Efficient Raney Nickel Filtration in Sorbitol Production
Case Study
Raney Nickel Filtration Using Diva Envitec’s CONTUFILT RN in a SORBITOL manufacturing site
A leading sorbitol manufacturer faced persistent challenges in filtering Raney Nickel catalyst during hydrogenation. Conventional leaf filters and filter presses resulted in inefficiencies, product losses, and frequent operational disruptions. Exposure to the atmosphere during handling raised safety concerns, while frequent leaks led to material wastage and increased maintenance costs.
Sorbitol Manufacturing Process
Sorbitol production involves the catalytic hydrogenation of glucose using Raney Nickel. The reaction is highly exothermic and operates under high hydrogen pressure. Once hydrogen consumption stops, pressure is reduced, and the catalyst is settled before sorbitol is filtered and polished for final use. The manufacturer used conventional filter presses, which required high maintenance and involved manual handling, leading to inefficiencies and safety risks.
Challenges with Conventional Filtration
The manufacturer encountered multiple operational issues with traditional filtration systems. Leaking filter presses caused frequent product losses and contamination, reducing batch yield. Open handling of the catalyst increased exposure risks, necessitating additional safety precautions. Catalyst losses were significant, adding to operational costs. The filtration process was slow, delaying batch turnover and limiting production capacity. Manual handling of the filter presses made the operation labour-intensive, increasing dependency on skilled workers and resulting in higher operational costs.
Transition to Diva Envitec’s CONTUFILT RN
To overcome these challenges, the manufacturer implemented CONTUFILT RN, a proprietary vacuum-fused media system designed specifically for Raney Nickel catalyst recovery. This advanced candle filtration system provided a more efficient and safer solution, eliminating many of the inefficiencies associated with traditional methods.
Key Benefits Achieved
- Higher Catalyst Recovery: The advanced filtration system significantly reduced catalyst losses, leading to substantial cost savings.
- Reduced Filtration Time: Faster and more efficient processing enabled higher batch throughput, increasing overall productivity.
- Lower Manpower Dependency: Automation reduced the need for manual intervention, lowering operational costs and improving efficiency.
- Elimination of Leakages: The closed-system design prevented leaks, ensuring cleaner operations and reducing maintenance requirements.
- Improved Product Quality: The advanced filtration process ensured consistent and superior sorbitol clarity, meeting higher quality standards.
- Safer Working Environment: The enclosed operation eliminated operator exposure to hazardous materials, enhancing workplace safety and regulatory compliance.
Conclusion
The adoption of CONTUFILT RN transformed the manufacturer’s filtration process, increasing efficiency, reducing costs, and enhancing product quality. By eliminating inefficiencies associated with conventional filtration, the company significantly improved profitability and streamlined operations, setting a new benchmark in catalyst filtration for sorbitol production.
