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BÁBOLNA BIO has been producing high standard active ingredients to be used in its own developed formulations in the multi-purpose Fine Chemicals Plant established 10 years ago. These intricate organic compounds can be prepared in more synthesis steps, often by applying special synthesis methods. The products must meet the requirements of high chemical purity that can be assured only by state-of-the-art and suitable analytical background.
The increase of international demands, in addition to the success of several of our own formulations on the market has required the modernisation of the plant and the significant enlargement of the active ingredient production capacity. The management of the company decided to invest about HUF 100 Million in 2000/2001 for the development of the technical level of plant taking into account the following aspects:
Short technical description of the Fine Chemicals Plant The process hall of Fine Chemicals Plant is of 18m x 6.5m, one air-space, internal height of 5.5m and has a steel operational framework. Due to the general planning, the ventilation and the electric assembling the process hall is categorised into the “A” fire hazard zone. There are analytical and preparative laboratories, two storing rooms, a large warehouse, three machinery rooms and social rooms belonging to the plant. The plant has its own steam-generator and cooling tower system.
There are three independent vacuum networks to meet the technological needs. The rough basic vacuum is provided by water-ring vacuum pumps, while the fine technological vacuum is provided by the piston vacuum pump with Root compressor at a level of down to 1 mbar. The cooling of condensers of expensive glass-wares is provided by two indirect cooling systems at different temperature levels. A high-performance glass washing tower filled with special glass-packing serves for scrubbing the acidic steam/gas side products. The reactor and evaporator units have effective after-condensers. These equipment assure the low emission of harmful materials.
Using short-path evaporator 2 - 5 kg/h throughput can be achieved at 250 oC and under 0.1 mbar vacuum range with excellent separation. Main technological equipment Reactor modules
This reactor module is excellent for heterogeneous reactions, extractions and execution of batch distillations both in atmospheric pressure and in vacuum. Lampart / SIMAX 250 The system consisting of borosilicate glass elements is connected to the glass-lined basic reactor with nominal working volume of 250 dm3. The glass system contains ascending and descending condensers, after-condensers for distillate, Marcusson-vessel and distillate receivers of 100 dm3. The r.p.m. of the high-performance impeller mixer can be continuously regulated, thus it always can be adjusted to the process requirements. This unit can be applied to different reactions, in addition extraction, distillation and crystallisation operations. Lampart 1250 The glass-lined duplicator of 1250 dm3 is assembled with glass-lined descending condenser and SIMAX Marcusson vessel. This group of equipment serves for less sensitive, large volume reactions, processing reaction mixtures, treatment of side products and wastes. Filters
Glass-lined
vacuum nutch (100 dm3) Rotatiaton evaporators
Rotation wiped film evaporators Glass-lined/glass QVF film-evaporator of 0.2 m2 The system is excellent for the purification of heat-sensitive, low volatile materials. The glass-lined body can be heated with steam of 6 bar pressure, therefore a wall temperature of even 150 oC can be assured. The application as film-reactor is also very promising because of high heat-transfer and low hold-up in the reactive zone. These benefits make the system suitable for realising especially dangerous, continuous technologies including highly exotherm reactions (such as nitration). Glass QVF short-path evaporator of 0.1 m2 This molecular distillation module first of all serves for refining and purification of high value, low volatile, heat-sensitive compounds but of course it is suitable for solution of simpler vacuum distillation tasks. The system has its own fine vacuum and heating supply units. Applied synthesis methods Synthesis processes applied routinely
Esterification Beyond the above the sophisticated equipment is especially appropriate for the syntheses in wide range as follows: Diazotation – Sandmayer reactions
Mannich condensation
Friedel-Crafts syntheses
Strecker-syntheses
Azidation
Reduction with sodium-borohydride and other complex hydrides
Mitsunobu-reactions
Quality assurance According to ISO 9001 the technological processes are regulated by written operational instructions. One of the most important element of quality assurance is the quality control based on state-of-the-art analytical instrumentation. In case of continuous plant-running it can be available in three shifts. The main analytical instruments:
Summary The realised reconstruction of Fine Chemicals Plant gives new perspectives for Bábolna Bioenvironmental Centre from the points of view below:
Dear Customer,The strategy of our company is the perfect service of our customers, meeting the increasing requirements in terms of quality and environmental protection. We are going to achieve our target with continuous training of our staff, on the other hand with the permanent development of our technical background. We are looking forward to be contacted:
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