Evaporation Technology

Astrolex Industries Pvt. Ltd.

Inspiring Innovative Engineering Solutions

About Astrolex

Astrolex Process Systems (a subsidiary of Astrolex Industries Pvt. Ltd.) is a process engineering company offering an extensive range of projects, equipment and innovative process solutions based on advance technology and a real understanding of customer needs.

In today's competitive world, rising manufacturing costs coupled with higher customer expectations make it a

challenging task to maintain profitability of plant operations. Astrolex Process Systems has the express business

mandate of delivering focused, high- value added products & services to the Process Industry.

We understand the need of the customers, who are under increasing

economic competitive and regulatory pressures and partner with them to design and deliver the most reliable,

efficient and innovative solutions for the process and overall project implementation.

Our Mission Our vision

To render unparalleled and innovative To grow as a globally recognized name, to be known by our customers technical solutions & services to a vast clientele with utmost integrity, for providing innovative Process dedication, resolute core values and technologies & Services that help committed deliverances for leaving an them be even more successful. indelible mark on the chemical & wide To be a place where passionate range of other processing industries. employees have room for creativity and entrepreneurship to make our Group unique

Comprehensive Process Solutions for Chemical Industry

Our Portfolio

Evaporation Technology

Falling Film Evaporator (FFE) Rising Film Evaporator (RFE)

Forced Circulation Evaporator

Multiple Effect Evaporator (MEE) Thermal Vapor Recompression

(TVR) Mechanical Vapor Recompression (MVR)

Short path Evaporation- Distillation Agitated Thin Film Evaporator (ATFE)

Distillation Technology

Solvent Recovery Steam Distillation

Vacuum Technology Ejectors Multistage Steam Jet Vacuum Systems Jet Mixers – Tank Mixing Systems Steam Jet Heaters Steam Jet & LRVP Thermocompressors Condensers

Heat Transfer Solutions

Shell & Tube Heat Exchanger Hairpin / Double Pipe Heat Exchanger Twisted Tube Heat Exchanger Tank Heating Coils

Environmental Technologies Packed Bed Tower Scrubbers High Energy Venturi Scrubber Fluidized Bed Scrubber Spray Tower Scrubber Jet Ejector Venturi Scrubber Tray Scrubbers

Zero Liquid Discharge (ZLD) MEE System

Essential oil Distillation Plant Steam operated Distillation system

Caustic Recovery Plant

Multiple effect evaporation plant

Plasticizer Technology Turnkey Solutions

Process Equipment

Process Reactors Pressure vessels Storage vessels

Engineering Services Process Engineering

Consultancy & Services

Brownfield Verification / As-Built Process

AUTOCAD, PDMS Drafting

Energy Audit

Evaporation Technology

Falling Film Evaporator (FFE) | Rising Film Evaporator (RFE) Forced Circulation Evaporator (FCE) | Multiple Effect Evaporator (MEE) Thermal Vapor Recompression (TVR) | Mechanical Vapor Recompression (MVR) Short Path Evaporation / Distillation Unit (SPEU / SPDU) Agitated Thin Film Dryer / Evaporator (ATFD / ATFE)

Evaporation Technology

Astrolex offers evaporation systems for your product evaporation, concentration or solvent recovery to treat your heat-sensitive, viscous and complex products.

Astrolex has expertise in design of Evaporation Evaporation technology is used in any System that guarantees high process quality, process that requires concentration of a resource conservation and the lowest possible stream by removal of water or other operating costs. Our activities focus on the solvent. It is used extensively in processing construction of new plants and the optimization of foods, chemicals, pharmaceuticals, fruit existing plants and processes. Considering your juices, dairy products, paper and pulp, and requirements, we develop a balanced concept that both malt and grain beverages. brings investment costs and operating costs into an efficient balance.

Falling Film Evaporator (FFE)

Gentle evaporation for heat- sensitive products

The falling film evaporator is a type of film evaporator which is used most commonly because of its wide operating range.

A Falling Film Evaporator (FFE) is a vertical shell & tube type of heat exchanger with vapor- liquid separator (VLS) mounted at the bottom.

The liquid to be concentrated is fed at the top of heated tubes and distributed in a way that it flows down on the inside surface of the tubes as at thin film. The liquid distributor at the top assures uniform liquid loading of all tubes. As the film gets heated, the vapors generated flow downwards through the tube bundle in co- current with the concentrate. The drag of the vapors increases the turbulence & improves heat transfer performance. Subsequently, the vapor phase is separated from the liquid phase in vapor liquid separator (VLS).

Falling Film Evaporator

Advantages: Applications:

• High heat transfer coefficients • Particularly suited for temperature-

• Short residence time on the heated tube surface sensitive products

• Can be used from smallest evaporation • Recovery of solvents & alcohols

capacities • For low viscous products • Little space needed • Suited for products with low fouling • Low pressure drop tendency

• Suitable for operation under high vacuum • Separation of multicomponent mixtures • High evaporation ratios • Concentration of starch products and • Low susceptibility for fouling derivatives in the starch industry • Suitable for GMP applications • Concentration of spent liquor in the • Single pass or with recirculation pulp industry • Process vapors and liquid flow co-currently or counter-currently • Chemical industry • Petrochemical industry • Several evaporator stages are possible in one apparatus • Polymer industry

Rising Film Evaporator (RFE)

Evaporation technology for concentration of moderately heat- sensitive liquids

The rising/climbing film evaporator is a type of film evaporator which can achieve moderate evaporation, suitable for high viscosity and heat sensitive materials.

A Rising Film Evaporator (RFE) is a vertical shell & tube type of heat exchanger with vapor-liquid separator (VLS) mounted at the top.

The rising film evaporator operates with the density difference of liquid / liquid-vapor mixture inside the tubes. The liquid to be concentrated is fed at the bottom of heated tube bundle. As the liquid feed receives the heat, the vapors generated lift the liquid upwards. The vapor and balance liquid are separated in vapor-liquid separator (VLS)

Rising Film Evaporator

Advantages: Applications:

• Shorter residence time • Juice concentration & food processing

• High evaporation ratio • Polymer production

• Suitable for evaporation of a wide range of liquid • thermal desalination, concentrations • Pharmaceuticals • High tube velocity minimizes fouling • Solvent recovery • System may be turned down without loss of efficiency or effectiveness • Waste water & Effluent treatment

• Able to achieve high concentrations at low temperatures

• Suitable for materials with higher evaporation temperature

• Suitable for low to medium viscosities liquids

• Suitable for heat sensitive materials

• Suitable for foamy liquids & liquids with suspended solids

Forced Circulation

Evaporator (FCE)

Forced Circulation Evaporator with axial flow pump experience reduced scaling

The forced circulation evaporator is designed for liquids with a high solids content, high viscosity & tendency to foul.

A Forced Circulation Evaporator (FCE) has Horizontal or vertical shell-and-tube heat exchanger as the calandria, with flash vessel/separator & a circulation pump for circulation of slurry through the tubes. Use of axial flow pump ensures good velocity in the tubes with minimum power requirement. Forced circulation leads to high tube side velocities (6-18 ft/s), and hence higher heat-transfer coefficients and smaller heating surfaces. Boiling in the forced circulation evaporator is suppressed in the heat exchanger by backpressure and takes place when the liquid enters the flash vessel/separator. Forced Circulation Evaporator

Advantages: Applications:

• Suitable for highly viscous, scaling & salting • Spent wash from distillery liquids • Corn Steep Liquor • Suitable for waste water with high suspended solids • Liquids with high tendency of fouling

• Fouling is minimized due to high liquid velocities • Highly viscous liquids & suppressed boiling in the tubes • Effluent Treatment Plants • High tube side velocities can be achieved • Polymers • Higher heat-transfer coefficients • Food products • Easy installation and move, skid mounted with • Pharmaceuticals small footprint

• Optimally suited as crystallizing evaporators for saline solutions.

• Axial flow pump ensures good velocity in the tubes with minimum power requirement

• Robust and reliable process

• Low energy consumption and minimum need of maintenance

Multiple Effect

Evaporator (MEE)

Multiple-effect evaporators (MEE) maximize steam economy as vapor generated from one effect is used to heat another.

In large-scale industrial production, it MEE system is perfect for continuous feed is often necessary to evaporate a applications, as fluids are progressively large amount of water which requires reduced in each effect to final concentration a large amount of energy to heat discharge. water to produce steam. To reduce Comparison of evaporator steam economies the consumption of heating steam, Steam Economy, kg water multi effect evaporator can be used. Type of Evaporator evaporated/kg steam Single-effect 0.90–0.98 The multiple-effect configuration combines two or Double-effect 1.7–2.0 more evaporator bodies to conserve steam. Water evaporated in the first-effect vapor body is Triple-effect 2.4–2.8 condensed in the second-effect heat exchanger, Triple-effect with TVR 4–8 which provides energy for evaporation in the second-effect vapor body (and so on for additional effects).

Multiple Effect Evaporator (MEE)

Advantages: Applications:

• Ability to maximize usage of input energy • Industrial effluent treatment (steam economy) • Brine liquid concentration • Reduced energy required to run full system • Recovery of metal salts • Reduced condensing load with additional effects (less cooling water needed) • Concentration of pharma and textile effluent • Liquor flow control • Pharma product concentration • Convenient foul condensate collection and processing • Concentration of RO reject till saturation of salts in dissolve liquid • Ability to do online cleaning of individual effects • Secondary treatment • Maximum thermal efficiency with concurrent flow option • Dairy industry for milk evaporation

• Fruit and tomato juice concentration

Thermal Vapor Recompression (TVR)

Thermal vapor recompression Below table represents steam consumption for double effect with & without TVR (TVR) gives the same Configuration lb/hr of 85 lb water evap./ steam/energy saving as an psig Steam lb Steam additional evaporation effect. Double Effect 12,800 1.94 Double Effect 8,540 2.90 TVR uses ejector to recover the with TVR

secondary steam, reduces the system requirement for fresh steam and Comparison between MVR & TVR achieve energy saving performance. Parameter Multi effect MEE with MEE with A fraction of process vapor from the first effect evaporation TVR MVR (MEE) evaporator is recycled & recompressed in a steam Capital Medium Medium Relatively jet ejector (TVR) to raise the temperature and investment high pressure of the vapors. The motive steam mixes Operating High Medium Low cost with this portion of the vapors generated from the Electrical Low Low High first effect evaporator. The resultant vapors (motive energy Thermal High Low Low steam plus vapors from the first effect) is used to energy heat the first evaporation stage thus reducing the

system requirement for fresh steam and achieving energy saving performance. This motive steam portion is transferred as excess vapor to the next effect or to the condenser. The energy of the excess vapors approximates the energy of the motive steam quantity used.

Thermal vapor recompression (TVR)

Advantages: Applications:

• TVR has no moving parts and are therefore not • Beverages and Food industry subject to wear and tear. (evaporation of whey, milk and sugar • Maximum operational reliability. solutions)

• Most energy efficient evaporation technology • Chemical industry (evaporation of aqueous solutions) • One-time investment of TVR is much lower than that of MVR • Salt Works industry (evaporation of saline solutions) • Almost no fresh steam & cooling water consumption • ZLD (concentration of waste water)

• At the same evaporation rate, an evaporator with TVR system uses 36 % lesser steam & 36 % lesser water compared to straight steam evaporator

• Evaporator equipped with TVR uses less heating surface than straight steam system

• Simple and effective design

Mechanical Vapor Recompression (M VR)

MVR reuses the secondary steam to heat the raw materials.

MVR achieves vapor compression through mechanically driven equipment such as blowers or compressors to increase the energy of the secondary steam and reuse it to heat the raw material, so as to recover the latent heat of the secondary steam.

The secondary steam produced by the evaporator will be compressed by the centrifugal blower or centrifugal compressor thus increasing its pressure and is sent to the heating chamber of the heat exchanger to heat the raw material. Therefore, the latent heat of the steam is recovered and utilized. Mechanical vapor recompression (MVR)

Advantages: Disadvantages:

• The evaporation capacity is up to 0.5t/h ~ 100t/h • One time investment is much higher than traditional multi effect evaporator • MVR requires almost no additional steam and cooling water during steady operation • The compressor/blower cost will account 30% cost in MVR system • MVR is the most energy efficient system for evaporation • For some area with high price electricity but lower price steam, MVR evaporator • MVR can work with any kind of evaporator, economic advantage is not obvious. including falling film evaporators, forced circulation TVR evaporator system is evaporators & Rising film evaporators recommended.

• The system only uses electricity without steam, Applications: and the energy consumption of evaporation for per ton of water is 15KW.h to 100KW.h, the • Industrial wastewater treatment discharge running cost is much lower concentration

• MVR has low energy consumption • Chemical industry for evaporation, crystallization, and purification • MVR has a higher performance coefficient • Salt brine concentration • MVR places a reduced load on the cooling tower • Beverage industry (milk, juice, sugar, etc.) • MVR simplifies the evaporation process and thus concentration plant operation • Food industry (MSG, soy, protein, sugar) • Compact structure, small footprint concentration

• Pharmaceutical industry (medicines, vitamins) concentration

Short Path Evaporation / Distillation (SPDU)

The rotor blades creates a mechanically Best solution for molecular agitated, thin product film on the heating distillation and purification of surface inside of the body. By means of gravity the product flows down in a spiral path, extremely heat-sensitive whereby the volatile portion of the product substances and products with very evaporates. The vapor passes by the shortest high boiling point, under extreme route and with practically no pressure drop to the internal condenser. vacuum conditions. The cage-type construction and location of the Short path evaporation / distillation is a internal condenser create a short vapor flow thermal separation technique that path or “short path”, extending the operating provides minimal pressure drop, pressure capability from 1 mbar to 0.001 mbar permitting deep vacuum operation down compared to a standard thin-film evaporator. to 0.001 mbar. The distillate and the remaining liquid concentrate (Residue) drain out through Short path evaporation is also called molecular separate outlets at the bottom of the unit. distillation while a short path evaporator is sometimes known as an SPE or SPDU (short path distillation unit). The short path evaporator (SPE) is specifically well suited for distillation, evaporation, concentration and stripping of heat sensitive products.

The unique combination of evaporation and condensation in extreme proximity permits the operation of the Short Path Evaporator with a vacuum up to 0.001 mbar (a). This operating range is unchallenged by any other type of evaporator.

Working:

The short path evaporator consist basically of a cylindrical body with a heating jacket, a rotor and an internal condenser. The rotor cage assembly surrounds an internal condenser and revolves at moderate speeds. Feed enters through a nozzle at the top of the unit and is spread into a thin film on the inside surface of the shell via the rotor blades

SPEU / SPDU

Advantages: • The rotor increases the turbulence of the product, rising greatly the process • Continuous distillation process side heat transfer coefficient, even with viscous fluids • Very low operating pressures possible (up to 0.001 mbar) • Rotor induced shear decreases the viscosity of some products • Residence time of few seconds, important for heat sensitive products. • One-trough operation so very low liquid hold-up • High evaporation rates • Rapid surface renewal • Low fouling on evaporator wall

• Suitable for viscous products. Applications: • Excellent turn down capability. • Chemical & Agrochemical Industry • Low power requirements. • Oils, Fats and Food Industry • Compact design • Salt brine concentration • Operating at very high temperature 300°F to 650°F (149°C to 343°C). • Pharmaceutical Industry

• High heat and mass transfer performance • Petrochemical Industry

• Polymers Industry

• Fragrances and Flavors Industry

• Environmental care

Agitated thin Film Dryer / Evaporator (ATFD / ATFE)

The Feed enters the dryer at its top which is Best solution for Highly Viscous, then evenly distributed by the rotor and its Heat sensitive, Fouling & High blades over the heating surface, forming a Boiling point liquids. thin liquid film of uniform thickness. Highly turbulent swirls are produced at the tip of the Due to its inherent design features, rotor blades with intensive mixing and ATFD/ATFE is ideal for thermal treatment agitation of the product, as it comes into contact with the heating surface. This assures of solutions that are highly viscous excellent heat transfer combined with (viscosities of several million centipoise), constant renewal of the product film and heat sensitive, fouling & high Boiling provides an even heating and short residence products, where reduced operating time of the feed through the heated zone. The temperatures and vacuum operating feed starts evaporating once it is heated to its pressures are desirable. Boiling point. The generated vapors flow counter currently and get cleaned by an An Agitated Thin Film Dryer / Evaporator (ATFD/ATFE), integrally mounted entertainment separator also known as Thin Film Evaporator (TFE) or Wiped while the final solid product is discharged by Film Evaporator (WFE). They are mainly used for gravity at the bottom of the dryer. difficult vaporization and heat exchange processes, especially where products to be handled are highly viscous and conventional plants can no longer meet user demands because heat transfer is insufficient. Due to the liquid film, mechanically generated on the heating surfaces, thin film equipment achieve much better heat transfer rates, even with highly viscous products containing solids. Working:

The typical Agitated Thin Film Evaporator consists of a tubular heat transfer area with an external heating jacket and a fast-revolving, inner rotor with rows of blades all over the length of the dryer. The hinged blades spread the wet feed product in a thin product layer over the heated wall and mix the product layer material intensively. Therefore the volatile components evaporate continuously from the product layer with high evaporation rates. The hinged blades are designed with a minimum gap to prevent fouling of the heating surface by product, but are never in contact with the heated wall. ATFD / ATFE

Advantages:

• Residence time of a few seconds with a narrow spread

• Excellent turn down capability • No dead zone, therefore overheating prevented and perpetual high product • Low product holdup, ideal of hazardous quality guaranteed applications • High Heat Transfer Coefficient value (U • Designed to give solid powder with value) even when working with highly moisture content around 5-10% viscous and contaminated products

• Widely accepted by pollution control board norms Applications: • Continuous operation • Wastewater & Sludge treatment • Less maintenance • Purification & Drying of Petrochemicals & • Easy to start, operate and shut down Organic Chemicals

• Low pressure drop • Solvent Recovery

• Operation under low vacuum • Concentration of Natural Extracts & Pharma Products • Evaporation ratios up to > 95% without recirculation • Concentration & Crystallization of Inorganic Salts • Able to process products with high viscosities • Concentration & Devolatilizing of Polymers (Resins, Fibers, Plastics) • Able to process systems that form deposits • Oil Recovery & Refining • Easy to clean (CIP) • Concentration and Purification of Fertilizers • Required evaporation is achieved in a single pass, avoiding product recirculation • Concentration and Purification of and possible degradation agrochemicals

• Scale formation on the heat transfer surface is reduced due to the intense agitation of the liquid film

Astrolex Industries Pvt. Ltd. Works Plot- 308/6 G.I.D.C Makarpura Vadodara-390010, Gujrat, India

Sales & Technical Office

E-304, Siddharth Samanvay Towers Old Chhani Road, Behind TVS Showroom Vadodara-390024, Gujrat, India

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