LOW TEMPERATURE EVAPORATION TECHNOLOGY

(RECYCLINGOFWASTEWATERTOCLEANWATER)

VIVEK VERMA
SPRAYENGINEERING DEVICES LIMITED

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 MISSION

Dedicated for Sustainable Environment Development

to Unlock Perpetual Food and EnergyResources.

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CURRENTEVAPORATIONSCENARIO

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MVR BASEDEVAPORATIONSCHEME

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CONVENTIONALZLDIN ELECTROPLATINGINDUSTRY

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 CONTEMPORARYTREATMENTSOLUTION

Replaced by
LowTemperature
Evaporator

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CONTEMPORARYTREATMENTSOLUTION

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 FACTORSGOVERNING ENERGYINPUT TO
EVAPORATION PROCESSAND ALTERNATIVE
SOLUTION
Evaporation possible at any
Temperature from 100C onwards
to avoid Feed Water Heating

U A ΔT
Heating Surface Area and
Temperature difference affects
Significant Energy Cost

Mechanical Vapour Recompressor

(MVR) is used for recycling enthalpy
& upgrade steam to eliminate Fuel
Burning in the Boiler

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PLATEHEATEXCHANGERARRANGEMENT

Solution side

Vapour flow path

Looking into the tube side flow direction

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WASTEWATER LOWTEMP.VAPOURS CLEANWATER NCG

10
 Compressed Vapour In

Vapor Out

Clean Water Out

Wastewater In

Feed Out

NCG

Heating Medium

MVR

Vacuum Pump

PHE

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LOW TEMPERATUREEVAPORATORPLANTS

Horizontal Type

Vertical Type
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LOW TEMPERATUREEVAPORATOR
(BASEDON MVR TECHNOLOGY)

All-in-one Combination of Plate Heat Exchanger +

Vacuum + MVR in a small foot print design delivers the
higher evaporation capacity as compared to other
Conventional design Evaporators.

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LOW TEMPERATUREEVAPORATIONTECHNOLOGY

• No need of steam generation unit, heat reject units & chemicals

• Minimal electric energy demand
• Electrical power consumption lower than any alternative technology
• Recovery of energy in the form of Bio-Gas in case of organic wastewater
• Recovery of nutrients in the form of Bio-Fertilizer in case oforganic wastewater
• 90 – 99 %recovery of water of highest quality
• Decentralized water recycling solution
• Small footprint, closed, compact and environment friendly
• Suitable for integration with district cooling, heating and recovery of deficit water to
make zero fresh water intake
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ADVANTAGES
Low operational and capital cost

Smaller foot print area

Compact and light weight

Lower maintenance cost and easy operation

Suitable to concentrate wide variety of liquor

High product quality due to precise control of parameters

Minimal manpower requirement andecofriendly

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FULLYAUTOMATICSYSTEM

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PROJECT– KUANTUM PAPERSINDUSTRY

Project Name : Kuantum Papers Ltd.

Location : Hoshiarpur, Punjab
Industry Type : Paper Industry
Equipment installed : Low Temperature Evaporator
with Stripper Column
Capacity : 1 Ton/hr.
Inlet Feed : Raw Effluent

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PROJECT– KUANTUM PAPERSINDUSTRY

RAWEFFLUENT/FEED RECOVEREDWATER/CONDENSATE REJECT/CONCENTRATE

Parameter Feed Condensate Reject

TDS(ppm) 6,660 17
52% Solid
TSS(ppm) 461 20
COD(ppm) 2,840 48 256,000

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PROJECT– ECOTECHPAPERINDUSTRY

Project Name : Eco TechPaper

Location : Guwahati, Assam
Industry Type : Paper Industry
Equipment installed : Low Temperature Evaporator
Pilot Plant Capacity : 1 Ton/hr.
Ongoing Plant capacity : 20Ton/hr.
Inlet Feed : Back Water

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PROJECT– ECO-TECHPAPERINDUSTRY

RAWEFFLUENT/FEED RECOVEREDWATER/CONDENSATE REJECT/ CONCENTRATE

Parameter Feed Condensate Reject

TDS(ppm) 30,000 47 720,000

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PROJECT– NAINI PAPERINDUSTRY

Project Name : Naini Papers Ltd.

Location : Kashipur, Uttarakhand
Industry Type : Paper Industry
Equipment installed : Low Temperature Evaporator
Plant capacity : 20 Ton/hr.
Inlet Feed : ROReject

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PROJECT– TEXTILEINDUSTRY,ERODE

Project Name : Uranuss Bleachers

Location : Erode, Tamilnadu
Industry Type : Textile Industry
Equipment installed : Low Temperature Evaporator
Capacity : 1 Ton/hr.
Inlet Feed : Raw Effluent/RO Reject

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PROJECT– TEXTILEINDUSTRY

RAWEFFLUENT/FEED RECOVEREDWATER/CONDENSATE REJECT/CONCENTRATE

RAW EFFLUENTASINLET FEED ROREJECTASINLETFEED

Parameter Feed Condensate Parameter Feed Condensate
TDS(ppm) 7,120 20 TDS(ppm) 65,000 12
TSS(ppm) 126 0 COD(ppm) 1,336 6
COD(ppm) 926 2.1
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ANALYSISREPORT– TEXTILEINDUSTRY

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PROJECT– BIOMETHANATIONPLANT

Project Name : Spectrum Renewable Energy

Pvt. Ltd.
Location : Kolhapur, Maharashtra
Industry Type : Biomethanation/Distillery
Equipment installed : Low Temperature Evaporator
Capacity : 1 Ton/hr.
Inlet Feed : Spentwash

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PROJECT– BIOMETHANATIONPLANT

RAWEFFLUENT/FEED RECOVEREDWATER/CONDENSATE REJECT/CONCENTRATE

Parameter Feed Condensate Reject

TS(ppm) 130,000 64 650,000

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ANALYSISREPORT– BIOMETHANATIONPLANT

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PROJECT– MUNICIPAL LANDFILLLEACHATE,GURUGRAM

Project Name : Municipal Corporation

Location : Gurugram, Haryana
Industry Type : Municipal Waste
Equipment installed : Low Temperature Evaporator
Capacity : 1 Ton/hr.
Inlet Feed : Municipal Landfill Leachate

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PROJECT– MUNICIPAL LANDFILLLEACHATE,GURUGRAM

RAWEFFLUENT/FEED RECOVEREDWATER/CONDENSATE REJECT/CONCENTRATE

Parameter Feed Condensate

TDS(ppm) 24,500 39
BOD(ppm) 9,343 5
COD(ppm) 16,800 24

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ANALYSISREPORT– MUNICIPAL LANDFILLLEACHATE,GURUGRAM

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OTHERPROJECTINSTALLATIONS

Megaline Enterprises, Ludhiana Crest Cellulose Pvt. Ltd., Hyderabad Mornisa Bio-Organics Pvt. Ltd., Maharashtra
(Dyeing Industry) (A unit of Aurobindo Pharma) (Jaggery Industry)

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PROJECT- SUGARREFINERY,DUBAI

WORLD’S LARGESTEVAPORATOR OFHSA=34,000m2

AL– KHALEEJSUGARCO.,DUBAI
(WORLD’S BIGGEST SUGARREFINERY)
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ONGOINGPROJECTS

100 KLDSYSTEMFOREVELINE
INTERNATIONAL, LUDHIANA

500 KLDSYSTEMFORNAINI PAPERS

LTD., KASHIPUR

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ONGOINGPROJECTS

1000 KLDSYSTEMFORMEGALINEENTERPRISES,LUDHIANA
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OPERATIONALCOSTANALYSIS

For MEE based 1000 m3/day evaporation capacity For MVR based 1000 m3/day evaporation capacity
only: only:
• Power requirement = 10-12 kWh/ton of
evaporation • Power requirement = 10 kWh/ton of evaporation
• Steam requirement for 5-Effects System = 200
Ton/day
Utilities Price/Unit Total Total Price (₹) Utilities Price/Unit Total Total Price(₹)
requireme requireme
nt per Day nt per Day
Steam ₹1.0/kg of 200,000 kg 200,000
steam Power ₹6.0/Unit 10000 kW 60,000

Power ₹6.0/Unit 12,000 kW 72,000 NET OPERATIONAL COST 60,000/-

NET OPERATIONALCOST 2,72,000/- NET COSTOFWATEREVAPORATION 7-10 paisa/kg

NET COSTOFWATEREVAPORATION 27-30 paisa/kg

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COMPARISON
CONVENTIONAL
• Civil Capex is very high
• Chemical Treatment Required
• ETPrequired
• High degree of uncertainty in Recycle water quality
• Ultrafiltration required
• Multi stage ROplants are required
• High quantity of steam is required. In most cases
separate is required.
• Very large quantity of sludge is generated
• Man power dependence is very high(15-20)
• Opex cost is 220 Rs./Per kl
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ADVANCED TREATMENT
• Civil Capex is negligible
• No chemical Treatment
• ETPnot required
• No uncertainty in recycle water quality
• Ultrafiltration not required
• RO plants are not required
• Steam not required in MVRoperation
• Man power dependence is very less
• Negligible quantity of sludge is generated
• Opex cost is 70 Rs./Per kl
OTHERAPPLICATIONS

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PROTECTIONOFINTELLECTUALASSETS
Protections for Low Temperature Evaporator (i.e. Spray Electrical Dehydrator)
Innovation Patent:
Patent No.: Patent Application No. 201911010031
Titled: Method, Process and Apparatus for the Very Low Temperature Evaporation System
Design Patents:
Granted Design Patent Nos.: 271709, 267392 and 260427
Copyrights:
Granted Certificate Nos: : L-58366/2014 and L-75959/2018

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REFERENCES
S. No. PROJECTNAME APPLICATIONS CAPACITY (TON/HR.)
1. Megaline Enterprises, Ludhiana Dyeing-ETP Water 42
2. Eco Tech Paper Mill, Guwahati Paper-ETP Water 20
3. Naini Papers Ltd.,Kashipur ROReject 20
4. Chandpur Enterprises Ltd., Uttar Pradesh Paper-ETP Water 20
5. Eveline International, Ludhiana Hosiery-ETP Water 6
6. IOL Chemicals & Pharmaceutical, Barnala Sodium Lite 1
7. Kuantum Papers Ltd., Hoshiarpur Paper-ETP Water 1
8. Kamachiamman Bleachink, Erode Dyeing Effluents 1
9. Ananda Murgan, Erode Dyeing Effluents 1
10. Uranuss Bleachers, Erode Dyeing Effluents 1+1
11. TechAuto Private Ltd., Ludhiana Electroplating Effluents 1
12. Inulite Enterprises, Baddi Pharmaceutical 1
13. Technico Industries Limited, Gurugram Electroplating Effluents 1
14. Jyoti Textiles, Rajasthan Textile Effluents 2
15. Spectrum Renewable Energy Pvt. Ltd., Warna Spentwash 1
16. Vaibhav Textiles Industry, Erode Textile-Effluent 6
17. United Phosphorous Ltd., Gujrat ROReject 1
18. ©
Copyright Crest
Spray Cellulose
Engineering Pvt.Limited
Devices Ltd., Hyderabad Pharma-Effluent 1 39
 THANK YOU
www.sprayengineering.com
water@sprayengineering.com

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