FC Crystallizer MVR Evaporator 3T / Hr For Potassium Chloride Project
Engineer-to-order MVR (Mechanical Vapor Recompression) evaporator integrated with an FC (Forced-Circulation) crystallizer for potassium chloride (KCl) concentration and crystal production. The train is sized for a nominal 3 t/h water removal, delivering stable supersaturation control, narrow crystal size distribution, and low OPEX for potash brines and carnallite conversion lines.
- Energy saving: Electric-driven vapor recompression minimizes fresh steam after start-up.
- Crystal quality: FC loop stabilizes supersaturation and residence time for tight KCl PSD.
- Scaling mitigation: High-velocity circulation maintains coefficients and limits deposition.
- Process flexibility: Handles sylvinite/carnallite liquors; integrates with flotation or hot-leach routes.
- Automated uptime: PLC/HMI recipes, alarms, historian, and remote diagnostics for 24/7 operation.
Potash brine is purified and concentrated under vacuum in the MVR body. The forced-circulation crystallizer runs at controlled slurry density and ΔT/LMTD; recompressed vapor provides the primary duty, achieving low specific energy while promoting predictable KCl crystallization and clarity.
Wetted parts in SS316L/duplex (Ti/Hastelloy on request) for chloride-rich brines. Drainable layouts, large clean-outs, and validated CIP extend campaign length and simplify turnarounds.
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Brine polishing: clarification/filtration; Mg/Ca control as required.![]()
- MVR evaporation (vacuum): compressor discharge sets ΔT; shell pressure defines boiling point.
- FC crystallization: seed addition; slurry density and residence time tuned for target PSD.
- Solid-liquid separation: pusher/peeler centrifuge; mother liquor recycle to circuit.
- Drying & sizing: fluid-bed/vibratory drying; screens for granular grades.
- MVR evaporator (falling film / forced circulation) with vapor-liquid separator
- Mechanical vapor compressor (turbo/Roots) with VFD for ΔT/capacity control
- FC crystallizer with circulation pump, draft tube/heat exchanger, slurry density control
- Surface condenser, vacuum/NCG handling, preheaters/heat-recovery HX
- PLC/HMI/SCADA; instruments (T/P/flow/cond/level/solids); CIP skid and antiscalant dosing
| Parameter | Typical Target / Range* |
|---|---|
| Evaporation rate | 3 t/h (water removal), adjustable via compressor VFD |
| Operating mode | Vacuum, continuous |
| KCl purity (dry) | ≥ 98-99% (feed-dependent, with proper purification) |
| Crystal size bands | Fine 0.3-0.6 mm; Standard 0.6-1.0 mm; Coarse 1.0-2.0 mm |
| Electric use (MVR) | ~15-40 kWh per ton H₂O evaporated (duty/CR dependent) |
| Fresh steam demand | Very low after start-up (backup/ancillary only) |
| Materials | SS316L / duplex; Ti/Hastelloy on request |
Can the line process carnallite liquors?
Yes--flowsheets can include Mg control and hot leach steps; the FC crystallizer is tuned for KCl selectivity and PSD.
How do you control scaling?
Optimized ΔT/velocity, antiscalant dosing, and scheduled CIP maintain heat-transfer coefficients and crystal purity.
Can we integrate with existing flotation/drying?
Yes--the MVR+FC module ties into upstream purification and downstream centrifuge/dryer/screening with minimal retrofit.
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