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During the 1990s many outside factors influenced the proper design of overhead condensers for pharmaceutical installations. The FDA, EPA, product costs, downtime costs, and global competition have all affected today’s condenser designs. The FDA has been a major factor with validation, contamination and CGMP regulations. Today’s condensers need to be totally non-contaminating. This means there can be no way for the service side fluid to contaminate the process. Any possible leak must have an external leak path.

The chlorinated organics produced are highly corrosive. The condensers must handle these compounds with zero corrosion as products of corrosion can be toxic and catalytic. The condensers must fully drain as any liquid holdup can increase flush times or contaminate the next batch.

The EPA has also been a major factor as the push for decreased emissions has lowered condensing temperatures. More of the light ends and volatile solvents are taken out of the vent stream when the condensing temperature is reduced. This has dictated a change to silicone based heat transfer fluids as the service side cooling medium. These fluids are very difficult to seal and has led to fully welded condenser designs.

Global competition, the cost of pharmaceutical products and the cost of downtime has demanded that the condensers be rugged, dependable and work all of the time. The cost of maintenance, spare parts and above all downtime can no longer be tolerated. Downtime means no product is being manufactured, which is the largest cost of all.

Today’s condensers must be . . .

• contamination-proof
• corrosion-proof
• fully drainable
• compatible with silicone based heat transfer fluids
• fully welded tube bundle
• rugged and maintenance free

Tantalum pharmaceutical condensers have met all of these challenges and are now the state of the art. These companies now use tantalum in most of their installations: