraction efficiency.
   
   

3. The centrifugal field separates the lighter and heavier phases rapidly, producing clear extract and raffinate streams.
   
   

4. Process parameters such as residence time, distribution coefficient, and extraction efficiency are recorded for scale-up analysis.
   
   

• High Extraction Efficiency: Enhanced phase contact and rapid separation yield superior mass transfer rates.
  
  

• Compact Design: Combines mixing and separation in a single unit, reducing equipment footprint.
  
  

• Scalable Results: Pilot data provides reliable correlations for commercial-scale design.
  
  

• Low Solvent Inventory: Minimizes solvent losses and reduces environmental impact.
  
  

• Precise Control: Adjustable rotor speed and flow rates for flexible operation.
  
  

• Continuous Operation: Enables steady-state trials for long-duration testing.
  
  

• Solvent Extraction Process Development: Determining phase ratios, number of stages, and extractant selection.
  
  

• Separation of Metal Ions: Used in hydrometallurgy and nuclear reprocessing for actinide and rare earth recovery.
  
  

• Pharmaceutical and Fine Chemicals: Extraction and purification of intermediates or active ingredients.
  
  

• Wastewater and Effluent Treatment: Recovery of valuable organics and removal of contaminants.
  
  

• Analytical and Research Studies: Validation of liquid-liquid extraction models and kinetics.
  
  

• Flow Rate Range: 0.1 to 100 L/h (depending on rotor size and design).
  
  

• Extraction Stages: Single-stage or multi-stage cascade trials.
  
  

• Operating Temperature: 10°C to 80°C (customizable).
  
  

• Materials of Construction (MOC): SS316, Hastelloy, PTFE-lined components for chemical compatibility.
  
  

• Instrumentation: Digital RPM control, flowmeters, temperature and pressure sensors, data logging.
  
  

• Sampling & Analysis: Online sample points for monitoring extract and raffinate composition.
  
  

• Validate extraction feasibility before full-scale investment.
  
  

• Determine phase separation behavior and steady-state performance.
  
  

• Optimize process parameters for maximum yield and purity.
  
  

• Reduce design uncertainties and operational risks during scale-up.
  
  

Additional Information:

• Delivery Time: 8 weeks

A Lab Cooling Type Crystallizer is an essential piece of equipment used in laboratories and pilot plants for crystallization studies and process development. It enables precise control over temperature, agitation, and cooling rate—key parameters influencing crystal formation, purity, and size distribution. The system is widely applied in the chemical, pharmaceutical, and food industries for research, scale-up, and optimization of crystallization processes.

Key Features

• Precise Temperature Control: Enables accurate management of cooling rates and setpoints for reproducible crystal growth.
  
  

• Variable Agitation Speed: Facilitates optimization of crystal size and uniformity.
  
  

• Transparent or Jacketed Vessel Options: Allows visual observation and temperature uniformity.
  
  

• Compact Design: Ideal for lab-scale trials and process development studies.
  
  

• Data Acquisition System: Records temperature, agitation, and process time for detailed analysis.
  
  

• Compatibility: Suitable for aqueous and organic solvent systems.
  
  

Applications

Pharmaceutical Industry:

• Crystallization of active pharmaceutical ingredients (APIs) and intermediates.
  
  

• Optimization of polymorphs and particle size distribution.
  
  

Chemical Industry:

• Crystallization of organic and inorganic salts.
  
  

• Recovery of valuable solutes from mother liquor.
  
  

Food and Nutraceutical Industry:

• Crystallization of sweeteners, amino acids, and nutraceutical compounds.
  
  

Research and Development:

• Fundamental studies on crystallization kinetics, solubility, and phase behavior.
  
  

Operational Parameters (Typical Range)

• Capacity: 0.5 L to 50 L (lab/pilot scale)
  
  

• Operating Temperature: -20°C to +100°C (depending on chiller and solvent system)
  
  

• Cooling Rate: 0.1°C/min to 5°C/min (programmable)
  
  

• Agitation Speed: 50 to 500 rpm
  
  

• Pressure Range: Atmospheric to full vacuum operation
  
  

• Material of Construction (MOC): Borosilicate glass, SS316, or Hastelloy based on chemical compatibility
  
  

Advantages

• Enhanced reproducibility and control over crystal properties.
  
  

• Short process time with high yield and purity.
  
  

• Applicable for both batch and continuous crystallization trials.
  
  

Valuable tool for scaling up to industrial crystallizer design.

• Product developmentPilot plant trials can be used to test and develop a production process, and to evaluate scale-up issues.  
• Material handlingPilot plant trials can help identify material handling restrictions.  
• Process optimizationPilot plant trials can help optimize process conditions by analyzing products in real-time and conducting feed rate studies.  
• ValidationPilot plant trials can provide crucial test results and validation for full-scale implementation.  

Additional Information:

• Delivery Time: 8 Weeks