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Thermosag is a leading mechanical vapor recompression (MVR) manufacturer in India, specializing in providing innovative and efficient solutions for thermal separation processes. With a focus on energy efficiency and environmental sustainability, Thermosag has established itself as a trusted name in the industry.
Thermal separation process i.e. Evaporation have been indispensable to a plethora of industries, particularly to chemical, Pharmaceuticals, Agrochemicals, Speciality Chemicals, Dyes and Intermediates, food & beverage, salt works, and environmental technology industries etc. Reduction of energy costs being one of the primary considerations led to the adoption of multiple-effect plants, followed by thermal vapor compression and now being replaced or converted to mechanical vapor recompression which is also known as ‘MVR’ for further reduction of energy cost, reduce overall water losses, minimize energy through reduction of fossil fuel consumption and to bring Environmental sustainability by reducing TOE for production.
As the name suggests, mechanical vapor recompression technology involves the use of a mechanical compressor that recompresses the vapor of an MVR evaporator to a higher pressure. Mechanical vapor recompressor functions as a heat pump adding more energy and increase temperature gradient to the vapor.
MVR technology (Mechanical vapour recompression) offers a whole gamut of benefits ranging from reduced specific energy consumption, low operational costs, seamless evaporation of the product owing to low-temperature differences, simplicity of the process, and top-notch partial load behaviour.
Mechanical Vapour Compression machines based on the dynamic principle have rotating impeller blades and a diffuser which is located downstream from the impeller. Impeller blades run at high circumferential speeds and the vapour is supplied with energy. Acceleration of the vapour takes place followed by its de-acceleration which is done by the diffuser. This process helps convert high velocity into high pressure. The machine would be called an Centrifugal Turbo Compressor.
The selection of compressor is determined by numerous parameters including operating conditions, the flow rate of the vapor to be compressed and the pressure rise needed.
To heat an evaporation plant, a temperature difference on the heating surface is needed. Simply put, the temperature and pressure of the heating steam must be higher than the pressure and boiling temperature of the product in the system. This temperature difference is achieved through the compression of evaporated vapor from MVR Evaporator in a compressor.
Centrifugal recompressors are generally used in evaporation plants function with 8-20 degC temperature differences. These are also continuous flow machines with a speed range of 10,000 and 35,000 RPM. There is a spiral type housing in these compressors with an axial suction nozzle and a open rotating impeller.
Impellers are manufactured using titanium alloys. The high rotating speeds and the resulting forces necessitate the shape and stability of impellers and hence the construction.
A single-stage turbo compressor helps achieve the compression ratio of more than 2 with a volume flow range of 1 and 140 m3/second.
Centrifugal turbo recompressors are designed with state-of-the-art construction and technology. Their supremacy to the centrifugal fan, Centrifugal Blower and rotary blower recompressors is unquestionable on account of a plethora of reasons and advantages. Stable performance, best cost-performance, optimum utilization of the equipment functioning, and perfect balance of investment and output ratio are some of the many reasons why centrifugal turbo compressors outperform other type of MVR’s.
The main benefit of MVR mechanical vapour recompression is that it allows for significant energy savings. Mechanical vapour compression, unlike the alternative thermal vapor compression, does not depend on large quantity of steam supply. And since no fluid mixing occurs, all of the available vapor can be compressed for complete energy recovery.
Mechanical vapour recompressors cost a little higher than a conventionally heated thermal plant of the same capacity; however, it turns out to be a beneficial investment, in the long run, paying back investment with a plethora of benefits. The investment costs get repaid in a short period in terms of energy saving itself apart from other benefits.
Thermosag’s centrifugal turbo recompressors remain a cut above the rest in terms of investment viability, productivity, and energy savings. This compressor is not only suited to variegated applications in various industries including (but not limited to) chemical, organic natural product production and food & beverage, but is also capable of achieving high temperature increases with sheer ease like Zero Liquid Discharge and Salt Recovery Plants.
A centrifugal turbo recompressor that operates under the mechanical vapour recompression principle also empowers your systems to achieve high temperature increases compared to any other type of Mechanical Vapour Compressor including Centrifugal Fan or Blower or Turbo Blower. Centrifugal Turbo Compressors offer exceptional energy efficiency with highest level of reliability.
Being a reputed MVR and Evaporators manufacturer supplier, one of the outstanding features of Thermosag’s centrifugal turbo compressor is its highly advanced design with latest tools and manufactured with extremely high precision.
Besides, the impeccable and wear-resistant impeller design facilitates better erosion resistance. Centrifugal turbo recompressors indeed are an ideal choice with an edge over other MVR technologies.
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Thermosag is one of the leading MVR evaporator manufacturers in India who are here to provide you the MVR systems with the below mentioned features and functionalities with further customization possibilities.
Construction
Performance
Multiple-effect evaporation plants unlike MVR Evaporator have been around for ages and they have been used across the world; however, a rapid upsurge in steam costs in the majority of regions in recent years made these plants lose their relevance. What was once considered an ideal plant arrangement, isn’t viable any longer. Unlike multiple-effect plants that would be heated using live steam OR in combination with a thermal vapor recompressor, contemporary mechanical vapor recompressors are electrically operated and viable by all means.
Now the question is whether or not it is possible to minimize the operational cost disadvantage. Energy costs have increased quite significantly in yesteryears and they are likely to increase even more in the future. Increasing the number of effects to minimize the specific energy needs is mostly not a good idea and hence retrofitting is an ideal solution to optimize the energy of existing multiple-effect plants.
Water Losses in Cooling Tower and higher fossil fuel or Bio Fuel consumption leading to environmental instability and increasing carbon foot print. Application of MVR instead of MVR is an effective alternative for shifting to unconventional green energy instead of using energy produced from Combustion of Fuel.
Conversion of MEE into MVR Often the multiple-effect Evaporation plants designed with 6-15 degC temperature differences between the respective heating surfaces can be directly converted from MEE to MVR using Centrifugal Turbo Compressor. This is to make it suitable for heating using the MVR technology. The process involves the replacement of existing vapor ducts with new ones and the installation of one or multiple mechanical recompressors. This arrangement causes a change in the energy flow of the plant. The majority of evaporated vapor can now be used to heat all effects and needing negligible amounts of live steam and cooling water.
In the cases where MEE are designed with larger Temperature difference there is a possibility of adding one Evaporator body and convert the plant from MEE to MVR.
| Type | Turbo Compressor | Turbo Blower | Centrifugal Fan | Roots Blower |
| Compression Ratio | ≤ 2 | ≤ 1.4 | ≤ 1.25 | ≤ 1.4 |
| Saturated Temp. Rise(oC) | ≤ 20 | ≤ 8 | ≤ 4 | ≤ 8 |
| Flow Rate @ 100 oC | > 100 T/hr | > 100 T/hr | > 100 T/hr | < 1 T/hr |
| Impeller | Centrifugal | Centrifugal | Centrifugal | Volumetric |
| Impeller Manu. Process | Mill | Weld | Weld | Cast |
| Manu. Cost | High | Lower | Lower | Lowest |
| Maintenance | Low | Low | Moderate | High |
| Downtime | Low | Low | Low | High |
| Operating Speed (RPM) | 5000-35000 | 4000-12000 | 2000-3000 | 1450-2900 |
| Noise Level (dBA) | ≤ 85 | ≤ 85 | ≤ 85 | ≤ 110 |
| Compression Efficiency in % | 75 – 88 | 75 – 88 | 75 – 88 | 45 – 55 |
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It is of utmost importance to bear in mind that the evaporation rate of Mechanical vapour recompression Evaporator of the plant might vary and hence the need of regulating the capacity of the compressor cannot be ruled out.
Some of the common and prime regulation variants for mechanical vapour recompressor evaporators include suction pressure control, speed control, pre-rotation control, and by-pass control. Leveraging various regulation mechanisms that influence the compressor curve becomes important in the process.
Short-term capacity fluctuations are pretty much on the cards, particularly in cases that require the evaporation plant to have fluctuating operating conditions of an upstream process. Besides, necessary measures must be taken to keep at bay the capacity losses during the long-term operation of the plant.
It is noteworthy that any small change in the mass flow, any of the product parameters or product temperature has a direct impact on the plant characteristic. Consequently, it calls for an adjustment in the thermal flow to be sent to the plant. At Thermosag, we are the mechanical vapor recompression manufacturer who can facilitate these adjustments by making necessary adjustments in the pressure or saturated steam temperature that is produced by the compressor in place.
Not just the dimensioning adjustments of plant components, but also the needed variance in the operating points play a pivotal role in the selection of an optimum regulation design for the vapor compressor.
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