Ethanol Crystallizer — MVR SS316L Single-Effect Falling Film Evaporator
Engineer-to-order single-effect falling film evaporator in SS316L, integrated with MVR (Mechanical Vapor Recompression) and an ethanol crystallizer section for solvent recovery, concentration, and controlled crystallization (API/fine chemicals/bioproducts). Vacuum operation and recompressed vapor duty provide low temperature, high efficiency, and consistent crystal quality.
Key Benefits
- Energy efficient: MVR recycles latent heat; minimal fresh steam after start-up.
- Crystal control: Tight supersaturation and residence-time management for narrow particle size.
- Product protection: Low ΔT falling-film duty preserves thermally sensitive actives.
- Clean & compliant: SS316L contact surfaces, drainable layouts, CIP-ready; solvent safety options.
- Solvent economy: High-purity ethanol condensate suitable for reuse after polishing.
Process & Thermal Economy
Secondary vapor is mechanically compressed to elevate saturation temperature and reused as the heating medium. Falling-film operation maintains uniform film temperature and high heat-transfer coefficients, limiting degradation and fouling while stabilizing supersaturation for crystallization downstream.
Materials & Safety
Wetted parts in SS316L (Duplex/Ti/Hastelloy on request). Solvent-service options: explosion protection (ATEX/NFPA concepts), nitrogen blanketing, solvent-rated seals, LEL monitoring, and conductive gaskets/hoses.
Process Overview — Ethanol Concentration & Crystallization
- Feed conditioning: filtration/degassing; pH or seed addition if required.
- Single-effect MVR evaporation (vacuum): compressor discharge sets ΔT; shell pressure defines boiling point.
- Crystallizer: controlled cooling/evaporation; seed loading for PSD tuning and habit control.
- Solid–liquid separation: centrifuge/filter; mother liquor recycle or recovery.
- Condensate handling: polishing (AC/ion exchange) for ethanol reuse; VOC management as required.
Key Components
- Falling-film evaporator (single effect) with vapor–liquid separator
- MVR mechanical vapor compressor (turbo/Roots) with VFD
- Crystallizer (DTB/OSLO or FC with cooling coil/HX), seed/feed systems
- Condenser, vacuum/NCG handling, solvent-rated piping and valves
- PLC/HMI/SCADA; instruments (T/P/flow/cond/level/VOC/LEL); CIP skid
Performance & Sizing
| Parameter | Typical Range* |
| Operation | Continuous, vacuum |
| Electric use (MVR) | ~15–40 kWh per ton of water/solvent evaporated |
| Film ΔT | Low (duty/CR dependent) to protect heat-sensitive actives |
| Crystal PSD (D50) | Tunable via seed load, ΔT, and residence time |
| Materials | SS316L standard; Duplex/Ti/Hastelloy optional |
*Performance depends on feed composition, viscosity/fouling tendency, compression ratio, and crystallization kinetics.
FAQ
Can one system both concentrate and crystallize?
Yes—falling-film MVR provides gentle concentration; the downstream crystallizer finalizes PSD and purity.
How is solvent safety addressed?
Options include nitrogen inerting, LEL/VOC monitoring, conductive components, and explosion-protection design per code.
What about ethanol recovery quality?
Condensate polishing (e.g., carbon/IX) delivers high-purity ethanol suitable for reuse, reducing make-up solvent cost.
Application
