Mechanical Vapor Recompression Evaporators (MVRE)
Mechanical Vapor Recompressor (MVR) evaporators are advanced thermal separation systems used for concentrating wastewater streams while minimizing energy consumption. At UAL we specialize in designing and implementing MVR evaporators to provide efficient and sustainable solutions for wastewater treatment. In this section, we will delve into the working principle, benefits, and applications of MVR evaporators.
Advantages
• Low Operational Cost.
• Small Footprint & Compact Design.
• High heat transfer performance thus specific energy consumption is low.
• Low Fouling.
• Fully Automated Smart System.
• High-water recovery rate – up to 99%.
• No requirement of cooling tower & Boiler.
Technology Overview
MVR Evaporation is the most thermodynamically efficient process to concentrate Effluent/ Wastewater streams or to achieve Zero Liquid Discharge (ZLD) in wide industries & applications including Textile, Pharmaceutical, Food & Beverages,Chemical, Paper, ETP & RO Reject etc. MVR Evaporator thermodynamic efficiency is derived from the application of the “heat pump” principle by a large volumetric flow compressor acting as the “heat pump”, which continuously recycles and keeps the latent heat exchanged in the evaporating and condensing sides within the system. The heat required to evaporate part of the processed feed, which flows on one side of a heat transfer surface, is supplied through the simultaneous condensation of the distillate, on the other side of the surface. This cycle of evaporation and condensation operates continuously. The MVR system will use electrical energy only & operates at a partial vacuum, reducing the boiling temperature & thus minimizing the scaling. Most of the process heat is recovered and recycled within the preheater and evaporator unit. Overall specific energy requirements are significantly reduced in comparison to conventional Evaporation systems.
Unitop MVR Evaporator delivers the highest energy & operational efficiencies as compared to conventional multiple effect evaporators & thus becomes a CHEAPER option. Unitop MVR Evaporator model starts from 250 Liters per hour and up to 100000 Liters per hour of water evaporation at an efficiency of 1000 liters per hour of water evaporated at 15 to 18 Kwh of power consumed.
Working Principle
The preheated wastewater stream (5) enters the main heat exchanger (1) from hold up tank (2) through Recirculation pump which is circulating heated wastewater through distributor to maintain proper wetting rate thus forming a thin film in the main heat exchanger (1) and back into the holdup tank (2). Vapors flows up under vacuum to inlet side of MVR Compressor (3). Compressed Vapors from MVR Compressor (3) is forced through the condensing side of main heat exchanger (1) giving up latent heat to the counter flowing wastewater. High temperature condensate flows out of the main heat exchanger (1). Concentrate (4) is periodically discharged based on concentration from bottom. Incoming wastewater (5) is preheated as it passes through a PHE (heat exchanger) (6) transferring heat from and cooling the exiting pure condensate (7).
Industries & Applications
MVR (Mechanical Vapor Recompression) evaporators play a crucial role in Zero Liquid Discharge (ZLD) systems across various industries, including steel, automobile, textile, metal, food and beverage processing, petrochemical, and oil refining. Here are some specific applications of MVR evaporators in these industries within ZLD systems:
- Steel Industry: In steel manufacturing, MVR evaporators are used to treat wastewater generated from various processes such as cooling, descaling, and rinsing. These evaporators help recover clean water from the wastewater, which can be reused in the steel production process or for other purposes.
- Automobile Industry: The automobile industry generates wastewater containing contaminants such as oils, greases, heavy metals, and organic compounds. MVR evaporators are employed in ZLD systems to remove these pollutants and recover water for reuse within the manufacturing process or for other industrial purposes.
- Textile Industry: Textile manufacturing involves dyeing, printing, and finishing processes that generate wastewater with high levels of dye, chemicals, and suspended solids. MVR evaporators facilitate the concentration and separation of these contaminants, enabling the recovery of clean water for reuse and the production of concentrated sludge for further treatment or disposal.
- Metal Industry: MVR evaporators are utilized in metal processing to treat wastewater contaminated with heavy metals, acids, and other pollutants. By evaporating the water, these evaporators enable the recovery of clean water and the concentration of metal-rich solutions for subsequent metal recovery or safe disposal.
- Food and Beverage Processing: MVR evaporators find application in the food and beverage industry to treat wastewater from various processes, including cleaning, washing, and food preparation. These evaporators help remove organic matter, nutrients, and contaminants, allowing the recovery of clean water for reuse and the production of concentrated byproducts.
- Petrochemical and Oil Refining: MVR evaporators play a vital role in ZLD systems in the petrochemical and oil refining industries. They are used to treat wastewater streams generated during the refining and chemical processes, removing pollutants such as oil, grease, dissolved solids, and organic compounds. The evaporators enable the recovery of clean water for reuse and the production of concentrated brine or other by products.
In all these industries, MVR evaporators offer advantages such as energy efficiency, reduced water consumption, and compliance with environmental regulations. They contribute to sustainable operations by minimizing freshwater intake and maximizing water recycling and resource recovery.
• Textile Industry (Dyeing, Mercerizing, Printing)
• Food & Beverages Industry
• Dairy
• Chemical Plants
• Pharmaceutical Industry
• Desalination
• Automobiles
• Paper Plant
• Cement
• Sugar Plants
• Effluent Treatment Plant
• RO Reject
Benefits of MVR Evaporators
At UAL we understand the significance of energy-efficient wastewater treatment solutions. MVR evaporators provide an innovative and sustainable approach to wastewater concentration, offering benefits such as energy efficiency, cost savings, and environmental sustainability.
- Energy Efficiency: MVR evaporators are designed to minimize energy consumption by utilizing the energy recovered from the vapor compression process. The compression of the vapor significantly increases its temperature and pressure, reducing the need for additional external heat sources.
- Cost Savings: By reducing energy consumption, MVR evaporators lead to significant cost savings in terms of operational expenses. The recovered energy can be used elsewhere in the process or for other heating requirements, reducing the overall energy demand of the wastewater treatment plant.
- Environmental Sustainability: MVR evaporators contribute to environmental sustainability by reducing greenhouse gas emissions associated with energy-intensive evaporation processes. The efficient use of energy resources aligns with sustainable practices and helps organizations meet their environmental goals.
- Versatility: MVR evaporators can handle a wide range of wastewater streams, including industrial effluents, process water, and other liquid waste streams. They are adaptable to different industries and applications, providing a versatile solution for wastewater concentration.
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