Astrolex Industries Pvt. Ltd.

Inspiring Innovative Engineering Solutions

Evaporation Technology

Our Mission
To render unparalleled and innovative
technical solutions & services to a vast
clientele with utmost integrity,
dedication, resolute core values and
committed deliverances for leaving an
indelible mark on the chemical & wide
range of other processing industries.
About Astrolex
Astrolex Process Systems (a subsidiary
of Astrolex Industries Pvt. Ltd.) is a
process engineering company offering
an extensive range of projects,
equipment and innovative process
solutions based on advance technology
and a real understanding of customer
needs.
In today's competitive world, rising
manufacturing costs coupled with
higher customer expectations make it a
challenging task to maintain profitability
of plant operations. Astrolex Process
Systems has the express business
mandate of delivering focused, high-
value added products & services to the
Process Industry.
We understand the need of the
customers, who are under increasing
economic competitive and regulatory
pressures and partner with them to
design and deliver the most reliable,
efficient and innovative solutions for the
process and overall project
implementation.
Our vision
To grow as a globally recognized
name, to be known by our customers
for providing innovative Process
technologies & Services that help
them be even more successful.
To be a place where passionate
employees have room for creativity
and entrepreneurship to make our
Group unique
Comprehensive Process Solutions
for Chemical Industry

Evaporation | Distillation | Vacuum Systems | Heat Transfer Solutions

Plasticizer Trunkey Plant | Caustic Recovery Plant | Process Equipment
Environmental Technologies | Zero Liquid Discharge (ZLD)
Engineering Services | Essential oil Distillation Plant
 Our Portfolio

Evaporation Technology
Falling Film Evaporator (FFE)
Rising Film Evaporator (RFE)
Forced Circulation Evaporator
Multiple Effect Evaporator
(MEE)
Thermal Vapor Recompression
(TVR)
Mechanical Vapor
Recompression (MVR)
Short path Evaporation-
Distillation
Agitated Thin Film Evaporator
(ATFE)

Distillation Technology
Solvent Recovery
Steam Distillation

Vacuum Technology
Ejectors
Multistage Steam Jet
Vacuum Systems
Jet Mixers – Tank Mixing
Systems
Steam Jet Heaters
Steam Jet & LRVP
Thermocompressors
Condensers
 Heat Transfer Solutions
Shell & Tube Heat
Exchanger
Hairpin / Double Pipe
Heat Exchanger
Twisted Tube Heat
Exchanger
Tank Heating Coils

Environmental Technologies
Packed Bed Tower Scrubbers
High Energy Venturi Scrubber
Fluidized Bed Scrubber
Spray Tower Scrubber
Jet Ejector Venturi Scrubber
Tray Scrubbers

Zero Liquid Discharge (ZLD)

MEE System

Essential oil Distillation Plant

Steam operated Distillation
system
Caustic Recovery Plant
Multiple effect
evaporation plant

Plasticizer Technology
Turnkey Solutions

Process Equipment
Process Reactors
Pressure vessels
Storage vessels

Engineering Services
Process Engineering
Consultancy &
Services
Brownfield Verification
/ As-Built Process
AUTOCAD, PDMS
Drafting
Energy Audit
Evaporation Technology
Falling Film Evaporator (FFE) | Rising Film Evaporator (RFE)
Forced Circulation Evaporator (FCE) | Multiple Effect Evaporator (MEE)
Thermal Vapor Recompression (TVR) | Mechanical Vapor Recompression (MVR)
Short Path Evaporation / Distillation Unit (SPEU / SPDU)
Agitated Thin Film Dryer / Evaporator (ATFD / ATFE)
Evaporation Technology

Astrolex offers evaporation systems

for your product evaporation,
concentration or solvent recovery to
treat your heat-sensitive, viscous and
complex products.
Astrolex has expertise in design of Evaporation Evaporation technology is used in any
System that guarantees high process quality, process that requires concentration of a
resource conservation and the lowest possible stream by removal of water or other
operating costs. Our activities focus on the solvent. It is used extensively in processing
construction of new plants and the optimization of foods, chemicals, pharmaceuticals, fruit
existing plants and processes. Considering your juices, dairy products, paper and pulp, and
requirements, we develop a balanced concept that both malt and grain beverages.
brings investment costs and operating costs into an
efficient balance.
Falling Film Evaporator (FFE)

Gentle evaporation for heat-

sensitive products
The falling film evaporator is a type
of film evaporator which is used
most commonly because of its wide
operating range.
A Falling Film Evaporator (FFE) is a vertical
shell & tube type of heat exchanger with vapor-
liquid separator (VLS) mounted at the bottom.

The liquid to be concentrated is fed at the top of

heated tubes and distributed in a way that it
flows down on the inside surface of the tubes as
at thin film. The liquid distributor at the top
assures uniform liquid loading of all tubes. As
the film gets heated, the vapors generated flow
downwards through the tube bundle in co-
current with the concentrate. The drag of the
vapors increases the turbulence & improves
heat transfer performance. Subsequently, the
vapor phase is separated from the liquid phase
in vapor liquid separator (VLS).

Falling Film Evaporator

 Advantages: Applications:
• High heat transfer coefficients • Particularly suited for temperature-

• Short residence time on the heated tube surface sensitive products

• Can be used from smallest evaporation • Recovery of solvents & alcohols

capacities • For low viscous products
• Little space needed • Suited for products with low fouling
• Low pressure drop tendency

• Suitable for operation under high vacuum • Separation of multicomponent

• High evaporation ratios mixtures

• Concentration of starch products and
• Low susceptibility for fouling
derivatives in the starch industry
• Suitable for GMP applications
• Concentration of spent liquor in the
• Single pass or with recirculation
pulp industry
• Process vapors and liquid flow co-currently or
• Chemical industry
counter-currently
• Petrochemical industry
• Several evaporator stages are possible in one
apparatus • Polymer industry
Rising Film Evaporator (RFE)

Evaporation technology for

concentration of moderately heat-
sensitive liquids
The rising/climbing film evaporator is a
type of film evaporator which can
achieve moderate evaporation, suitable
for high viscosity and heat sensitive
materials.
A Rising Film Evaporator (RFE) is a vertical shell &
tube type of heat exchanger with vapor-liquid
separator (VLS) mounted at the top.

The rising film evaporator operates with the density

difference of liquid / liquid-vapor mixture inside the
tubes. The liquid to be concentrated is fed at the
bottom of heated tube bundle. As the liquid feed
receives the heat, the vapors generated lift the liquid
upwards. The vapor and balance liquid are
separated in vapor-liquid separator (VLS)

Rising Film Evaporator

 Advantages: Applications:
• Shorter residence time • Juice concentration & food processing
• High evaporation ratio • Polymer production
• Suitable for evaporation of a wide range of liquid • thermal desalination,
concentrations
• Pharmaceuticals
• High tube velocity minimizes fouling
• Solvent recovery
• System may be turned down without loss of
efficiency or effectiveness • Waste water & Effluent treatment

• Able to achieve high concentrations at low

temperatures
• Suitable for materials with higher evaporation
temperature
• Suitable for low to medium viscosities liquids
• Suitable for heat sensitive materials
• Suitable for foamy liquids & liquids with
suspended solids
Forced Circulation
Evaporator (FCE)

Forced Circulation Evaporator

with axial flow pump
experience reduced scaling
The forced circulation evaporator
is designed for liquids with a high
solids content, high viscosity &
tendency to foul.
A Forced Circulation Evaporator (FCE) has
Horizontal or vertical shell-and-tube heat
exchanger as the calandria, with flash
vessel/separator & a circulation pump for
circulation of slurry through the tubes. Use of
axial flow pump ensures good velocity in the
tubes with minimum power
requirement. Forced circulation leads to high
tube side velocities (6-18 ft/s), and hence
higher heat-transfer coefficients and smaller
heating surfaces. Boiling in the forced
circulation evaporator is suppressed in the
heat exchanger by backpressure and takes
place when the liquid enters the flash
vessel/separator.
Forced Circulation Evaporator
 Advantages: Applications:
• Suitable for highly viscous, scaling & salting • Spent wash from distillery
liquids
• Corn Steep Liquor
• Suitable for waste water with high suspended
solids • Liquids with high tendency of fouling

• Fouling is minimized due to high liquid velocities • Highly viscous liquids

& suppressed boiling in the tubes • Effluent Treatment Plants
• High tube side velocities can be achieved • Polymers
• Higher heat-transfer coefficients • Food products
• Easy installation and move, skid mounted with • Pharmaceuticals
small footprint
• Optimally suited as crystallizing evaporators for
saline solutions.
• Axial flow pump ensures good velocity in the
tubes with minimum power requirement
• Robust and reliable process
• Low energy consumption and minimum need of
maintenance
 Multiple Effect
Evaporator (MEE)

Multiple-effect evaporators (MEE)

maximize steam economy as
vapor generated from one effect
is used to heat another.
In large-scale industrial production, it MEE system is perfect for continuous feed
is often necessary to evaporate a applications, as fluids are progressively
large amount of water which requires reduced in each effect to final concentration
a large amount of energy to heat discharge.
water to produce steam. To reduce Comparison of evaporator steam economies
the consumption of heating steam, Steam Economy, kg water
multi effect evaporator can be used. Type of Evaporator evaporated/kg steam
Single-effect 0.90–0.98
The multiple-effect configuration combines two or
Double-effect 1.7–2.0
more evaporator bodies to conserve steam. Water
evaporated in the first-effect vapor body is Triple-effect 2.4–2.8

condensed in the second-effect heat exchanger, Triple-effect with TVR 4–8

which provides energy for evaporation in the
second-effect vapor body (and so on for additional
effects).

Multiple Effect Evaporator (MEE)

 Advantages:
• Ability to maximize usage of input energy
(steam economy)
• Reduced energy required to run full system
• Reduced condensing load with additional effects
(less cooling water needed)
• Liquor flow control
• Convenient foul condensate collection
and processing
• Ability to do online cleaning of individual effects
• Maximum thermal efficiency with concurrent
flow option
Applications:
• Industrial effluent treatment
• Brine liquid concentration
• Recovery of metal salts
• Concentration of pharma and textile
effluent
• Pharma product concentration
• Concentration of RO reject till saturation
of salts in dissolve liquid
• Secondary treatment
• Dairy industry for milk evaporation
• Fruit and tomato juice concentration
Thermal Vapor
Recompression (TVR)

Thermal vapor recompression Below table represents steam consumption for

double effect with & without TVR
(TVR) gives the same
Configuration lb/hr of 85 lb water evap./
steam/energy saving as an psig Steam lb Steam
additional evaporation effect. Double Effect 12,800 1.94

Double Effect 8,540 2.90

TVR uses ejector to recover the with TVR

secondary steam, reduces the system

requirement for fresh steam and Comparison between MVR & TVR
achieve energy saving performance.
Parameter Multi effect MEE with MEE with
A fraction of process vapor from the first effect evaporation TVR MVR
(MEE)
evaporator is recycled & recompressed in a steam Capital Medium Medium Relatively
jet ejector (TVR) to raise the temperature and investment high
Operating High Medium Low
pressure of the vapors. The motive steam mixes
cost
with this portion of the vapors generated from the Electrical Low Low High
first effect evaporator. The resultant vapors (motive energy
Thermal High Low Low
steam plus vapors from the first effect) is used to energy
heat the first evaporation stage thus reducing the
system requirement for fresh steam and achieving
energy saving performance. This motive steam
portion is transferred as excess vapor to the next
effect or to the condenser. The energy of the
excess vapors approximates the energy of the
motive steam quantity used.

Thermal vapor recompression (TVR)

 Advantages: Applications:
• TVR has no moving parts and are therefore not • Beverages and Food industry
subject to wear and tear. (evaporation of whey, milk and sugar
• Maximum operational reliability. solutions)

• Most energy efficient evaporation technology • Chemical industry (evaporation of

• One-time investment of TVR is much lower than
that of MVR
• Almost no fresh steam & cooling water
consumption
aqueous solutions)
• Salt Works industry (evaporation of saline
solutions)
• ZLD (concentration of waste water)

• At the same evaporation rate, an evaporator

with TVR system uses 36 % lesser steam & 36
% lesser water compared to straight steam
evaporator
• Evaporator equipped with TVR uses less
heating surface than straight steam system
• Simple and effective design
Mechanical Vapor
Recompression (MVR)

MVR reuses the secondary

steam to heat the raw materials.
MVR achieves vapor compression
through mechanically driven
equipment such as blowers or
compressors to increase the energy
of the secondary steam and reuse it
to heat the raw material, so as to
recover the latent heat of the
secondary steam.
The secondary steam produced by the
evaporator will be compressed by the
centrifugal blower or centrifugal compressor
thus increasing its pressure and is sent to the
heating chamber of the heat exchanger to heat
the raw material. Therefore, the latent heat of
the steam is recovered and utilized.
Mechanical vapor recompression (MVR)
 Advantages:
• The evaporation capacity is up to 0.5t/h ~ 100t/h
• MVR requires almost no additional steam and
cooling water during steady operation
• MVR is the most energy efficient system for
evaporation
• MVR can work with any kind of evaporator,
including falling film evaporators, forced circulation
evaporators & Rising film evaporators
• The system only uses electricity without steam,
and the energy consumption of evaporation for
per ton of water is 15KW.h to 100KW.h, the
running cost is much lower
• MVR has low energy consumption
• MVR has a higher performance coefficient
• MVR places a reduced load on the cooling tower
• MVR simplifies the evaporation process and thus
plant operation
• Compact structure, small footprint
Disadvantages:
• One time investment is much higher
than traditional multi effect evaporator
• The compressor/blower cost will
account 30% cost in MVR system
• For some area with high price electricity
but lower price steam, MVR evaporator
economic advantage is not obvious.
TVR evaporator system is
recommended.
Applications:
• Industrial wastewater treatment discharge
concentration
• Chemical industry for evaporation,
crystallization, and purification
• Salt brine concentration
• Beverage industry (milk, juice, sugar, etc.)
concentration
• Food industry (MSG, soy, protein, sugar)
concentration
• Pharmaceutical industry (medicines,
vitamins) concentration
Short Path Evaporation /
Distillation (SPDU)
Best solution for molecular
distillation and purification of
extremely heat-sensitive
substances and products with very
high boiling point, under extreme
vacuum conditions.
Short path evaporation / distillation is a
thermal separation technique that
provides minimal pressure drop,
permitting deep vacuum operation down
to 0.001 mbar.
Short path evaporation is also called molecular
distillation while a short path evaporator is sometimes
known as an SPE or SPDU (short path distillation
unit). The short path evaporator (SPE) is specifically
well suited for distillation, evaporation, concentration
and stripping of heat sensitive products.
The rotor blades creates a mechanically
agitated, thin product film on the heating
surface inside of the body. By means of
gravity the product flows down in a spiral path,
whereby the volatile portion of the product
evaporates. The vapor passes by the shortest
route and with practically no pressure drop to
the internal condenser.
The cage-type construction and location of the
internal condenser create a short vapor flow
path or “short path”, extending the operating
pressure capability from 1 mbar to 0.001 mbar
compared to a standard thin-film evaporator.
The distillate and the remaining liquid
concentrate (Residue) drain out through
separate outlets at the bottom of the unit.

The unique combination of evaporation and

condensation in extreme proximity permits the
operation of the Short Path Evaporator with a vacuum
up to 0.001 mbar (a). This operating range is
unchallenged by any other type of evaporator.

Working:
The short path evaporator consist basically of a
cylindrical body with a heating jacket, a rotor and an
internal condenser. The rotor cage assembly
surrounds an internal condenser and revolves at
moderate speeds. Feed enters through a nozzle at
the top of the unit and is spread into a thin film on the
inside surface of the shell via the rotor blades

SPEU / SPDU
 Advantages:
• Continuous distillation process
• Very low operating pressures possible (up to
0.001 mbar)
• Residence time of few seconds, important for
heat sensitive products.
• High evaporation rates
• Low fouling on evaporator wall
• Suitable for viscous products.
• Excellent turn down capability.
• Low power requirements.
• Compact design
• Operating at very high temperature 300°F to
650°F (149°C to 343°C).
• High heat and mass transfer performance
• The rotor increases the turbulence of
the product, rising greatly the process
side heat transfer coefficient, even
with viscous fluids
• Rotor induced shear decreases the
viscosity of some products
• One-trough operation so very low
liquid hold-up
• Rapid surface renewal
Applications:
• Chemical & Agrochemical Industry
• Oils, Fats and Food Industry
• Salt brine concentration
• Pharmaceutical Industry
• Petrochemical Industry
• Polymers Industry
• Fragrances and Flavors Industry
• Environmental care
Agitated thin Film Dryer /
Evaporator (ATFD / ATFE)
Best solution for Highly Viscous,
Heat sensitive, Fouling & High
Boiling point liquids.
Due to its inherent design features,
ATFD/ATFE is ideal for thermal treatment
of solutions that are highly viscous
(viscosities of several million centipoise),
heat sensitive, fouling & high Boiling
products, where reduced operating
temperatures and vacuum operating
pressures are desirable.
An Agitated Thin Film Dryer / Evaporator (ATFD/ATFE),
also known as Thin Film Evaporator (TFE) or Wiped
Film Evaporator (WFE). They are mainly used for
difficult vaporization and heat exchange processes,
especially where products to be handled are highly
viscous and conventional plants can no longer meet
user demands because heat transfer is insufficient. Due
to the liquid film, mechanically generated on the heating
surfaces, thin film equipment achieve much better heat
transfer rates, even with highly viscous products
containing solids.
The Feed enters the dryer at its top which is
then evenly distributed by the rotor and its
blades over the heating surface, forming a
thin liquid film of uniform thickness. Highly
turbulent swirls are produced at the tip of the
rotor blades with intensive mixing and
agitation of the product, as it comes into
contact with the heating surface. This assures
excellent heat transfer combined with
constant renewal of the product film and
provides an even heating and short residence
time of the feed through the heated zone. The
feed starts evaporating once it is heated to its
Boiling point. The generated vapors flow
counter currently and get cleaned by an
integrally mounted entertainment separator
while the final solid product is discharged by
gravity at the bottom of the dryer.

Working:
The typical Agitated Thin Film Evaporator consists of
a tubular heat transfer area with an external heating
jacket and a fast-revolving, inner rotor with rows of
blades all over the length of the dryer. The hinged
blades spread the wet feed product in a thin product
layer over the heated wall and mix the product layer
material intensively. Therefore the volatile
components evaporate continuously from the product
layer with high evaporation rates. The hinged blades
are designed with a minimum gap to prevent fouling of
the heating surface by product, but are never in
contact with the heated wall. ATFD / ATFE
 Advantages:
• Residence time of a few seconds with a
narrow spread
• Excellent turn down capability • No dead zone, therefore overheating
prevented and perpetual high product
• Low product holdup, ideal of hazardous quality guaranteed
applications
• High Heat Transfer Coefficient value (U
• Designed to give solid powder with value) even when working with highly
moisture content around 5-10% viscous and contaminated products
• Widely accepted by pollution control board
norms Applications:
• Continuous operation
• Wastewater & Sludge treatment
• Less maintenance
• Purification & Drying of Petrochemicals &
• Easy to start, operate and shut down Organic Chemicals
• Low pressure drop • Solvent Recovery
• Operation under low vacuum • Concentration of Natural Extracts &
Pharma Products
• Evaporation ratios up to > 95% without
recirculation • Concentration & Crystallization of Inorganic
Salts
• Able to process products with high
viscosities • Concentration & Devolatilizing of Polymers
(Resins, Fibers, Plastics)
• Able to process systems that form deposits
• Oil Recovery & Refining
• Easy to clean (CIP)
• Concentration and Purification of Fertilizers
• Required evaporation is achieved in a
single pass, avoiding product recirculation • Concentration and Purification of
and possible degradation agrochemicals
• Scale formation on the heat transfer
surface is reduced due to the intense
agitation of the liquid film
Astrolex Industries Pvt. Ltd. Works
Plot- 308/6
G.I.D.C Makarpura
Vadodara-390010, Gujrat, India

Sales & Technical Office

E-304, Siddharth Samanvay Towers
Old Chhani Road, Behind TVS Showroom
Vadodara-390024, Gujrat, India

Email: astrolexindustries@gmail.com
Cell no: +91 7990862428
Web: www.indiamart.com/astrolexindustries/