Customized Continuous Operation MVR Evaporator — Automatic for Wastewater Treatment
Engineer-to-order Mechanical Vapor Recompression (MVR) evaporator designed for 24/7 continuous operation and fully automatic control in industrial wastewater treatment and ZLD schemes. By recompressing secondary vapor as the primary heat source, the system delivers low OPEX, stable throughput, and high-quality condensate for reuse.
- Customized to site: power (380–480 V LV / 3.3–11 kV MV), utilities, layout, and effluent targets
- Automatic operation: PLC/HMI with recipes, alarms, historian, and remote diagnostics
- Energy efficiency: minimal fresh steam after start-up; electric-driven vapor recompression
- Uptime by design: redundancy on critical pumps, online fouling monitoring, planned CIP windows
Typical Wastewater Duties
High-salinity brines, RO/NF concentrates, dye/printing effluents, chemical & pharma mother liquors, landfill leachate, and other high-COD streams requiring volume reduction, resource recovery, or ZLD compliance.
Process & Thermal Economy
Secondary vapor is mechanically compressed to raise temperature and reused as the heating medium, maximizing latent heat recovery and reducing utility bills.
Controls & Safety
Closed-loop control of level, ΔT, pressure, and conductivity; interlocks for compressor/VFD, vacuum system, and condensate quality guard.
Materials & Cleanability
SS316L/duplex for wetted parts, drainable layouts, anti-scale dosing, and validated CIP for long, stable campaigns.
Process Overview — Continuous Automatic MVR
- Feed conditioning: filtration/softening, pH trim, and deaeration to limit scaling/corrosion
- MVR evaporation (vacuum): forced circulation with tight ΔT control for stable heat transfer
- Condensate management: polishing (if required) to meet reuse/discharge limits
- Concentrate routing: to crystallizer/centrifuge/dryer for solids discharge or further treatment per ZLD
- Automation: start/stop recipes, load following via VFD, alarm interlocks, and remote support
Key Components
- MVR evaporator/crystallizer body with circulation pumps and vapor–liquid separator
- Mechanical vapor compressor (turbo/Roots) with VFD and inlet filtration/silencing
- Main heater, preheaters, condensers, vacuum/NCG handling skid
- PLC/HMI/SCADA, instrumentation (T/P/flow/cond/level), historian & remote access
- CIP skid, anti-scale dosing, and optional polishing filters/RO for condensate
Performance & Sizing
| Parameter | Typical Range* |
| Operation | Continuous, 24/7 |
| Electric use (MVR) | ~15–40 kWh per ton of water evaporated (duty/CR dependent) |
| Fresh steam demand | Very low after start-up (backup/ancillary only) |
| Turndown | 50–100% with stable ΔT and quality |
| Availability | ≥95–98% with redundancy and planned CIP |
| Condensate quality | Low conductivity/TOC (with polishing as required) |
| Materials | SS316L / duplex; Ti/Hastelloy on request |
*Actual performance depends on feed characteristics, compression ratio, and heat-transfer design.
FAQ
Can this system integrate into our ZLD plant?
Yes. Common flowsheets pair RO/NF pre-concentration with MVR for final concentration/crystallization and solid handling.
How is fouling controlled?
Proper softening/pH control, optimized LMTD/velocity, anti-scale dosing, and scheduled CIP cycles with online monitoring.
Is it fully automatic?
PLC recipes, alarm interlocks, historian, and optional remote service support continuous, unmanned operation.
