In the field of wet phosphoric acid purification, the leap from laboratory-scale trials to industrial-scale production is fraught with a significant gap that must be bridged with reliable technology and equipment. A certain wet-process phosphoric acid project, with an ambitious blueprint for a daily processing capacity of 150 tons and aiming for industrial-grade phosphoric acid quality, faces a critical step in transitioning from small-scale reactor trials to continuous, efficient, and stable pilot-scale production. The deep removal of impurities (sulfate, magnesium, manganese, and other metal ions) is the core challenge determining whether the product can reach peak quality.
While traditional batch reactor operations have demonstrated the feasibility of the process route in the laboratory stage, once scaled up, intermittent operation, efficiency bottlenecks, and uncertainties in separation accuracy and stability all become potential risks on the road to industrialization. How can the success of small-scale trials be efficiently, and economically transformed into scalable industrial production? This requires a more robust process platform.

Zhengzhou Tiei Extraction, with its CWL-M series centrifugal extractor as the core, provides you with a complete chain solution from experimental verification to industrial scale-up, making the extraction and purification of wet-process phosphoric acid more stable, faster, and further.

Challenges: From "Feasible" to "High Efficiency and Quality", The Industrialization Dilemma of Reactor Processes

The feasibility of the impurity removal route was verified through small-scale reactor experiments, undoubtedly a successful first step. However, when looking towards pilot-scale and future large-scale industrial production, the limitations of reactor processes become apparent:

• Significant Scale-up Effect: The mixing, mass transfer, and separation conditions observed in small-scale trials are difficult to accurately replicate in scale-up, affecting product consistency.
• Poor Efficiency and Continuity: Batch operations lead to discontinuous production, with numerous manual intervention steps, making it difficult to meet the demands of large-scale continuous production.
• High Precision Control Requirements: For industrial-grade phosphoric acid, precise control of impurity content is crucial; the intermittent nature of the reactor can cause batch-to-batch quality fluctuations.

Breakthrough: CWL-M Centrifugal Extractor--Born for Continuous and Efficient Purification

The CWL-M centrifugal extractor is designed to address the aforementioned pain points in industrialization. It doesn't simply replace the reactor; rather, it elevates unit operations such as extraction, washing, and stripping to a new level of continuous, automated, and precise operation.

Its core working principle and advantages are:

• 1.Enhanced Mass Transfer, Doubling Efficiency: In a high-speed centrifugal force field, the phosphoric acid solution and extractant are instantly sheared and mixed into extremely fine droplets. Compared to mechanical stirring, the mass transfer surface area and mass transfer rate increase exponentially, ensuring that impurity ions (such as magnesium and manganese) are efficiently and thoroughly captured and transferred.
• 2.Powerful Centrifugation, Rapid Phase Separation: Utilizing centrifugal force thousands of times greater than gravity, instantaneous and clear separation of the light and heavy phases is achieved, with a processing time of only seconds. This not only solves potential emulsification problems, ensuring the clarity and purity of the aqueous phase (refined phosphoric acid), but also makes continuous and stable production possible.
• 3.Precise control, consistent quality: By precisely controlling parameters such as rotation speed and flow ratio, extraction efficiency and separation effect can be precisely controlled, ensuring that the quality of phosphoric acid produced at every moment remains consistently above industrial-grade standards, perfectly addressing the challenge of synergistic removal of sulfate and various metal ions.
• 4.Modular design, easy scale-up: The CWL-M model adopts a scientific series-connected flow path design, allowing for linear scaling up of process parameters from pilot-scale to industrial production, greatly reducing the technical risks and time costs from experimentation to industrialization.

Why Choose CWL-M Centrifugal Extractor for Pilot-Scale Process Validation?

Pilot-scale testing serves as a bridge between the laboratory and industrialization. Using CWL-M centrifugal extractor for pilot-scale testing, its continuous process mode and enhanced mass transfer and separation effects more realistically reflect the operating conditions of future industrial production. The data obtained (such as stage efficiency, processing capacity, and final product indicators) has direct guiding value for the design of industrial-scale plants.

Under continuous operation, the system was tested to verify the CWL-M centrifugal extractor's ability to deeply and stably remove complex impurities (especially those with low levels of calcium and magnesium manganese ions), confirming its ability to continuously and stably produce refined phosphoric acid that meets industrial-grade standards.

Through pilot-scale testing, key process parameters such as extractant selection, flow ratio, and number of stages can be precisely optimized, and the energy consumption, solvent loss, and overall operating costs of continuous production can be calculated, providing a solid basis for the project's final economic decisions.

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