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Thin Film Evaporator

Thin Film Evaporator

Turnkey Thin Film Evaporator (TFE) Systems

Advanced Distillation & Separation Plants for Heat-Sensitive and Viscous Materials

Atılım Grup Makina specializes in the process engineering, design, and turnkey manufacturing of advanced Thin Film Evaporator (TFE) systems. Our customized solutions are highly engineered to process difficult-to-handle media, including heat-sensitive (thermolabile), high-viscosity, and severe-fouling products.

From pilot-scale units to multi-ton industrial plants, we deliver complete, automated evaporation facilities compliant with global standards (ASME, PED, CE, ATEX).

1. The Working Principle of TFE

Standard batch distillation often destroys heat-sensitive products due to long exposure to high temperatures. The Thin Film Evaporator overcomes this by utilizing a mechanically agitated thin liquid film.

  1. Feeding: The raw liquid enters above the heating zone and is distributed evenly around the inner circumference of the cylinder.
  2. Film Formation: A high-speed rotating mechanical rotor spreads the liquid into a highly turbulent, extremely thin film (typically 0.5 to 2 mm) along the heated inner wall.
  3. Rapid Evaporation: Due to intense turbulence and high heat transfer coefficients, the volatile components evaporate in mere seconds.
  4. Separation: Vapors flow either co-currently or counter-currently to an external or internal condenser, while the concentrated heavy phase (bottom product) is continuously discharged.

2. Core Technical Advantages

Our TFE plants offer superior performance over conventional shell-and-tube or falling film evaporators:

  • Ultra-Short Residence Time: The product remains in the heating zone for only a few seconds, completely preventing thermal degradation, polymerization, or discoloration.
  • High Viscosity Capability: Equipped with custom-designed rotor blades, our systems efficiently process materials with viscosities up to 100,000 mPa·s (cP) at operating temperatures.
  • Fouling & Scaling Prevention: The continuous wiping action of the rotor blades creates a "bow wave" effect, preventing localized overheating (hot spots) and crust formation on the heating wall.
  • Deep Vacuum Operation: Highly precise machining allows operation under extreme vacuum conditions (down to 1 mbar), significantly lowering the boiling point of heavy compounds.
  • Single-Pass Efficiency: High evaporation ratios are achieved in a single pass without the need for recirculation.

3. Industrial Applications

Atılım Grup Makina designs TFE facilities tailored to various high-value industries:

Chemical & Polymer Industry

  • Stripping of monomers and solvents from polymer solutions (e.g., silicone oils, acrylic resins).
  • Purification of specialty chemicals, intermediates, and synthetic resins.
  • Concentration of high-boiling point organic compounds.

Waste Oil Recycling & Green Chemistry

  • Re-refining of used lubricating oils (lube oil distillation).
  • Solvent recovery from hazardous industrial waste streams.
  • Separation of heavy metals and ash from organic fluids.

Pharmaceutical & Cosmetics

  • Concentration of Active Pharmaceutical Ingredients (APIs) and plant extracts.
  • Deodorization and purification of essential oils, Omega-3 fatty acids, and lanolin.

Food & Bio-Products

  • Concentration of fruit juices, purees, and high-sugar syrups.
  • Lecithin drying and edible oil refining.

4. Equipment Specifications & Metallurgy

We manufacture robust, high-precision evaporators customized to your chemical process:

  • Materials of Construction: Stainless steel (AISI 316L, 316Ti), Duplex steels, Hastelloy, or special corrosion-resistant alloys.
  • Rotor Configurations:
    • Fixed Clearance Rotors: For highly viscous materials.
    • Hinged Wiper Blades (PTFE, Carbon, or Metallic): Self-adjusting blades for maximum surface contact and cleaning.
  • Heating Media: Double jacket or limpet coil design suitable for thermal oil (up to 350°C) or steam.
  • Surface Finish: High-precision internal boring and mechanical polishing (Ra < 0.4 µm for pharma/food applications).

5. Our Turnkey Scope of Supply

As a single-source provider, Atılım Grup Makina delivers fully operational plants ready for integration:

  1. Process Engineering: Mass/heat balance calculations and P&ID development.
  2. Manufacturing: TFE unit, condensers, degassing tanks, pre-heaters, and heavy-duty discharge pumps.
  3. Vacuum Systems: Multi-stage roots pumps and liquid ring vacuum pump integrations.
  4. Automation: ATEX-certified explosion-proof design integrated with a central PLC/SCADA system for automated recipe management, temperature ramping, and safety interlocks.
  5. Installation & Start-Up: On-site mechanical assembly, commissioning, and operator training.