EvapCryst logo

Skid-Mounted & Modular Evaporation Systems

Complete evaporation and crystallization trains built, wired and tested in the factory — shipped in ISO containers or on flat racks, lifted onto your foundation and hooked up to power, feed and discharge in days. From 25 kg/h containerized pilots to 10 t/h process skids, expanded by bolting modules side by side.

Skid-mounted MVR evaporation module on factory skid frame: evaporator body, vapor compressor, separator and PLC cabinet
At a Glance

The Modular Route in Four Numbers

Reference ranges from published skid and containerized system data across heat-pump, MVR and multi-effect builds.

Single-Skid Capacity
25 kg/h–10 t/h
containerized heat-pump units at 25–300 kg/h; MVR process skids at 0.5–10 t/h; multi-skid parallel to 10,000 t/y class
Site Installation
2–5 days
pipe & power hook-up after lift-in; total modular installation 10–15 days vs. 3–6 months field-erected
Installed Power
5–410 kW
from small heat-pump vacuum skids to 410 kW modular MVR units; MVR skids need electricity only, no live steam
Footprint vs. Conventional
≈1/3
containerized builds occupy about one third of conventional systems; vertical stacked layouts cut plan area 40–50%
System & Process Flow

From Factory Floor to First Product in Weeks

One skid carries the whole train — evaporator body, compressor, separator, pumps, piping and controls — prefabricated, tested and shipped as a single piece.

Simplified Skid Module Composition

Feed tank → Preheater → Evaporator module (falling film / forced circulation) → MVR compressor or heat pump → Separator → Concentrate or crystallizer → Product / distillate — all on one skid frame with PLC cabinet & CIP station

Concentration and crystallization variants share one platform: the crystallization skid swaps the discharge end for a crystallizer and centrifuge; the scraper keeps heat surfaces clean on scaling feeds. Condensate returns as clean water; the compressor loop recycles every kilojoule of vapor latent heat.

Skid-mounted modular evaporation system PFD: plate preheater, falling-film evaporator body, liquid-ring vacuum unit, compressor and dense interconnecting piping
01
Factory Prefabrication & FAT
80–90% of piping and electrical integration completed in the factory, followed by static commissioning and a witnessed FAT before anything ships.
02
Containerized Shipping
Built to 40 HC ISO container or flat-rack transport dimensions — truckable as one piece, no oversized-load logistics for most capacities.
03
Lift, Set & Hook-Up
Crane onto a level pad, then 2–5 days of pipe and power connection — feed, discharge, three-phase power and it is ready.
04
Commissioning & Start-Up
Pre-programmed PLC with one-key start; remote diagnostics and cloud monitoring from day one, no resident operator required.
Module Composition

Core Modules vs. Optional Modules

Every skid starts from the same core set; corrosion package, crystallization end and pretreatment are added by duty.

Core Modules

  • Evaporator module — falling-film or forced-circulation body, tube or plate heat exchanger matrix
  • Vapor compressor / heat pump — Roots, scroll or screw machine with 3-stage anti-surge protection (alarm → control → trip)
  • Vapor–liquid separator and circulation pump — 2.0–2.5 m/s tube-side velocity to delay fouling
  • Preheater / condenser and vacuum system
  • PLC / HMI control cabinet — one-key start, remote diagnostics, cloud monitoring
  • Feed & discharge pumps, interconnecting piping and valves — factory-integrated

Optional Modules

  • Crystallizer section — concentration and crystallization variants on one platform
  • CIP cleaning module — high-turbulence designs double the cleaning interval
  • Motorized scraper for heat surfaces on crystallizing, scaling feeds
  • Foam detector with automatic antifoam dosing loop
  • Wetted-part upgrades: SS316L → Duplex 2205/2507 → TA2 / Hastelloy (pH 1–14, >20-year design life)
  • Ceramic-membrane, pH-adjustment and oil-removal pretreatment skids
  • VOC management system for open / containerized evaporation duty
Technical Specifications

Capacity Steps Across the Modular Range

Aggregated from published containerized and skid-mounted system data — indicative ranges for preliminary sizing, not a process guarantee.

System ClassParameterRange / RatingCondition
Containerized heat-pump unitsConcentration series, 6 models25–300 kg/h · 5–38 kW / 4–33 kWh · ≈38 °Chigh-vacuum low-temperature evaporation; scroll (small) / screw (large) compressors; plug-and-play container, 1/3 footprint
Crystallization series, 6 models25–300 kg/h · 8.5–90 kW / 5.5–75 kWh · ≈38 °Cvacuum evaporation with salt-out crystallization; motorized scraper keeps heat surfaces clean; same platform as concentration series
Containerized & skid MVRContainerized MVR, 5 capacity steps100–1,000 kg/h · 30–130 kW / 20–110 kWhRoots vapor compressor; falling-film / forced-circulation × tube / plate exchanger matrix; truckable single-piece delivery
Integrated truckable MVR, 6 steps100 / 200 / 300 / 400 / 500 / 1,000 kg/hfalling-film or forced-circulation; 3-stage anti-surge protection; installation and commissioning completed before ex-works
Modular MVR units3–10 t/h standard modules · 1–4 t/h · 110–410 kWplate / tube exchangers shipped whole; zero live steam, electricity only; envelope 4.3×2.6×4.5 to 6.0×3.0×7.0 m; >80% energy saving class
Skid evaporation / crystallization systems0.5–10 t/h per skid · SEC 20–35 kWh/m³multi-skid parallel to 10,000-t/y class; SS316L / Duplex 2205 / 2507 / TA2 / Hastelloy; 40 HC or flat-rack transport
Multi-effect & open evaporation skidsModular MEE + vacuum crystallization0.5–80 t/h · HP-series 3–50 t/htriple-effect at 99 / 76 / 53 °C and 0 / 448 / 640 mmHg; live steam 0.6–1.0 MPa(abs); removable skid modules avoid long shutdowns
Open evaporation containers100 t/d reduction per unitAB-100 class: 4 evaporation modules in an ISO container frame; ≈2,400 MJ per tonne of water; no pressure vessels
Multi-unit expansionparallel, on demandunits bolt side by side; closed-mode option produces compliant water or vents clean vapor only
Low-temperature heat-pump skidsLPD standard series, 6 steps1 / 2 / 3 / 4 / 5 / 10 t/d · 18–144 kW installed6–7 kPa, 30–37 °C, 10–108 kW running; envelope 2.5×1.5×2.3 to 5.5×2.2×2.3 m; heat-pump COP 3–6
Heat-pump vacuum skids, 13 models10.4–416.7 L/h · 130–160 kWh/t−0.95 bar, 35 °C; fully electric, closed refrigerant loop, no cooling water; SS316L modular structure
Double-effect heat pump, 6 models208.3–833.3 L/h · 80–100 kWh/t45% energy cut vs. single-effect; same −0.95 bar / 35 °C envelope
VR series, 4 models500 / 1,000 / 2,000 / 3,000 L/d · ≈180 kWh/m³R407c / R134a refrigerant; jacket heat exchanger never contacts the feed; foam detector + auto antifoam loop
LT series, 3 models0.2 / 0.6 / 1 t/d · ≈100 kWh/m³≈−96 kPa, ≈37 °C; Siemens PLC + touch screen, remote monitoring
Compact continuous skid45 L/h · 12 kW · 195–215 W/L2.7×1.8×2.8 m envelope; continuous evaporation, no batch dump shutdowns
Delivery & site requirementsFactory completion80–90%piping & electrical integration, static commissioning + FAT before shipment
Site installation vs. field-erected10–15 d vs. 3–6 monthshook-up 2–5 days; ≈30% less civil works; level pad + three-phase power + feed/discharge connections

Ranges aggregate published specifications from containerized heat-pump, MVR and multi-effect system suppliers; figures are indicative for screening and must be verified against your feed analysis, site power limit and logistics constraints.

Modular System Selection

Which Skid for Which Duty

Pick the platform by duty and utilities — the evaporator physics is the same, the packaging and energy source are not.

System TypeEnergy / TemperatureBest ForWatch-outs
Containerized heat-pump≈38 °C · electric onlySmall waste minimization, oily cutting / degreasing concentrates, lab & pilot ZLD at 25–300 kg/hconcentrate handling needed; small throughput per box
Low-temperature heat-pump skid30–37 °C · COP 3–6Heat-sensitive feeds — juice, honey, landfill leachate, small-scale ZLD at 1–10 t/drefrigerant loop maintenance; electric-only site required
Skid / modular MVR20–35 kWh/m³ · no live steamProcess concentration & crystallization at 0.5–10 t/h, 24/7 duty, multi-skid expansionhigher CAPEX; compressor know-how for maintenance
Modular MEE skidlive steam 0.6–1.0 MPaLarger duties where steam exists: salt separation, ZLD preconcentration to 80 t/hneeds boiler house; effect stack adds height
Open evaporation container≈2,400 MJ/t waterHigh-volume brine reduction (100 t/d per unit) where power is expensive; VOC-managedwater leaves as humid air; closed-mode option for distillate

Energy figures follow published data for each platform; final selection needs your electricity / steam price ratio, footprint limit and discharge permit.

Reference Configurations

Three Duties, Three Skid Builds

Published modular systems scale from laboratory pilots to containerized MVR process skids on the same delivery logic.

CONFIG A · PILOT
Lab & Pilot Containerized Skid
Containerized heat-pump unit at ≈38 °C vacuum, one-key PLC start, plug-and-play delivery. Concentration and crystallization variants on one platform; 20-liter sample trials validate boiling-point elevation and viscosity before the design is fixed.
25–300 kg/h≈38 °C · container delivery · 1/3 footprint
CONFIG B · SMALL ZLD
Small-Scale Zero Liquid Discharge Skid
Low-temperature heat-pump skid at 30–37 °C with COP 3–6, fully electric. Distillate to discharge standard or reuse; concentrate to crystallizer or handleable solids; VOC management where the feed carries volatile organics.
1–10 t/d30–37 °C · COP 3–6 · electric only
CONFIG C · PROCESS MVR
Containerized / Modular MVR Skid
Factory-built MVR skid with Roots compressor, plate or tube exchangers, SS316L to TA2 materials, 3-stage anti-surge protection. FAT-tested, 2–5 day hook-up, 24/7 operation; multi-skid parallel to 10,000-t/y class capacity.
0.5–10 t/hmulti-skid to 10,000 t/y · 2–5 d hook-up
Reference Installations

What These Skids Achieve on Site

Anonymized configurations reconstructed from published supplier project data.

CONTAINERIZED HEAT-PUMP PAIR
Concentration + Crystallization, 25–300 kg/h
Paired containerized units on one platform: ≈38 °C high-vacuum evaporation with scroll / screw heat-pump compressors, motorized scraper against scaling, PLC one-key start. Container delivery with plug-and-play installation at one third of conventional footprint.
≈38 °C · 1/3 footprintconcentration and crystallization variants, same platform
SODIUM PERCHLORATE SKID MVR
Duplex 2507 Skid System, 0.5–10 t/h
Skid-mounted evaporator and crystallization systems in Duplex 2205 / 2507 for sodium perchlorate duty: 90% assembly and static testing completed before shipment with FAT, site installation in 2–5 days of pipe and power hook-up, 24/7 continuous operation at 10,000-t/y class capacity.
0.5–10 t/h2–5 d site hook-up · FAT before shipping
CONTAINERIZED OPEN EVAPORATION
AB-100 Class Brine Reduction, 100 t/d
Four evaporation modules packed into an ISO container frame; the air humidification–dehumidification cycle replaces steam and heat-transfer surfaces, so no pressure vessels are needed. Multiple units run parallel on demand; a VOC management system keeps benzene, ammonia and methanol in.
100 t/d per unit≈2,400 MJ/t water · no pressure vessels
Positioning & Evidence

This page aggregates published supplier specifications and project data (containerized heat-pump and MVR system builders, modular multi-effect suppliers, open-evaporation unit manufacturers) into an engineering screening view. All names are withheld; configurations are described generically. Figures are indicative ranges for preliminary sizing — final selection requires your feed analysis, site power limit, transport constraints and discharge permit.

FAQ · Engineering Answers

Modular System Questions We Answer Most

Recurring questions from engineers weighing the skid route.

QSkid-mounted vs. field-erected — how do I choose?

Skids win on schedule and certainty: 80–90% factory completion with FAT, 2–5 day hook-up, 10–15 days total installation versus 3–6 months of field assembly, and roughly 30% less civil works. Above roughly 10 t/h per train — or with layouts a container frame cannot hold — field-erected trains take over; below that, skids cut cost, schedule and interface risk.

QHow much capacity does one skid carry, and how do I expand later?

Published systems span 25–300 kg/h containerized heat-pump units to 0.5–10 t/h MVR process skids. Expansion is by parallel modules: multi-skid plants run 10,000-t/y class duty 24/7, and open-evaporation containers scale the same way at 100 t/d per unit — capacity is added by bolting units side by side, not by rebuilding.

QWhat utilities do I need on site?

A level pad, three-phase power, and feed / discharge connections. MVR skids need electricity only — no live steam at steady state. Heat-pump units run fully electric with closed refrigerant loops and no cooling water. Modular multi-effect skids are the exception: they need live steam at 0.6–1.0 MPa from your boiler house.

QCan a pilot skid predict full-scale performance?

That is what it is for: 20-liter sample campaigns measure boiling-point elevation and viscosity before the full-scale design is fixed, and the pilot runs the same evaporator body type as the production skid — so heat transfer and scaling behavior transfer directly. Crystallizing and scaling feeds additionally run scraped-surface pilot duty before material selection.

QWhat material options cover corrosive feeds?

SS316L covers general duty; Duplex 2205 and 2507 handle high-chloride brines; TA1 / TA2 titanium and Hastelloy cover the extremes — a ladder that spans pH 1–14 with over 20-year design life. High-chloride systems also use stepped protection, for example titanium tubes with a 2205 shell.

QWhat is checked before a skid leaves the factory?

80–90% of piping and electrical integration, static commissioning, and a witnessed FAT. Larger MVR skids add 3-stage anti-surge protection — alarm, control, trip — tuned at the factory, so site work is hook-up and start-up only, with remote diagnostics and cloud monitoring from day one.

Skid & Modular Systems in the Field — Case Studies & Technical Guides

Specifying a Skid or Modular System?

Send feed composition and rate, concentration target, site power limit and footprint constraint. We return a skid or module layout with capacity steps, transport plan and hook-up scope — not a brochure.

Request a Proposal

Send your feed characterization (TDS, COD, main salts, viscosity), throughput and product targets — we respond with a preliminary process route within two business days.