2t/h ammonium sulfate MVR evaporation crystallization system for fine chemical industry

I.Project Background

High-concentration ammonium sulfate wastewater is often generated during fine chemical production processes. Direct discharge of this wastewater will cause serious environmental pollution and result in the loss of valuable ammonium sulfate resources. Conqinpi's fine chemical client's production line generates a large amount of ammonium sulfate mother liquor daily, requiring urgent treatment and placing extremely high demands on operating costs, system stability, and resource recovery rates.

II.Solution

Addressing the client's pain points, Conqinphi customized a 2-ton/hour ammonium sulfate MVR evaporation crystallization system. The core of this solution is the use of MVR (Mechanical Vapor Recompression) technology, an advanced process, to achieve efficient, energy-saving, and environmentally friendly wastewater treatment and resource recovery.

III.System Core Advantages

1.Extreme Energy Saving, Significantly Reduced Operating Costs：Compared to traditional multi-effect evaporators, the core advantage of the MVR system lies in its significantly lower energy consumption. The system uses a compressor to compress the secondary steam generated during evaporation, increasing its temperature and pressure before reusing it as a heat source for the system. This system recovers the latent heat of steam, significantly reducing the amount of fresh steam needed for replenishment. Operating energy consumption is only one-third to one-quarter of that of traditional evaporators, bringing substantial economic benefits to customers.

2.High-efficiency crystallization for high-purity ammonium sulfate recovery: The system is specifically designed for the physicochemical properties of ammonium sulfate. By precisely controlling supersaturation, circulation flow rate, and crystallization residence time, it cultivates uniformly sized, high-purity ammonium sulfate crystals within the crystallizer. The recovered ammonium sulfate can be sold as an industrial raw material or reused in production processes, truly turning waste into treasure and creating additional economic value.

3.Automated operation, stable and reliable: The entire system adopts an advanced PLC/DCS control system, achieving fully automated control from feeding, evaporation, crystallization to discharging and cleaning. The system can automatically adapt to fluctuations in operating conditions, ensuring long-term stable operation, significantly reducing the intensity of manual operation and intervention risks, and guaranteeing the uniformity of product quality.

4.Compact design, small footprint: The MVR system has a compact structure and a high degree of integration, maximizing processing capacity within limited plant space and saving customers valuable land resources.

5.Green and Environmentally Friendly, Achieving Cleaner Production：This system successfully transforms high-concentration ammonium sulfate wastewater into clean condensate and valuable crystals, fundamentally solving environmental problems and helping customers achieve green, sustainable, and clean production goals, enhancing their corporate image and social responsibility.

IV. System Process Flow Introduction

1.Feeding and Preheating: After filtration, the raw liquid enters the heat exchange network, undergoing multi-stage heat exchange with the system's condensate and finished liquid, fully recovering waste heat.

2.MVR Evaporation: The preheated material enters the evaporator and boils under vacuum conditions. The generated secondary steam is compressed by a high-efficiency compressor, becoming a high-quality heat source, and returned to the heating chamber to continuously heat the material, forming an energy cycle.

3.Crystallization and Growth: The concentrated supersaturated solution enters the crystallizer, where, under controlled conditions, ammonium sulfate molecules precipitate and grow in an orderly manner, forming standard crystals.

4.Solid-Liquid Separation and Packaging: The crystal slurry is pumped to a centrifuge for dehydration to obtain wet ammonium sulfate, which can then be dried and packaged as the final product. The mother liquor is returned to the system for further evaporation and crystallization.

5.Condensate Reuse: The condensate generated during the evaporation process, after further treatment, can be reused as high-quality process water, achieving water resource recycling.

V.Project Achievements and Customer Value

Since the commissioning of this 2t/h ammonium sulfate MVR evaporation crystallization system, it has operated stably and efficiently:

1.Economic Benefits: Annual savings of over one million yuan in steam consumption costs, and significant revenue generated from the recovery of ammonium sulfate products.

2.Environmental Benefits: Achieves near-zero wastewater discharge, reducing COD emissions by tens of tons annually, fully complying with national environmental regulations.

3.Operational Benefits: High degree of automation, requiring only one person to monitor and operate, convenient management, and significantly improved production continuity.

The success of this project not only solved the environmental and cost challenges for the customer but also became a benchmark case for the resource-based treatment of high-salt wastewater in the fine chemical industry, fully demonstrating Conqinphi's strong technical strength and engineering capabilities in the field of high-difficulty industrial wastewater treatment.

We are committed to providing customized evaporation crystallization solutions for the chemical, pharmaceutical, and environmental protection industries. If you have similar needs, please contact us to create value together!