Windsor Sathyam Separation Systems

1. Windsor Sathyam Separation Systems Jus Evaporate Your Wastewater problems & Relax Waste Water Evaporation System Using Polymeric Heat Exchangers

2. “The Zero Machine” Zero Steam Zero Corrosion Zero Scaling Zero Pretreatment Zero Maintenance Zero Discharge Free template from www.brainybetty.com

3. Windsor Mechanical Vapour Recompression Evaporation System Free template from www.brainybetty.com

4. About Conventional Evaporator • Very high operating costs • Economically Unfeasible. • Frequent cleaning/maintenance for descaling • High Downtime. Free template from www.brainybetty.com

5. Pitting on the metal surface due to corrosion even with expensive material of construction like titanium. • Replacement of Heat exchanger required periodically. • Continuous high additional investment. • Separate Steam System required. • Investment on boiler with additional operational and maintenance costs. • Water Wastage Through Boiler Blow down. Free template from www.brainybetty.com

6. Separate System for Condenser Cooling System : • Investment on cooling tower with additional operational and maintenance costs. • Huge water wastage in cooling tower Blow Down. Free template from www.brainybetty.com

7. MVR Evaporation System Operating Principle Free template from www.brainybetty.com

8. Sequence of Operation • Waste Water Pumped into the Evaporator kept under Vacuum created by a vacuum pump • Initially water is heated to 550C using steam (only for Start Up ). • Vapors formed (550 C) will be sucked through a mechanical vapor recompressor and discharged to the inside of the heat exchanger bags (made of polymeric material) with increased latent heat and temperature (57.50 C) Delta T - 2.50 C). Free template from www.brainybetty.com

9. Waste water is circulated outside the heat exchanger bags through circulation pumps. • Vapor inside the bag transfer the latent heat obtained from the vapor compressor to the circulating waste water andcondense inside the bags which will be recovered as pure water. Free template from www.brainybetty.com

10. This latent heat transferred is sufficient for continuous vapor formation and no more steam addition is required. • Waste water equivalent to the quantity of water recovered will be pumped into the evaporator vessel for continuous operation using a feed pump. Free template from www.brainybetty.com

11. Innovation Free template from www.brainybetty.com

12. The innovation in this technology is the use of polymeric film material for the heat exchanger construction instead of metal plates. Heat Transfer Coefficient of Various Materials. Free template from www.brainybetty.com

13. Benefits of the new Technology Free template from www.brainybetty.com

14. Operates under vacuum - In this condition the boiling of a liquid is very low (50 - 600 C) • Hence very low energy is required for vaporization. • Polymeric heat exchange surface. • Scaling can be avoided completely as the system can be operated at very low PH (5).This is not possible with conventional evaporator because metal corrodes in low PH water. • No corrosion - No expensive heat exchanger replacements Free template from www.brainybetty.com

15. The major advantage of the this technology is huge heat exchanger surface area can be incorporated into the system at a very low cost. Free template from www.brainybetty.com

16. Any Evaporation Design is based on the Equations given below: = k x A x T Pc = C x x T Where: = Evaporating capacity , K = Heat transfer coefficient A = Evaporative surface area , T=Temperature difference, Pc = Fan power consumption , C = Fan coefficient. The descriptive analogy of the equation - More the heat exchange surface area, less the delta T required and hence lesser the power consumption of the compressor ( Energy required for evaporator). I I Free template from www.brainybetty.com

17. Table(1) gives the detailed surface area requirement with temperature differences for a 250 cum/day evaporator capacity CAPACITY : 250 M3/DAY SURFACE AREA POWER CONSUMPTION • T 2000 2.5 75 kW 1500 3.33 130 kW 1000 5 180 kW 750 6.67 240 kW 500 10 370 kW Evaporator using metal heat exchanger can be designed only with minimum surface area because of huge investment costs.Hence the energy costs will also be very high. Free template from www.brainybetty.com

18. Industries & Applications Free template from www.brainybetty.com

19. Our plants are designed to the strictest safety and highest performance standards. We offer technology to the manufacturers of many chemical, dairy, food, and pharmaceutical products by supplying individual plants or engineering of complete processing lines. • The following is a partial list of those wastewater applications: • Textile Industries Wastewater. • Tanneries • Seawater Desalination • Chemical Process Industires • Distilleries • Breweries • Metal Treatment Industries • Ink & Printing • Pulp & Paper • Fuel IndustriesAnd many others…………. Free template from www.brainybetty.com

20. Why Polymeric Heat Exchangers ? Free template from www.brainybetty.com

21. Free template from www.brainybetty.com

22. Thickness Metal : 1mm Polymer : 0.44mm Efficiency of 0.04mm thick polymer is equivalent to Efficiency of 1mm thick Metal like SS. Cost – wise Cheaper. Free template from www.brainybetty.com

23. Advantages of Polymer Heat Exchanger Free template from www.brainybetty.com

24. Corrosion is completely avoided so it can be operated even at very low pH. • Scaling problems are reduced about 70 – 80% because polymer being a thin film, is not stationary. • Scaling occurs on static surface so possibilities of scaling is very less. Free template from www.brainybetty.com

25. Disadvantages of using Metal Heat Exchanger Free template from www.brainybetty.com

26. Corrosion problems Mechanical Vapour Recompression can also be used with metal Heat Exchanger but the problem is : (1) Design of evaporator is based on capacity Q, Q = K x A x delta T Where K = Constant, A = Heat Transfer area, delta T = Temperature Difference (2) Comparing the design of metal Heat Exchanger and Polymer Heat Exchanger Q = delta TA = delta TA Free template from www.brainybetty.com

27. Metal Heat Exchanger Polymer Heat Exchanger 20 = 10 x 2 A is fixed to be 2m due to area constrain 20 = 2 x 10 Area can be increased since space occupied is less More heat is required to bring about a temperature difference of 10oC Less heat required Cost – High Cost – Cheaper Assume Capacity = 20m3 Free template from www.brainybetty.com

28. The standard polymeric material used for the heat exchanger cartridge is suitable for a wide range of aggressive process streams. This advantage allows WINDSOR to utilize large surface areas even in extremely hostile environments. The direct benefit of the ability to use large surface areas is the reduction of both power consumption and capital cost. Additionally, the larger surface area and reduced pressure ratio make it possible to use a simple low-speed fan instead of a complex compressor, which further reduces the capital, operational, and maintenance costs. Free template from www.brainybetty.com

29. Contact Us Free template from www.brainybetty.com

30. M/s. Windsor Sathyam Separation Systems 61/2, U.R. Nagar, Park Road,Annanagar (W) Extn., Chennai - 600101. Tamilnadu. India. Phone : ++91 44 26151554 , 26153058 Fax : ++91 44 26153087 E-mail : info@windsorsathyam.com url : www.windsorsathyam.com Free template from www.brainybetty.com

31. The End Free template from www.brainybetty.com