Evaporator Technology

SKTMPL is positioned to be as one of the leading suppliers of evaporation technologies to the Indian market. SKTMPL has developed unique energy efficient technical solutions and products for a number of separation and purification processes. Evaporation is a thermal separation method for dividing a liquid into condensate and concentrate, the latter having a high dry matter concentration. The condensate is clean distilled water. The SKTMPL evaporators are characterized by an energy optimized design, compact layout and high reliability. SKTMPL delivers the evaporator technology listed below, either as standalone units or in combined systems.

  • Falling Film Evaporators (Multi Effect Falling Film)
  • Forced circulation Evaporators (Multi Effect Forced Circulation)
  • Falling Film with Forced Circulation (Multi Effect Evaporator)
  • Evaporation with Crystallization and separation of Crystals
  • Evaporation with Dryers for production of powders.

By combining comprehensive knowledge with extensive experience, we engineer, produce and install energy efficient evaporation technology to separate liquids from solids or purify any wastewater derived from your industrial processes. This enables you to squeeze the last drop of value from your production cycle in a cost-efficient and eco- friendly manner.

TVR Technology

To reduce energy consumption, water vapor from an evaporator is entrained and compressed with high pressure steam in a thermo-compressor so it can be condensed in the evaporator heat exchanger. The resultant pressure is intermediate to that of the motive steam and the water vapor. A thermo-compressor is similar to a steam-jet air ejector used to maintain vacuum in an evaporator.

Only a portion of the vapor from an evaporator can be compressed in a thermo-compressor with the remainder condensed in the next-effect heat exchanger or a condenser. A thermo-compressor is normally used on a single-effect evaporator or on the first effect of a double- or triple-effect evaporator to reduce energy consumption. As with mechanical recompression, thermal recompression is more applicable to low boiling-point rise liquids and low to moderate differential temperatures in the heat exchanger to minimize the compression ratio.

To illustrate the energy effectiveness of a thermo-compressor, compare the steam usage for a double-effect evaporator with that of a double-effect evaporator with a thermo-compressor. Motive steam at 6.0 bar g is utilized to compress first-effect vapor from 0.6561 bar to 1.1050 bar absolute.

Evaporator Configuration Kg/h, Steam at Pressure 6.0 bar g Kg Evaporation/Kg stream
Double Effect 5800 1.94
Double Effect with TVR 3870 2.9

The double-effect evaporator with thermal recompression requires 33% {= (1-(3870/5800)} less steam than the conventional double effect. In essence, the steam usage for the double effect with thermal recompression is comparable to that of a triple-effect evaporator.

The main advantage of thermal recompression is improved steam economy for a moderate capital expenditure which is less than that for an additional effect.

MVR Technology

At the core of our technology is our Mechanical Vapour Recompression (MVR) unit, that typically uses 80-98% less energy than a conventional boiling process. For SKTMPL and our customers, it is essential to ensure that we choose the correct technical solution for each and every project. Consequently, we provide both complete new installations and convert existing evaporation technology into our more efficient MVR technology.

Our goal is to provide reliable support and flexibility during the plant’s complete life cycle: from testing and sales to project engineering, commissioning, supervision, support and 24-hour After Sales services.

In the present scenario of energy savings, filtration technology has come to play a key role by being part of the evaporation system; there are lot of improvements and it is reliable, such that, many plants are considering the installation of membrane filtration equipment, rather than pre-concentrating evaporators to reduce up front capital costs during new construction. Falling film finishing evaporators are being used more frequently to generate the total solids required in the drying process. This often leads to a decision of whether to install a thermal vapor recompression (steam ejector) style evaporator or a mechanical vapor recompression style evaporator.

The question of whether to use thermal vapor recompression (TVR) or mechanical vapor recompression(MVR) is most often a question of long term operational costs versus up front capital costs.

The decision over whether to install a TVR versus an MVR finisher for many companies comes down to steam generation costs (most importantly the uncertainty of fuel prices in today’s volatile fossil fuel market place), how those costs compare to electrical costs per kWh, and the upfront capital costs of a turbofan or turbo compressor.

Energy Economics

The decision to install a TVR or MVR evaporator will always be a question of energy economics. Both current energy prices and future energy prices must be considered when making the decision. It is one thing to make a decision based on current energy prices, but as recent history has shown, fossil fuel prices can be extremely volatile. One must carefully consider all aspects and weigh the pros and cons of each technology.

Falling Film Multistage

In this type of evaporator the Liquid to be concentrated is pumped to the Top distribution system in such a way that the film is formed inside of the Tubes.

Forced Circulation

The Forced Circulation Evaporator is Most Ideal for the Sticky Material and is mainly used for the higher concentrated liquids whose viscosity is more.

Agitated Thin Film

This is mechanical Type evaporator; a thin film is achieved through mechanical agitation inside a Cylinder through the Rotor agitator.

Rising Film

These operate on a “thermo-siphon” principle. Feed product enters the bottom of the heating tubes and as it heats, steam begins to form.

Falling Film cum Force Circulation

The combination of falling film evaporator followed by forced circulation evaporator system is the most economical operation.