Technologies

Conventional Evaporation
Technology

Our Approach

For maximum evaporation rates and reliable operation. As a specialist in plant engineering and thermal separation technology, we offer customized process solutions for various industries. In conventional evaporation technology, we utilize different evaporator types and process solutions to efficiently and reliably concentrate low-viscosity substances.

Our Solutions

Energy efficiency with high evaporation rates

Multiple Effect Evaporation Plants

In multi-effect evaporation plants, the vapor from the liquid medium is used to heat the subsequent stages. This significantly reduces the use of primary steam, allowing the plant to operate in a cost- and energy-efficient manner.

GKT manufactures its key components and special pressure equipment in Austria. In Gloggnitz, we focus on our falling-film evaporators and lamella production.

GKT has been a leading provider of the following falling-film concepts for years:

Single Effect Evaporation
Multiple Effect Evaporation
Technology combinations (forced circulation, rising film, etc.)

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Applications

How it works

While the first evaporation stage is heated with live steam, vapor from the previous stage is used to heat the heating surfaces in the subsequent stages. As the number of effects increases, the specific live steam input gets reduced.

The number of stages usually depends on the specified temperature effects. The temperature sensitivity of the medium, the maximum available heating steam pressure, and the cooling water temperature are further important parameters.

Applications

PULP INDUSTRY

Concentration of sulfite spent liquor, black liquor, lignosulfonates, bleachery wastewater
Recovery of spinning bath solutions from the fiber industry

GENERAL APPLICATION AREAS

Recovery of solvents and alcohol as well as recyclables
Separation of water, solvents, alcohols and multi-substance mixtures
Volume reduction of liquid-liquid-mixtures

OTHER INDUSTRIAL APPLICATIONS

Chemical Industry
Starch industry
Sugar industry
Wastewater

Advantages

Optimized energy consumption/costs
Highest evaporation rates possible
Ideal for substances with a higher boiling point rise
Improved condensate quality through condensate separation

Lower steam, cooling water, and CO₂ with electricity-based evaporation

Mechanical Vapor Recompression (MVR)

In mechanical vapor recompression, an electrically driven compressor compresses the vapor and utilizes it for heating the evaporator. Depending on the requirements, single-stage or multi-stage turbo compressors are used.

MVR enables a significant reduction in a plant‘s CO2 footprint if electricity from renewable sources is used. Additionally, the system stands out with exceptionally low operating costs and minimal cooling water requirements.

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Applications

How it works

Process steam (vapor) is compressed by an electrically driven compressor, its temperature and thus energy level is raised, and finally reused to heat the evaporator.

Depending on the application (boiling point increase, heat transfer) single-stage or multi-stage turbo compressors work on the principle of an open heat pump.

Applications

Pre-evaporation of black liquor
Sulfite liquor
Solvent recoveries
Lactic acid
Starch
Alcohols
Chemicals
Wastewater

Advantages

Reduced demand of live steam and cooling water
Significantly reduced operating costs in many cases
CO2 savings through electrical energy as the main energy source
Gentle evaporation temperature
Reuse of low-pressure steam possible

Lower live steam and cooling water with steam-based evaporation

Thermal Vapor Recompression (TVR)

Thermal vapor recompression (TVR) is based on the same principle as the mechanical alternative (MVR) but uses only a portion of the generated vapor for heating the system. Steam is used as the energy source.

With thermal vapor recompression, the consumption of live steam and cooling water – and thus operating costs – can be significantly reduced.

The resulting energy savings often correspond to approximately an additional evaporation stage.

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Applications

How it works

Thermal vapor recompression uses part of the process vapor to heat the evaporator. The other part is passed on to the next stage or converted into condensate.

Steam compression for heat recovery takes place in a steam jet compressor, which is usually designed for a specific operating point. Motive steam (live steam) is required to operate a thermal vapor recompressor.

Advantages

Reduced consumption of live steam and cooling water
Significantly reduced operating costs in many cases
Gentle evaporation temperature
Reuse of low-pressure steam possible

High evaporation rates for low-viscosity and heavily fouling media

Plate Falling-film Evaporators

High evaporation rates for low-viscosity and heavily fouling media

Our plate falling-film evaporators stand out for their exceptional quality, outstanding energy efficiency, superior condensate quality, and remarkably long service life.

We ensure these qualities through our many years of experience in design, our extensive expertise in welding and fabrication technology, and the consistent automation of processes.

All key components are manufactured in our state-of-the-art, in-house production facility in Gloggnitz, Austria, and are subjected to the strictest quality controls.

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Applications

How it works

The medium to be thickened is concentrated along the plate-type heating elements (lamellas), which are arranged as a bundle in the evaporator. The more volatile component is evaporated and removed from the apparatus. Optimized distribution systems are used to ensure the best possible distribution of the medium on the heating bundle and thus a high evaporation rate.

Applications

Concentration of black liquor, spent sulfite liquor, and waste water
Recovery and separation of solvents and alcohols
Volume reduction of liquid-liquid mixtures
Separation of multi-component mixtures
Water separation
Concentration of the liquid phase of fermentation residues in biogas plants

Advantages

Ideal for heavily fouling media
Highest evaporation rates
Excellent separation of liquid and vapor phase
Optimized spot-welded and laser-welded lamellas
Long service life
Minimal risk of fouling and corrosion
Energy-optimized design
Integrated droplet separator
Condensate separation thanks to secondary heating surface

Suitable for very small capacities and low- to moderately fouling media

Tube Falling-film Evaporators

The GKT tube falling-film evaporators are used in many standard applications and especially for smaller evaporation capacities compared to plate falling-film evaporators.

We apply our extensive technical know-how in particular to droplet separation and cleaning of the apparatus and offer customized solutions.

Like our plate falling-film evaporators, our tube falling-film evaporators are also manufactured in-house and tested to the highest quality standards.

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Applications

How it works

The medium to be thickened is thickened via vertically aligned tube bundles. The substance forms a thin film on the inside of the tube and flows downwards with gravity.

Vaporization of the more volatile medium on the heating surface produces steam, which is channeled in the tubes in co-current with the boiling liquid.

The vapor phase is then separated from the liquid phase in the lower evaporator chamber via droplet separators or cyclone separators. Steam is generally used to heat the evaporator on the shell side.

Applications

Concentration of moderately fouling liquids and wastewater
Volume reduction of liquid-liquid mixtures
Recovery and separation of solvents like alcohols
Separation of multi-component mixtures and separation of water
Recovery of valuable materials

Advantages

Ideal for low evaporation rates
Can be used flexibly for a wide range of industries and moderately fouling media
Optimized droplet separator design
Cost-effective cleaning
Compact design and small footprint

POWER Spot and LASER Luxe Lamellas

Lamella Technology

GKT manufactures lamellas in a wide range of formats and materials, using various welding techniques.

For decades, producing lamellas for plate falling-film evaporators has been one of our core competencies. We continuously refine this expertise with a strong focus on maximum quality and efficiency. The heating elements are produced in-house at our plate manufacturing facility in Gloggnitz, Austria – under strict quality standards.

With its POWER Spot and LASER Luxe Lamellas, GIG Karasek offers both spot-welded and laser-welded plate heating elements in all standard formats.

Thanks to our specially developed plate forming process and fully closed edge welding, both lamella types feature a long lifetime as well as minimal risk of fouling and corrosion.

Our forming process also allows the spot weld pattern to be flexibly adapted to the specific application. This enables us to achieve the maximum plate height for both types while ensuring particularly energy-efficient heating up of the lamellas.

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Applications

POWER Spot Lamella - Spot-welded heating elements

Our spot-welded lamellas are characterized above all by their resistance to fouling and corrosion, as the welding spot does not come into contact with the substance.

In a forming process specially developed by GKT, the welding spots are not exposed to any force during the forming process of the lamellas. This minimizes material deformation and stresses at the welding spot. In combination with our fully closed edge welding, the product impresses with a very long lamella lifetime.

The distances between the welding spots are adapted to the respective application. This means that spot-welded lamellas can be designed with a larger plate volume, reducing pressure losses during operation.

LASER Luxe Lamella - Laser-welded heating elements

With our laser-welded lamellas, we apply the advantages of our special forming process and thus minimize the stresses at the weld seams. The edges of the lamellas are designed identically to the spot-welded lamellas.

However, thanks to our forming process, we can also implement the larger plate volumes for minimal pressure losses for laser-welded lamellas. Thus, we offer an advanced version of the standard laser lamellas for maximum lifetime.

Advantages

Highest evaporation rates, optimum cleaning possibilities and minimal corrosion, even for heavily fouling substances
Flexibility in terms of formats, materials, welding processes and customer-pecific requirements
Minimal risk of fouling
Minimal risk of corrosion
Long lifetime
Optimum utilization of heating surface
Optimized spot- and laser-welded lamellas

Our Use Case

World's largest mechanical vapor recompression evaporation plant for Sulphite Spent Liquor at the Sappi Saiccor pulp mill in South Africa

GKT has completed the world’s largest mechanical vapor recompression evaporation plant for sulphite spent liquor at Sappi Saiccor in South Africa. Supplied on an EPC basis, the 16 MW plant evaporates 300 tons of water per hour and sets a new benchmark for energy-efficient evaporation in the sulphite industry.

WHAT OUR TEAM SAYS

“When energy becomes a cost factor, process knowledge makes the difference. With our experience, we further develop proven evaporation technology tailored to each specific application.”

Thomas Gurker, Head of Business Unit, Conventional Evaporation Technology

Position AT COMPANY

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Whether you’re looking to improve efficiency, scale production, or explore new technologies - we’re here to support your next step. Let’s build the solution that moves your business forward.

Conventional Evaporation Technology

Our Approach

Our Solutions

Multiple Effect Evaporation Plants

Mechanical Vapor Recompression (MVR)

Thermal Vapor Recompression (TVR)

Plate Falling-film Evaporators

Tube Falling-film Evaporators

Lamella Technology

Our Use Case

World's largest mechanical vapor recompression evaporation plant for Sulphite Spent Liquor at the Sappi Saiccor pulp mill in South Africa

WHAT OUR TEAM SAYS

GET IN TOUCH WITH Us

Intrigued? Let’s talk!

Conventional Evaporation
Technology

Intrigued?
Let’s talk!