Magnetic impulse cavitation reactors ROTON

with cavitation process automated control system ЕССЕ

             The magnetic impulse cavitation reactors ROTON are the result of the latest developments of our company in the field of cavitation processing of liquids in different combinations, as well as liquid and solids mixtures.

             The reactors ROTON create cavitation by means of magnetic impulse hydrodynamic method directly in the fluid stream, which enables effective processing of any liquids in industrial-scale volumes. Magnetic field holds the cavitation cloud precisely in the region of the reactor where the processing occurs and makes an immediate effect on feedstock passing through the cavitator. This ensures high efficiency, reliability and durability of our reactors.

Cavitation reactors ROTON can help you to resolve the following technological challenges:

 

-production of biodiesel from various vegetable oils and fats using cutting-edge technology, distinguished by its high degree of conversion of fatty acid methyl esters, of up to 99%.There is no methanol recuperation and no need for the biodiesel to be washed or dried. Continuous biodiesel production 24/7.

-intensive emulsification and homogenization of liquids that are difficult to mix with the purpose of obtaining stable over time high-quality emulsions. Used in the food, pharmaceutical and chemical industries;

-production of liquid feed in agriculture;

-intensification of extraction processes. Cavitation effects are efficiently used for extraction of medical cannabinoids, pectins, carotene, tannins, astaxanthin and other valuable biomass substances. It is used in the pharmaceutical industry and medicine;

-supplementation of liquid fuel with various additives in order to reduce viscosity, ash content, sulfur and its oxides content, pour-depressant additives and additives for emission reduction. It is used in the petrochemistry and fuel industry;

-highly efficient homogenization “liquid + solids” with a simultaneous solid particles size reduction in the ready mixture (increase in dispersion). In these circumstances, hydromodulus can reach a value of 4, i.e. 4 parts of a liquid and 1 part of a solid substance. Solid inclusions can be various – whole grain products, plant seeds, fruit pits, eggshells, small crustaceans with a shell, dried crushed plants, etc. It is used in the food and pharmaceutical industries;

-significant acceleration of solid dissolution in a fluid solvent, intensification of chemical reactions, especially for multicomponent mixtures. It is used in the chemical industry;

- water and aqueous solutions activation. The effect of cavitation on water changes its physical and chemical properties: reduction of the oxidation-reduction potential (ORP) of water, recovery of the natural structure of water and activation of its molecules. It is used in the food, chemical and pharmaceutical industries;

-water degasification from dissolved active gases during water treatment;

-cavitation heating of the product being processed occurs evenly throughout the liquid in the absence of heating surfaces, such as, for example, heating elements, which eliminates the risk of burn-on, local overheating, etc. It is used in any industries where volume heating is required;

-reagentless disinfection of water, liquid food products (pasteurization). It is used in the food and pharmaceutical industries.

The industrial cavitation reactors ROTON are distinguished by ease of operation and maintenance, reliability and durability, high efficiency of cavitation processing of products. The reactors ROTON are designed for continuous operation in an industrial environment – 24/7. The flow passage of the reactors (cavitation chamber) is made from special stainless steel, which makes it possible to use them in the food, pharmaceutical and chemical industries.

CT SYSTEMS produces two product lines of cavitation reactors:

-       ROTON. For general industrial use, with a wide range of effects on various media;

-       ROTON-B. For the production of biodiesel. This reactor was designed for the conduction of transesterification reaction with maximum efficiency, taking into account the viscosity of the components being treated and the temperature of the process.

The reactors ROTON can be supplemented by the cavitation process automated control system ECCE in order to fine-tune cavitation processes and achieve maximum effect on the medium being processed in a wide variety of viscosities and temperatures.

ЕССЕ – Electronics Cavitation Control Enclosure

 ЕССЕcan be effectively implemented where various liquids with a broad range of viscosity are used in technological processes, the temperature conditions of processing vary greatly, the hydromodulus may vary, etc. for example, during extraction processes. In these cases, ЕССЕcan help to achieve maximum efficiency of cavitation processing, taking into account the changing parameters of the medium being treated and to extend the range of application.

This system was created following the in-depth study of the consistent patterns of cavities formation, their nucleation and evolution, building empirical dependences and forecasting the behavior of gas-vapor cavities in various conditions.

The effectiveness of cavitation depends on the shape and movement of cavitation bubbles, the maximum pressure and the temperature during micro-explosions, which are the acting factors of cavitation that depend on the parameters of the medium. Thanks to observed data and estimation of the physical parameters of the energy of the cavitation effect, our engineers determined the values ​​of the acoustic parameters, their dependence on the physical properties of the liquid and the forecast of the technological influence on the medium being processed. The created system makes it possible to control the saturated vapour pressure and the cavitation number in various liquids, emulsions and suspensions, as well as automatically support supercavitation mode, taking into account the temperature, pressure inside the cavitator and the viscosity of the medium being processed.

The automated complex ROTON+ЕССЕ is designed on the principle of “monitoring system”. The sensors installed in the cavitator transmit various physical parameters to the control unit, where software processes the data. After processing the data, the PLC (controller) issues commands to the actuation units. ЕССЕsystem is an accurate and reliable tool for modeling cavitation and automatic control of cavitation processes.

The magnetic impulse cavitation reactors ROTON show high efficiency in the production of various extracts using food-grade solvents, such as ethanol, oil and water and provide high quality homogenization, deep extraction and capacity combined with low energy consumption.

The cavitation reactor ROTON can process liquids with a viscosity of up to 1000 cSt and above with a capacity of up to 8000 liters per hour, any combination of various liquids and liquids with solids with the minimum hydromodulus of 4.

Extraction of plant materials is currently carried out by inefficient, time-consuming and complex methods.

Classical method for isolating biologically active compounds from plant materials is extraction with the use of toxic solvents, and there is always the problem of solvent residues separation from the extract, which can lead to partial or even complete destruction of some components of the extract, as well as contamination of the final product with non-food chemical compounds.

The extraction with liquefied gases is the most popular of the existing extraction methods nowadays. This is butane extraction and extraction with liquefied carbon dioxide (CO2). Both of these methods have several significant drawbacks:

Butane extraction:

  1. Butane is a toxic substance. There is no possibility of its 100% removal from the extract.
  2. Low yield due to batch processing (portions).
  3. Frequent replacement of filters.
  4. High energy costs and high cost of equipment for re-liquefying the solvent.

Carbon dioxide extraction:

  1. Ultra-high pressure (from tens to hundreds of atmospheres).
  2. High cost of equipment (compressors, high pressure vessels) and high energy costs.
  3. CO2 is a non-polar solvent. Selective extraction, frequent loss of useful components.

 

Our technology is not only devoid of these drawbacks, but also has a number of significant advantages, such as:

  1. High processing performance of raw materials in the flow, unlike traditional batch processing.
  2. Significantly lower extraction cost compared to traditional methods listed above.
  3. Universality of the technical process. On the same equipment, extraction of various types of raw materials without reconfiguring the process line is possible.
  4. Increasing the degree of extraction through the destruction of cell membranes.

Cavitation mechanically destroys the cell wall by shear forces, facilitates the transfer of mass from the cell to the solvent. The reduction in particle size through cavitation increases the contact surface area of the solid and liquid phases.

  1. Use of non-toxic polar solvents (alcohols, water and ethers), as a result, the possibility of extracting more complex compounds.
  2. Safety of the extraction process – no high pressures, no toxic solvents.
  3. Esterification of organic acids with the release of ethers in the extraction process, which are more easily absorbed by the human body.
  4. Receiving of organic materials only – 100% of natural ingredients are involved in the extraction.
  5. The reactors ROTON can be used to homogenize and/or disperse different types of raw materials.

 

Some examples of the magnetic impulse cavitation reactors ROTON application for technological processes:

 Ethanol extraction of plant and animal raw materials.

One such example of solving a very complex extraction problem is the extraction of krill oil. Krill oil is a very valuable and expensive food additive, more effective than fish oil. The active nutrients of krill oil are Omega-3 fatty acids, phospholipids and astaxanthin – the most powerful natural antioxidant. All these three types of substances have different solubilities in polar and non-polar solvents. Traditional extraction is carried out with at least two different solvents in two stages. Moreover, one of these solvents is necessarily non-food. Therefore, all samples of krill oil available on the market cannot be certified as an organic product.

Our company, using the unique cavitation reactor ROTON, has developed and tested the technology of flow cavitation extraction of krill oil with food-grade ethanol. At the same time, in one stage, it was possible to simultaneously extract fats, phospholipids and astaxanthin. All the parameters of the extract meet market standards for krill oil.

Medical cannabis extraction. Such extract contains a significant amount of medical cannabidiol (CBD) – a very useful substance that effectively helps to get rid of stress, insomnia, alcohol or drug addiction and has a number of therapeutic effects.

The preparation of medical cannabis extract in our cavitation reactors is made with the help of food-grade ethanol 95.5% and more than 95% of cannabinoids are extracted.

Pilot-plant equipment for herbal plant ethanol extraction (cannabis etc.)

            Alcohol extraction of natural oak extract for the production of cognac products.

Cavitation processing of specially prepared oak chips for cognac production allows accelerating the degree and depth of extraction of oak wood components into cognac alcohol ten times. All this ultimately leads to products with improved organoleptic properties manufactured in a shorter period of time.

            Aqueous non-reagent extraction of humic substances.

When processing raw materials in the reactor ROTON, processes of dispersion, extraction, dissolution, disintegration of cellular structures, cellulose destruction occur simultaneously. The result is an increase in the efficiency of the final product without the use of chemical reagents.

            High-performance waste-free production of juices, purees, pastes.

This technology allows processing of vegetables and fruit, such as tomatoes or citrus fruits with the skin, as the grinding occurs at the micro level.

Processing takes place without air access while preserving all components of the fruit chemical composition, including insoluble ones: fiber, protopectin and fat-soluble pigments. Due to the complete preservation of the constituent parts of raw materials, the value of juices with pulp is higher than that of clarified ones.

             Production of liquid complex fertilizers.

This technology allows introducing micro and macro elements into a concentrated aqueous solution of humic acids to produce complex humic fertilizers with different content of plant nutrients.

             The use of the magnetic-impulse cavitation reactor ROTON in the brewing industry.

Processing of wort mash in the reactor ROTON increases the efficiency of beer production due to greater isolation of extractive substances of malt and raw materials saving, improves the quality of beer wort, has a positive effect on the fermentation process and the quality of the finished beverage.

Pilot-plant equipment for brewing industry

Processing of wort mash in the reactor ROTON for 5 minutes is sufficient for saccharification of the mash and accumulation of the required amount of dry substances, leads to more complete protein breakdown, reduces the extraction of polyphenols. The duration of fermentation is reduced to 4 days.

                 Recycling wine-making wastes (skin and grape seed).

Recycling makes it possible to get valuable products needed for a number of sectors of the national economy: ethyl alcohol, tartaric acid, grape oil, polyphenolic concentrates, low alcohol and soft drinks and other food, cosmetic and pharmaceutical products.

                 Pasteurization and simultaneous homogenization of milk, juice, beverages, etc.

Homogenization of protein-fat milk drops to a size of 1-2 microns. Cold cavitation pasteurization with guaranteed destruction of bacteria while preserving vitamins. The cost of electricity for the processing of the milk flow in the above-mentioned process is ten times less than in traditional plunger homogenizers with powerful electric drives.

Technical parameters of ROTONS

Model
Rated power, KW
Maximal* capacity, liters per hour
Nominal** capacity, liters per hour
ROTON-7
7.5
2000
1000
ROTON-15
15
4000
2000
ROTON-30
30
8000
4000

* Maximal capacity – permissible value of flow of liquid which passes through the reactor where the minimum cavitation processing of liquid is sufficient for most of emulsification, dispergation, extraction tasks occurs.

** Nominal capacity – flow of liquid passing through the reactor by which the effective cavitation processing is generated to perform the complex technological tasks: emulsification on molecular level, dispergation of solids in a liquid, maximal extraction with food solvents (water, ethanol, oil). The reduction of flow results in increase of cavitation processing time with simultaneous heating of processed liquid, that allows the performance of the special production tasks.