10 ways to improve your bio-based chemical plant – Alfa Laval

8. Design your evaporation system for maximum benefit

Evaporation is used in many bio-based chemical plants and is often the position which consumes the most energy. Choosing the right evaporation system not only minimizes energy consumption, but also reduces investment costs and improves product quality.

Minimize energy consumption

Energy costs is a major part of most chemical producers’ budgets. As energy prices are predicted to rise over time, it is crucial you make sure your plant is as energy efficient as possible to stay competitive.

There are several different ways to reduce energy consumption in an evaporation system, for example by using multiple effect evaporation, thermal or mechanical compressors and preheating with waste heat from the evaporator itself or other process steps.

When designing an evaporation system, you need to balance the costs and savings that come with different options. Adding more effects saves operating costs but means you need to invest in more equipment. Mechanical compression of the vapour comes at a lower operating cost than thermal compression but the investment cost is higher.

We are glad to help you design the optimal evaporation system for your plant. We analyse a number of factors such as production rate, product price and steam cost to work out the perfect balance between investment and operating costs from a lifecycle perspective.

Reduce investment costs

Where other solutions need several floors, lots of piping and large recirculation pumps, the low height of the AlfaVap system makes it possible to install in one floor with small pumps (or even without). This results in significantly lower installation, building and equipment costs.

Improved product quality

The low hold-up volume in the AlfaVap system means the product has a short residence time in the evaporation system. This minimizes product degradation due to high temperature and secures high quality for the end product.

The low hold-up volume also ensures fast and smooth start-up and easy process control.

Recycle the condensate

Running the condensate through a membrane filtration system makes it possible to reuse it as process water, thereby cutting both costs and environmental impact.