AcetoneShield AD-5000 Series
Explosion-Proof Acetone Drum Filling Machine
Precision. Safety. Zero Emissions.
Technical Specifications
Parameter | AD-5100 (Standard) | AD-5200X (ATEX Zone 0) | AD-5300U (Ultra-Pure) |
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Capacity | 20-220L (±0.15%) | 20-220L (±0.2%) | 20-220L (±0.1%) |
Throughput | 22 drums/hour | 20 drums/hour | 18 drums/hour |
Accuracy | ±0.15% mass flow | ±0.2% | ±0.1% gravimetric |
Material Contact | Hastelloy C276 | Alloy 59 | Zirconium-lined 316L |
Explosion Protection | N/A | ATEX/IECEx Zone 0 | Same + Overpressure vent |
Vapor Recovery | >99.9% Carbon Adsorption | >99.99% Condensation + RTO | >99.999% Molecular Sieve |
Static Control | <10⁵ Ω (NFPA 77) | <10⁴ Ω | <10³ Ω (ANSI/ESD S20.20) |
Filling Technology | Mass Flow Coriolis | Ex ia Diaphragm Pump | Peristaltic Pump |
Leakage Rate | <0.001 ml/min | <0.0005 ml/min | <0.0001 ml/min |
N₂ Inerting | 50 L/min (O₂<0.5%) | 60 L/min (O₂<0.1%) | 40 L/min (O₂<0.05%) |
Power | 480V/60Hz, 8.5kW | 24VDC Ex ia | 480V/60Hz, 7.2kW |
Decon System | Solvent CIP | Steam Purge | Plasma Cleaning |
Certifications | CE PED | IECEx T4 | USP Class VI |
Triple-Layer Safety Architecture
1. Explosion Containment
Certifications:
ATEX 2014/34/EU Cat.1 Zone 0
IECEx IEC 60079-11 (Ex ia IIC T4)
NFPA 69 Explosion Prevention
2. Zero-Leak Technology
Component | Technology | Performance |
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Seals | Kalrez® 6375 (-20°C to 327°C) | Permeation <0.01μg/cm²/min |
Nozzles | Double Bellows + Vacuum Suction | Residual <0.05ml |
Connections | Helium-Tested VCR Fittings | Leak Rate <10⁻⁹ mbar·L/s |
Industry-Specific Solutions
Chemical Manufacturing
Feature | Specification |
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Purity Maintenance | 316L Electropolished (Ra<0.4μm) |
Cross-Contamination | Double Block & Bleed Valves |
OSHA Compliance | PSM Audit Package |
Pharmaceuticals
Electronics Industry
Particle Control:
ISO Class 5 Enclosure
<5 particles/ml @ ≥0.5μm
Metal Ion Limits:
Element | Limit |
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Fe | <1 ppb |
Na | <2 ppb |
Smart Control System
10" ATEX HMI with ChemOS™
AI Safety Modules:
Vapor Cloud Detection:
Concentration | Action |
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>10% LEL | Alarm + Flow Stop |
>25% LEL | N₂ Flood + Shutdown |
Predictive Maintenance:
Parameter | Alert Threshold |
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Seal Swelling >3% | Replacement Warning |
Vibration >4mm/s | Bearing Service Alert |
Performance Validation
Dow Chemical Texas Plant Report:
*"After 6 months using AD-5200X:
Explosion Risk: Reduced to SIL-3 Level
Acetone Loss: 2.1% → 0.08% ($480k/year saved)
VOC Emissions: 850 ppm → <1 ppm
ROI: 9 months"*
Certifications
► ATEX Category 1G Zone 0 (II 1G Ex ia IIC T4)
► IECEx IEC 60079-0/11/31
► ASME B31.3 Process Piping
► ISO 80079-36:2016
► FDA 21 CFR 175.300
Operational Workflow
1. AGV Drum Loading → 2. N₂ Purging (O₂<0.5%) →
3. Sealed Nozzle Docking → 4. Mass Flow Filling (±0.15%) →
5. Vapor Recovery Activation → 6. Helium Leak Test →
7. Robotic Sealing
Cycle Time: 2.7 minutes/drum
Pricing & Packages
Model | Base Price | Key Features |
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AD-5100 | $152,000 | Standard Zone 1 |
AD-5200X | $218,000 | ATEX Zone 0 Certified |
AD-5300U | $285,000 | 0.1μm Particle Control |
ROI Calculator:
► Typical Savings:
- Acetone Recovery: $38,000/year (99.9% vapor capture)
- Safety Downtime: $120,000/year (zero incidents)
- EPA Fines Avoided: $250,000/year
► Payback Period: 10-14 months