ANYAN AYAN-F100 Molecular Distillation Instrument for Laboratory-Scale Chemical Purification

Overview

The ANYAN AYAN-F100 Molecular Distillation Instrument is a precision-engineered short-path distillation system designed for high-efficiency, low-thermal-stress separation of thermally labile, high-boiling, and oxidation-sensitive compounds in research laboratories and pilot-scale process development. Unlike conventional vacuum or fractional distillation—where separation relies on relative boiling points—molecular distillation operates under ultra-high vacuum (typically <10 Pa), enabling separation based on differences in molecular mean free path and vapor pressure at sub-boiling temperatures. In this regime, evaporated molecules travel unimpeded from the heated evaporative surface to a closely spaced condenser (distance < mean free path), minimizing residence time (<30 seconds), thermal degradation, and oxidative side reactions. The AYAN-F100 integrates a vertically oriented, rotating wiper-film evaporator with an internal concentric condenser, ensuring uniform thin-film formation (<0.5 mm thickness), high heat transfer efficiency, and reproducible mass transfer kinetics—critical for isolating bioactive lipids, natural antioxidants, pharmaceutical intermediates, and specialty polymers.

Key Features

• Ultra-high vacuum capability: Achieves <10 Pa base pressure (no-load), compatible with dual-stage oil-sealed or dry scroll vacuum pumps; optional vacuum gauge and controller support real-time pressure monitoring and closed-loop regulation.
• Thin-film evaporation geometry: Precision-machined 100 mm internal diameter stainless steel evaporator drum with adjustable PTFE/SS316L wiper blades ensures consistent film thickness, laminar flow, and minimal backmixing—even for highly viscous feeds.
• Dual-collection configuration: Independent light- and heavy-fraction receivers (2 L each), both cooled and isolated under vacuum, enable parallel fraction collection without cross-contamination.
• Integrated cold trap: Built-in liquid nitrogen or dry ice-compatible cold trap prevents volatile pump oil contamination and enhances system vacuum stability during extended operation.
• Temperature-controlled feed preheating: Optional jacketed feed tank with PID-regulated heating (ambient to 100 °C) ensures precise thermal conditioning prior to film formation, improving volatility control and separation selectivity.
• Chemically resistant construction: All wetted parts contact-grade SS316L; sealing interfaces utilize FKM fluoroelastomer gaskets (standard), with PTFE gasket kits available for aggressive solvents or halogenated media.
• Modular scalability: Designed as part of the AYAN-F series (F60 to F250), the F100 serves as a validated bridge between benchtop screening (F60/F80) and pilot-scale purification (F150+); custom evaporator geometries and condenser configurations are available upon request.

Sample Compatibility & Compliance

The AYAN-F100 accommodates a broad range of liquid feedstocks—including crude plant extracts, polymer oligomers, fatty acid esters, vitamin concentrates, and post-extraction solvent residues—with viscosities up to 500 cP at processing temperature. Its non-boiling, surface-driven evaporation mechanism eliminates foaming, bumping, and thermal decomposition—making it suitable for materials governed by USP , ISO 10993, and ICH Q5C guidelines for purity-critical applications. While not certified to GLP or FDA 21 CFR Part 11 out-of-the-box, the system’s analog sensor outputs (temperature, pressure, rotation speed) are compatible with third-party data acquisition systems supporting audit trails, electronic signatures, and 21 CFR Part 11-compliant archiving when integrated into validated laboratory workflows.

Software & Data Management

The AYAN-F100 operates via front-panel digital controls with independent PID loops for heater zone, feed preheat (if equipped), and condenser cooling (via external chiller interface). Analog output signals (4–20 mA or 0–10 V) for temperature, vacuum level, and rotational speed allow seamless integration with LabVIEW, DeltaV, or SCADA platforms. Optional USB-connected data logger records time-stamped parameters at 1 Hz resolution, generating CSV files traceable for method development reports, regulatory submissions, or internal SOP documentation. No proprietary cloud service or mandatory firmware updates are required—ensuring full user data sovereignty and long-term operational continuity.

Applications

• Purification of omega-3 fatty acids (EPA/DHA) from fish oil hydrolysates, preserving cis-configuration integrity and peroxide value stability.
• De-solventization of botanical extracts following ethanol or supercritical CO₂ extraction—removing residual solvents to <50 ppm without thermal caramelization.
• Separation of monoglycerides from glycerolysis reaction mixtures in emulsifier synthesis.
• Recovery and concentration of heat-labile fragrances and essential oil constituents (e.g., linalool, citral) from hydrosols.
• Removal of catalyst residues and unreacted monomers from polycondensation prepolymers prior to final polymerization.
• Isolation of tocopherol isomers from deodorizer distillates in edible oil refining R&D.

FAQ

What vacuum level is required to achieve true molecular distillation conditions?
True molecular distillation requires operating pressure where the mean free path exceeds the evaporator-to-condenser spacing—typically <0.1 Pa (1×10⁻³ mbar) for optimal separation of high-molecular-weight organics. The AYAN-F100 achieves <10 Pa under no-load; pairing with a turbomolecular or cryo-pumped secondary stage enables sub-Pa operation.
Can the AYAN-F100 handle viscous or particulate-containing feeds?
Yes—its robust wiper design tolerates viscosities up to 500 cP at 80 °C. For slurries or suspended solids, inline filtration (e.g., 50 µm sintered metal filter) upstream of the feed inlet is recommended to prevent wiper jamming.
Is the system compliant with ISO/IEC 17025 calibration requirements?
All primary sensors (PT100 RTDs, capacitance manometers, tachometers) are factory-calibrated and supplied with traceable calibration certificates. Users may perform in-house verification using NIST-traceable references per ISO/IEC 17025 Section 6.6.
What maintenance intervals are recommended for long-term reliability?
Wiper blade inspection every 200 operating hours; vacuum seal replacement annually or after 500 h under continuous <100 Pa operation; cold trap cleaning after each batch when processing high-volatility solvents.
Does ANYAN provide method development support for new applications?
Yes—application engineers offer remote consultation, fractional recovery optimization protocols, and comparative distillation curve analysis (ASTM D2892/D5236 adapted for short-path geometry) upon instrument purchase.