DODGEN
Melt Crystallizer
High-efficiency heat transfer; inner & outer dual falling-film design; easy scale-up.
Melt Crystallizer Introduction
The DODGEN Melt Crystallizer is a high-efficiency purification unit integrating swirl distribution and falling-film crystallization technology. It adopts a vertical tube-bundle structure, in which the feed forms a spiral liquid film inside the tubes, and crystallization is achieved via indirect cooling by an external coolant. The core advantages lie in enhanced heat-transfer performance and improved crystal uniformity. DODGEN can supply a single unit with a capacity of 10 kg/h, as well as a single unit with a throughput of 10 t/h. The system has been industrially applied in continuous purification processes for acrylic acid, caprolactam, and related chemical intermediates.
Melt Crystallizer Equipment Structure
1
Feed Distribution System
Feed Distribution System
A specially designed top-mounted swirl distributor ensures the feed enters each crystallization tube uniformly, forming stable and even falling-film flow.
2
Vertical Crystallization Tube Bundle
Vertical Crystallization Tube Bundle
The crystallization section consists of multiple vertically arranged heat-transfer tubes.
The inner tube surface functions as the crystallization interface, while the shell side circulates the heat-transfer medium.
This configuration enables precise control of cooling and heating profiles during crystallization, sweating, and melting stages.
The inner tube surface functions as the crystallization interface, while the shell side circulates the heat-transfer medium.
This configuration enables precise control of cooling and heating profiles during crystallization, sweating, and melting stages.
3
Heat-Transfer Medium Circulation System
Heat-Transfer Medium Circulation System
Independently controlled hot and cold HTM loops enable accurate temperature control across multi-stage operations such as crystallization, sweating, and melting.
4
Automation Control System
Automation Control System
Integrated PLC/DCS system automatically regulates
Flow rate
Temperature
Pressure
Cycle sequencing
The system enables fully automated cyclic operation.
Flow rate
Temperature
Pressure
Cycle sequencing
The system enables fully automated cyclic operation.
5
Modular Shell and Support Structure
Modular Shell and Support Structure
The chemical crystallizer adopts a compact modular structure.
This design simplifies transportation, on-site installation, and future capacity expansion.
This design simplifies transportation, on-site installation, and future capacity expansion.
Melt Crystallizer Equipment Manufacturing
As a leading melt crystallizer manufacturer, DODGEN has full-process manufacturing capabilities covering design, material procurement, fabrication, testing, and delivery:
1
Precision Manufacturing
Precision Manufacturing
High-precision CNC machining and automated welding processes (TIG/PTIG) are adopted to ensure the quality of key components such as tube sheets and distributors.
2
Optimized Material Selection
Optimized Material Selection
Different types of metallic materials are selected based on feed corrosiveness, cleanliness requirements, and customer specifications.
3
Quality Inspection and Compliance
Quality Inspection and Compliance
Each unit undergoes
Pressure testing
Leak-tightness verification
Surface treatment inspection
Cleanliness validation
Manufacturing and inspection processes comply with international standards including ASME and PED.
Pressure testing
Leak-tightness verification
Surface treatment inspection
Cleanliness validation
Manufacturing and inspection processes comply with international standards including ASME and PED.
4
Pre-assembly and Commissioning
Pre-assembly and Commissioning
Key components are pre-assembled and functionally tested prior to shipment, reducing on-site installation and commissioning time.
5
Customized Configuration
Customized Configuration
Single-stage, multi-stage, parallel, or hybrid configurations combined with static crystallization can be provided according to customer requirements.
Manufacturing Advantages
1
High-efficiency heat transfer, stable crystallization
High-efficiency heat transfer, stable crystallization
Uniform swirl liquid-film thickness enables fast crystal growth, delivering stable product purity.
2
Anti-blocking and anti-polymerization, reliable operation
Anti-blocking and anti-polymerization, reliable operation
Swirl distribution and fully liquid-phase flow throughout the process prevent local overcooling or hold-up, significantly reducing polymerization and fouling/scaling risks. The continuous operating cycle is long, with no risk of crystal blockage.
3
High operating flexibility, precise control
High operating flexibility, precise control
By adjusting the temperature and flow rate of the heat-transfer medium, crystallization rate, sweating ratio, and product yield can be flexibly controlled.
4
Low system pressure drop, significant energy savings
Low system pressure drop, significant energy savings
Holdup volume is reduced by 40%–80% compared with conventional falling-film crystallization machine, resulting in low circulation energy consumption. Compared with distillation, energy savings of 50%–70% can be achieved, substantially reducing operating cost and carbon footprint.
5
Easy cleaning and maintenance, short downtime
Easy cleaning and maintenance, short downtime
Simple structure without complex internals; circulation cleaning or in-place cleaning (CIP) can be applied.
6
Reliable scale-up, high integration
Reliable scale-up, high integration
Uses the same tubular unit as the pilot-scale system, with no scale-up risk. Can be equipped with DODGEN’s self-developed control system to provide an integrated purification solution.
7
Intelligent monitoring, transparent operation
Intelligent monitoring, transparent operation
Integrated smart crystallization software enables real-time monitoring of operating status, supporting predictive maintenance and intelligent management.
8
Fast delivery, continuous support
Fast delivery, continuous support
Standardized modular design combined with flexible manufacturing shortens lead time, supported by 24/7 technical consulting and engineering services.
Chemical Process Solutions
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Application
Sustainability
Reaction and Separation Professional, Low Carbon Technology Partners
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