Industrial
MVR
Evaporator
-
Zero
Liquid
Discharge
for
Sugar
&
Starch
Syrup
Engineer-to-order
Mechanical
Vapor
Recompression
(MVR)
evaporator
for
sugar
juice,
molasses,
and
starch
syrup
concentration
with
integrated
Zero
Liquid
Discharge
(ZLD)
options.
The
system
recycles
latent
heat
by
mechanically
recompressing
secondary
vapor,
delivering
low
OPEX,
stable
°Bx/DS
control,
and
minimal
effluent
for
sustainable
operation.
Key
Benefits
-
Energy
Efficiency:
Electric-duty
MVR
slashes
fresh
steam
use
after
start-up.
-
Product
Quality:
Vacuum/low
ΔT
evaporation
protects
color,
flavor,
and
DE;
tight
°Bx/solids
control.
-
ZLD
Readiness:
Condensate
polishing
for
reuse;
concentrate
routed
to
crystallizer/dryer
for
solids
discharge.
-
Hygienic
Design:
Food-contact
stainless
steels,
drainable
layouts,
optional
CIP/SIP.
-
High
Availability:
24/7
automatic
operation
with
redundancy
and
predictive
fouling
monitoring.
Process
&
Thermal
Economy
Secondary
vapor
is
mechanically
compressed
to
raise
saturation
temperature
and
reused
as
the
heating
medium.
Optimized
Δ
T/LMTD,
residence
time,
and
circulation
preserve
sucrose/invert
balance
and
DE,
while
enabling
deep
concentration
for
syrup
finishing
and
ZLD
schemes.
Materials
&
Hygiene
Wetted
parts
in
SS316L/duplex
(electropolish
on
request);
sanitary
connections,
food-grade
elastomers,
sloped/drainable
piping;
validated
CIP/SIP
supporting
HACCP/ISO
22000.
Process
Overview
--
Sugar
&
Starch
Syrup
ZLD
-
Feed
prep:
clarification/filtration,
pH
trim,
degassing
to
minimize
color
pickup
and
scaling.
-
MVR
evaporation
(vacuum):
falling
film/forced
circulation
with
tight
ΔT
for
gentle,
efficient
concentration.
-
Condensate
polishing:
filters/RO/AC
to
meet
reuse
(process/CIP)
or
discharge
limits.
-
Finishing/ZLD:
syrup
to
target
°Bx/DS;
mother
liquor
to
crystallizer/centrifuge/dryer
for
solids
discharge.
-
Automation:
PLC/HMI
recipes
for
crop/seasonal
variability,
alarm
interlocks,
historian,
remote
support.
Key
Components
-
MVR
evaporator
(falling
film
/
forced
circulation)
with
vapor-liquid
separator
-
Mechanical
vapor
compressor
(turbo/Roots)
with
VFD
-
Preheaters,
main
heater,
condensers,
vacuum/NCG
handling
-
PLC/HMI/SCADA;
instruments
(T/P/flow/cond/level/°Bx
or
DS)
-
CIP/SIP
skid;
condensate
polishing
filters/RO;
optional
aroma
capture
Performance
&
Sizing
|
Parameter
|
Typical
Range*
|
|
Operation
|
Continuous,
24/7
|
|
Electric
use
(MVR)
|
~15-40
kWh
per
ton
of
water
evaporated
(duty/CR
dependent)
|
|
Product
temperature
|
Low-temp
vacuum
duty
to
protect
color/DE
and
reduce
inversion
|
|
Sugar
syrup
(°Bx)
|
e.g.,
60-75
°Bx;
tighter
spec
via
inline
°Bx/viscosity
control
|
|
Starch
syrup
(DS/DE)
|
e.g.,
70-85%
DS;
DE
preserved
with
gentle
ΔT
and
residence
time
|
|
Condensate
quality
|
Polished
for
reuse
(process/CIP)
per
site
standards
|
|
Materials
|
SS316L/duplex;
Ti/Hastelloy
available
for
corrosives
|
*Performance
depends
on
feed
composition,
viscosity/fouling
tendency,
compression
ratio,
and
heat-exchanger
design.
FAQ
Can
one
line
handle
both
sugar
and
starch
syrup?
Yes--recipe-based
setpoints
(ΔT,
residence
time,
pressure)
and
sanitary
changeover
enable
multi-product
operation.
How
is
product
quality
protected?
Vacuum
boiling
lowers
temperature;
uniform
thin
film
and
tight
ΔT
minimize
color
formation
and
inversion/degradation.
How
does
ZLD
integrate?
Condensate
is
polished
for
reuse;
mother
liquor
proceeds
to
crystallization,
centrifugation,
and
drying
for
solid
discharge.
Application
