TURBOFLASH: The Evolution in vacuum evaporation for ZEWATECH’s wastewater treatment
At ZEWATECH, our mission is to develop advanced technological solutions for the treatment of industrial wastewater. We specialize in creating high-efficiency equipment that allows companies to reduce their environmental impact and optimize resource use. Since our inception, we have continuously sought to innovate, and our commitment to sustainability and energy efficiency has led us to lead the market with products such as TURBOFLASH.
1. Operation and technology of theZEWATECH’s TURBOFLASH:
The systemTURBOFLASHdesigned and manufactured byZEWATECHarises from the need to solve the problems and limitations of conventional mechanical vapor compression (MVC) equipment, being the most efficient wastewater treatment systems byvacuum evaporationcurrently marketed. They are based on the same operating principle, where steam is generated cyclically by a feedback system.
To start the process, external heat energy is supplied to the wastewater in question, contained in a boiling tank, until the saturation point of the product is reached and its evaporation is caused. The steam pressure is increased by a high-efficiency blower, thus generating a sufficient temperature difference between the compressed steam and the product to be treated that allows the energy exchange between both fluids by using a heat exchanger. By taking advantage of the latent heat provided by the steam during its condensation process, it is possible to evaporate an amount of water of the same mass value, which will be reintroduced into the blower, thus generating a closed evaporation cycle without the need to provide thermal energy and guaranteeing high energy efficiency.
The result obtained is a concentrated product, because a large part of the water has been extracted as a result of evaporation, and a distillate free of any contaminant with a boiling point lower than that of water.
The systemTURBOFLASHdesigned and manufactured byZEWATECHarises from the need to solve the problems and limitations of conventional mechanical vapor compression (MVC) equipment, being the most efficient wastewater treatment systems by vacuum evaporation currently marketed. They are based on the same operating principle, where steam is generated cyclically by a feedback system.
To start the process, external heat energy is supplied to the wastewater in question, contained in a boiling tank, until the saturation point of the product is reached and its evaporation is caused. The steam pressure is increased by a high-efficiency blower, thus generating a sufficient temperature difference between the compressed steam and the product to be treated that allows the energy exchange between both fluids by using a heat exchanger. By taking advantage of the latent heat provided by the steam during its condensation process, it is possible to evaporate an amount of water of the same mass value, which will be reintroduced into the blower, thus generating a closed evaporation cycle without the need to provide thermal energy and guaranteeing high energy efficiency.
The result obtained is a concentrated product, because a large part of the water has been extracted as a result of evaporation, and a distillate free of any contaminant with a boiling point lower than that of water.
2. Benefits and Applications
The systemTURBOFLASHrepresents a major technological advance over conventionalMVCsystems in virtually all fields of vacuum evaporation equipment.
Greater efficiency
ZEWATECHguarantees the lowest operating costs available in the vacuum evaporation market thanks to the use of high-efficiency blowers that represent a saving in electricity consumption of up to 66% compared to conventionalMVCsystems
Lower maintenance cost and use of consumables
The high speed of the product to be treated achieved inside the exchangers with the use of high-flow pumps, adapting the minimum temperature differences and the flash vessel system, represent a drastic reduction of the generated incrustations and consequently, of the cleaning periods. In this way, the use of anti-scaling and descaling consumables, labor cost, and equipment downtime periods are minimized.
Greater versatility in application fields
The main limitation of the use of conventionalMVCsystems, is the presence of volatile elements in the waters to be treated with corrosive effects for the blower. The blower used in theTURBOFLASHsystems is entirely made of 316L stainless steel, so it is capable of covering a much wider range of possibilities than conventional MVC systems.
ZEWATECHalso has a wide range of materials for the manufacture of equipment and boiler making in direct contact with the product to be treated, the most common being 316L stainless steel, SAF 2507 stainless steel, SAF 2707HD stainless steel, 254 SMO stainless steel or titanium, so there is hardly any limitation in working with aggressive products.
3.TURBOFLASH, the evolution of conventional MVCs:
TheTURBOFLASHequipment can treat practically any type of water, as long as the viscosity and density of the product are suitable for pumping.
Among some of the applications NOT SUITABLE for conventionalMVCsystems, but that can now be treated withTURBOFLASHare:
- Waters with the presence of aggressive volatiles.
- Waters with high contents of corrosive salts.
- Waters with significant increases in the boiling point.
4.SUCCESS CASE: Implementation of the TURBOFLASH System in the Biogas Plant of SELECCIÓ DESEURAS SL
Recently,ZEWATECHhas carried out a notable project at the biogas plant ofDESEURAS, where they faced a significant challenge with the treatment of digestate. After going through centrifugation, physicochemical treatment and ultrafiltration processes, the resulting concentrate still contained high levels of ammonia and other substances that made it unsuitable for discharge into the environment.
DESEURAScontactedZEWATECHlooking for an efficient solution to this problem. Initially, several proposals were evaluated, but they were discarded due to the high contents of ammonia in the water. This is where theTURBOFLASHtechnology showed its true potential.
Thanks to theTURBOFLASHsystem, ammonia was no longer an obstacle. This technology allows the separation of ammonia in the form of ammoniacal gas, turning a problem into a significant advantage. The stripping process of the ammonia contained in the liquid fraction of the digestate is carried out efficiently, allowing its elimination and improving the quality of the treated effluent.
To validate the proposed solution,ZEWATECHcarried out a pilot test for three weeks at theDESEURASfacilities with a pilot plant. The results were thoroughly analyzed, and the viability of the project was demonstrated tangibly. With these results in hand, the client accepted the technological challenge of theTURBOFLASH.
Since its implementation, theTURBOFLASHsystem has exceeded all expectations at the biogas plant ofDESEURAS. The results have been exceptional both in terms of energy cost and operational performance. An efficient separation and elimination of ammonia has been achieved, far exceeding the project’s objectives.
This success has marked a turning point in the treatment of digestates, not only at theDESEURASplant, but in the general handling of these liquid fractions. Now, the treated wastewater can be reused for irrigation or directly discharged into the environment, with concentrates that can be valued as by-products, including ammonia.
TheTURBOFLASHsystem fromZEWATECHrepresents a significant advance in the treatment of industrial wastewater, offering greater efficiency, lower maintenance costs, and superior versatility in its applications. If your company faces challenges with wastewater treatment and is looking for advanced and efficient solutions, theTURBOFLASHmay be the answer.
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