MVR-Based Evaporation System for 300 KLPD RO Reject

Industry Context

In the Chemical, Pharma, Textile and food industry, wastewater treatment and solvent recovery play a crucial role in sustainable operations. Efficient evaporation systems are essential for minimizing effluent discharge, reducing energy consumption, and optimizing resource utilization. This case study highlights our successful implementation of an MVR-based Multiple Effect Evaporation (MEE) system, focusing on high-efficiency evaporation with minimum steam usage.

Challenges Mitigated

1. Solvent Separation for Reuse

Recovering solvents from the effluent stream was essential to enable their reuse in biogas production, reducing waste and enhancing overall process efficiency.
Ensuring efficient solvent separation required precise process control and system integration to maximize recovery while maintaining operational stability.

2. Minimizing Steam Consumption

Traditional evaporation systems rely heavily on steam, leading to high operational costs and energy consumption. The project required a solution that eliminated steam usage in evaporator calendrias.
Implementing Mechanical Vapor Recompression (MVR) technology allowed evaporation to be driven by recompressed vapors instead of external steam sources, significantly improving energy efficiency.

3. Optimized Electricity Consumption

Since MVR technology relies on electricity, achieving low power consumption while maintaining high evaporation rates was critical for cost-effective operations.

The system was designed to intelligently integrate Falling Film (FF) and Forced Circulation (FC) evaporators, ensuring the most energy-efficient evaporation process.

Key Features of the Solution

1. Combination of Stripper, Falling Film & Forced Circulation Evaporators

  • Smart integration of stripper with FF and FC evaporators for precise evaporation and concentration.
  • Right selection of FF and FC technology based on process needs to ensure optimal performance.

2. State-of-the-Art MVR Machines

  • Eliminates steam consumption in evaporator calendrias, reducing overall energy usage.
  • Enables high evaporation capacity & achieving concentration up to 30% w/w solids.

Value Delivered

  • Highly Energy-Efficient MVR-Based MEE System
  • Significant Reduction in Effluent Discharge
  • Zero Steam Usage in Evaporator Calendrias
  • Effective Solvent Recovery for Biogas Production
  • Process Condensate Reuse for Water Conservation

Conclusion

This project underscores our expertise in designing and delivering high-performance MVR-based evaporation systems. By implementing an advanced solvent separation and wastewater treatment solution, we successfully helped our customer achieve sustainability goals while optimizing energy and resource utilization.

This project sets a new industry benchmark for MVR-based evaporation technology, reinforcing our commitment to innovation, resource optimization, and environmental responsibility.