VWT Italia -­‐ Ver. GB 2.0 Rif. FM 1186

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1 Technical characteristics Nominal production capacity of distillate with water: 60000 [l/24h]

Available versions: (selection dependent on corrosion resistance)

RV F 60 AA# (austenitic stainless steel) RV F 60 FF# (superduplex stainless steel)

Electrical equipment: RV F 60 –-­3 (400 [V] 50 [Hz] 3F) RV F 60 –-­4 (460 [V] 60 [Hz] 3F)

Construction: double module on a stainless steel frame

Heating/condensation exchanger: external shell and tube with forced circulation (heating through the tubes, condensing through the shell)

Evaporation type: conveyed vacuum flash

Evaporation conditions: absolute pressure 70 kPa temperature 90 [°C]

Distillate temperature: 20-­90 [°C] depending on feeding temperature and on the discharge mode chosen (e.g. manual discharge)

Concentrate temperature: 20-­90 [°C] depending on working mode (discharge frequency) and on feeding temperature if concentrate thermal recovery device is present

Drop separation: perforated grill demister with packing elements Heating/cooling technology: VR (vapour recompression) Circulation pump: centrifugal with fluxed double mechanical seal

Blower: positive displacement blower (handled by a variable frequency drive)

Vacuum system: created by the blower

Operating control:

automatic, continuous 24/24h 7/7 days by PLC Siemens S7-­300;; status information and consent to equipment operation remotable through digital signals

Operator panel: touch screen Proface SP5000 International Protection Rating: IP 54 Noise: ≤ 83 [dB(A)]

Main reference legislation: (CE marking)

Machinery Directive (2006/42/CE) Electromagnetic compatibility (2004/108/CE) Electrical safety (EN 60204-­1)

2 Nominal performance The data reported in the following table refer to the performances achieved during FAT (Factory Acceptance Test) with clean machine fed with tap water in standard atmospheric conditions. Version RV F 60 -­-­3 RV F 60 -­-­4 Electrical power supply 400 [V] 50 [Hz] 3F 460 [V] 60 [Hz] 3F Maximum production of distillate with water 65000 [l/24h] ± 10% 65000 [l/24h] ± 10% Absorbed power under normal working conditions

110 [kW] ± 10% 110 [kW] ± 10%

Installed power 226 [kW] 226 [kW] Power factor [cosø] 0,9 [cosø] 0,9 Electrical specific consumption per litre of distillate

40 [Wh/l] ± 10% 40 [Wh/l] ± 10%

Heat generated by thermal dissipation 75 [kW] ± 10% 75 [kW] ± 10%

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3 Functional description The machine RV F 60 is a mechanical vapour recompression evaporator for the treatment of water based liquids. For component identification refer to figure 1.

Figure 1

The circles with alphanumeric characters indicate the main sensors on the machine. The Roman numerals and dashed rectangles indicate the optional systems and accessories. The numbers next to the inlets and outlets indicate the various connections to the process lines.

3.1 Process liquids circuit The liquid to be treated, before entering the boiling chamber D01 (where the vacuum conditions of 70 kPa and 90°C are maintained), is preheated in the heat exchanger E03 by the concentrate (if the optional system V is installed) and in E02 by the discharging distillate. Pump G02 works continuously recirculating the liquid to be treated in order to keep clean the exchanger E02 and feeding the boiler through opening of valve VP01, controlled by the level sensor LS01. The concentrate is recirculated by the pump G01 which pumps it through the primary heat exchanger E01 (tube side). Within E01 the liquid receives from the condensing vapour the heat necessary to boil;; once heated, the concentrate is sent again to the boiling chamber D01. As a result of the vacuum, a portion of the liquid immediately boils (flash evaporation). The produced vapour passes through the drops separator (H04) in order to eliminate suspended liquid drops and improve the quality of the output distillate. The blower K01 compresses the vapour and sends it to the heat exchanger E01 (shell side) where it releases the latent heat to the process liquid. The condensed vapour is collected in the tank D02 and then it is discharged by the pump G03 after a heat exchange in E02. The sensor CE01 measures the conductivity of the distillate: high conductivity means high entrainment of liquid in the boiling chamber and the machine shows an alarm to the operator. The temperature sensor TE02 measures the temperature of the distillate in D02. The flow sensor FT01 measures the amount of distillate discharged.

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The concentrate is discharged automatically through the valve VP05. Flow sensor FT02 measures the amount of concentrate discharged. The density meter DT01 (if the optional system I is installed) allows to discharge the concentrate once it reaches a density value set by the user. During the startup of the machine the liquid in the boiler D01 and the distillate in D02 are heated by the resistors ER01-­ ER02-­ ER03-­ER05-­ER06. The incondensable gases are discharged through a dedicated chimney (outlet 5, see Figure 1). Dry cooler K03 (if the optional system VI is installed) allows to condense possible residual vapours exiting through the vent.

3.2 Mechanical vapour recompression The produced vapour in the boiling chamber D01 is sucked into the positive displacement blower K01 that, by means of the compression, raises the temperature;; afterwards the vapour passes through the shell of the exchanger E01 where it condenses and releases the latent heat to the recirculated liquid of the boiling chamber. Valve VP10, during startup phase, is open in order to allow a gradual startup of the blower K01. Fan K02 allows to keep controlled the temperature of the oil in the blower in order to extend its service life in case of operation in thermally hard conditions.

3.3 Thermal recovery systems Thermal recovery is realised through the exchangers E03 (if the optional system V is installed) and E02. The liquid to be treated crosses both of them and warms up before entering the boiling chamber. Temperature sensor TE08 measures the temperature of the liquid to be treated entering the boiler after the recovery exchangers. The concentrate passes through the tube and shell heat exchanger E03 and cools down, before its discharging, as a consequence of the heat exchange with the liquid to be treated. Valve VP03 (if the optional system V is installed) allows the flow of the liquid to be treated through exchanger E03. The distillate enters the heat exchanger E02 and cools down, before its discharging, as a consequence of the heat exchange with the liquid to be treated. Temperature sensor TE07 measures the temperature of the distillate editing the machine.

3.4 Auxiliary liquids Antifoam, supplied by the opening of the timed valve VP06. If optional OC AF F is present, antifoam is metered automatically. The foam sensor SS01 detects the presence of foam in D01 and commands the opening of valve VP06. Additive supplied with pump G07 if the optional system OM AD F is installed. Tap water for washing of components inside the boiling chamber D01, through timed valves VP07 (sensor LS01 washing) and VP12 (foam sensor SS01 washing, if the optional system OC AF F is installed). Bactericide for the distillate, if the optional system AM BT D is installed.

4 Configurations The evaporator can be configured according to the specific needs of the customer in terms of chemical-­physical properties of the feed liquid and ambient temperature of the installation site. The configurable components are described in the following table, with their identification codes. Component Code Description Criteria for choosing Blower K01 C BR SS Blower in stainless steel Chemical-­physical properties of

the feed liquid C BR CI* Blower in cast iron Electrical panel C EB AC Electrical panel with air conditioner Ambient temperature of the

installation site C EB NC Electrical panel without air conditioner * available only for version RV F 60 AA#RG

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5 Options and Accessories (*1) Code Description Standard/Opt [-­] OC CN D Distillate conductivity control device S [-­] OC FM D Distillate flow rate measuring device S [-­] OC ST Device for the control/inspection of the boiler with ladder S [-­] OM AF F Antifoam agent dosing device S [-­] [-­] Provision for level control on external process liquid tanks S I OC DN C Concentrate density control and measuring device O II OM AD F Additive dosing device O III OC AF F Automatic foam in boiler control device O V OR HE C Concentrate recovery heat exchanger device(*2) (*4) O VI OR FV S Vapour condensation device with dry cooler O

[-­] OW CH (RV F) Automatic chemical washing system for series RV F evaporators (*2) O

[-­] OC EN Ethernet interface device (*2) O [-­] OC PB Profibus interface device (*2) O [-­] OI RC Remote control via ADSL/UMTS (*2) (*3). Ethernet option “OC EN” required O [-­] AM BT D Bactericide dosing device O *1) See the diagram in the figure 1. *2) To be considered when ordering. *3) Can be combined with remote control contract EVA-­Link. *4) Recommended if the process performance to be reached is lower than 80%. As regards the automatic chemical washing system OW CH (RV F) refer to the specific technical report.

6 Construction materials The main materials that come into contact with the process liquids are listed in the following tables. Component ID RV F NN FF# RV F NN AA# Evaporation chamber D01 DUPLEX INOX 316/L Drops separator (packing elements) H04 PP PP Distillate storage tank D02 INOX 316/L INOX 316/L Tube and shell heat exchanger (tube -­ shell) E01 DUPLEX -­ INOX

316/L INOX 316/L -­ INOX

316/L Thermal recovery exchanger (tube -­ shell) E02 DUPLEX -­ PTFE INOX 316/L -­ PTFE Thermal recovery exchanger (tubes and shell) E03 DUPLEX INOX 316/L Circulation pump G01 DUPLEX INOX 316/L Feed pump G02 INOX 316/L INOX 316/L Distillate discharge pump G03 INOX 316/L INOX 316/L Liquid injection pump G04 INOX 316/L INOX 316/L Antifoam metering pump G05 PP PP Blower . Configurations: K01 -­ C BR SS INOX INOX -­ C BR CI* -­ IRON* Level switches inside the boiling chamber (blades) LS01/02/03 ECTFE INOX 316/L / INOX

316Ti Structure and frame -­ INOX 304/L INOX 304/L Piping and line parts -­ DUPLEX + PVDF +

INOX 316/L INOX 316/L + PVDF

Flanges -­ Al Al Gaskets: -­ Components in contact with feed/concentrate FPM+EPDM+PTFE FPM+EPDM+PTFE Components in contact with vapour/distillate EPDM+PTFE EPDM+PTFE * available only for version RV F 60 AA#RG

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Materials: INOX 304/L Austenitic stainless steel AISI 304 (EN 1.4301) / AISI 304L (EN 1.4307) INOX 316/L Austenitic stainless steel AISI 316 (EN 1.4401) / AISI 316L (EN 1.4404) INOX 316Ti Austenitic stainless steel AISI 316Ti (EN 1.4581) DUPLEX Superduplex stainless steel UNS S32750/UNS S32760/UNS 32205 (EN 1.4410/EN 1.4501/EN

1.4462) INOX Stainless steel alloy PVDF Polyvinylidene Fluoride IRON Cast iron (UNI-­ISO 185 G 200) Al Aluminium ECTFE Ethylene chlorotrifluoroethylene PP Polypropylene FPM Fluoropolymer EPDM Ethylene-­Propylene Diene Monomer PTFE Polytetrafluorethylene

7 Dimensions and clearance zones

* Dimensions in millimetres [ [mm].

Figure 2 If a crane or a bridge crane is available in the installation site, the clearance zones for the manoeuvre of the fork lift are not required. Contact VWT Italia for details. A clearance height of ~2000 mm is required above the machine for maintenance operations.

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8 Dimensions, weight, packaging, storage and handling The standard machine is supplied with protection panels and the standard packing is constituted by the panels themselves. Type Module Dimensions [mm] Weight [Kg]* Standard packaging

Condenser module 6000 x 2220 x 2730 h

8880

Boiler module 4950 x 1900 x 2200 h

950

Fan and pipe box 2350 x 2350 x 1130 h

670

Packaging with wooden crate

Condenser module 6300 x 2320 x 3180 h

11000

Boiler module 5300 x 2000 x 2650 h

1950

Fan and pipe box 2350 x 2350 x 1130 h

670

Empty without packaging/under normal conditions with water see figure 2 10400/12800 *1) The weights refer to the machine full optional The temperature of storage site may be within +5 e +45°C and relative humidity between 20% and 60%, non-­condensing. The evaporator may be handled by a self-­propelled crane or overhead travelling crane;; previously machine shall be hooked to the provided eyebolts.

9 Environmental conditions Temperature Working conditions 5÷40 [°C] Normal conditions 0÷5 [°C] Start-­up allowed only with specific precautions >40 [°C] Electrical panel with air conditioner configuration C EB AC -­ Contact VWT Italia

The machine is designed to be installed at a maximum altitude of 1000 metres a.s.l. (for installations at higher altitude contact VWT Italia). The nominal performances stated in this document are guaranteed with a feed temperature between +20 and +70°C and a concentrate discharge ≤ 20% facing the liquid to be treated;; these performances are guaranteed for an atmospheric pressure of the installation environment of 1013 mbar (about 14.7 psi corresponding to 0 meters above the sea level).

10 Installation requirements The machine is designed to be installed outdoor (atmospheric agent resistant), on a horizontal surface that can support the weights listed in section 8. Around the machine perimeter it is necessary to set some clearance zones to allow the personnel and the maintenance operators to work with no obstacles and to keep the air transit free (shown in Figure 2). The features of the hydraulic connections are listed below:

(*1) Description Type DN [mm] Available outlet pressure [barg]

Required inlet pressure [barg]

1 Liquid to be treated inlet Flanged 32 -­ (*) 2 Concentrate discharge Flanged 32 ~0,5 -­ 3 Distillate discharge Flanged 32 ~2 -­

*1) Ref. Figure 1 (*): the machine is equipped with a feed pump that requires a minimum positive hydrostatic head. The feed pipe must be sized in order to assure the required head at pump suction, with recommended flow velocity < 0,5 m/s. The remote installation of the feed pump can be evaluated on request by VWT Italia.

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The sectioning of the process lines by means of manual valves is at user’s charge. The liquid to be treated must contain a low amount of coarse material that must have a diameter lower than 800μm. Otherwise it is necessary to install a feed prefiltration device. The machine is supplied with a collector for the conveyance of vapour and non-­condensable gases (see output 5 in figure 1) that must be advisably canalized, if necessary, in respect of the local regulations. The machine requires the following utilities to operate:

Setup Required pressure [barg]

Flow rate [Nm3/h] Connection Features

Compressed air RV F 60 -­-­3/4 6 4 PE tube

(Dext 10 mm) Dehydrated and without oils

Setup Frequency (Hz)

Voltage (V)

Nominal current (A) Power supply

Electric energy RV F 60 -­-­3 50 (±2%) 400 (±4%) 350 3 PHASE + GROUND

Electric energy RV F 60 -­-­4 60 (±2%) 460 (±4%) 350 3 PHASE + GROUND

The electric cables are at customer care and need to be connected to a switch suitably designed by a qualified technician, following the good working regulation and respecting the electric cabinet rating.

11 Environmental Impact Reduction: CO2 emissions Below are the results of our Carbon Footprint study and a comparison with an extreme case of pollution: kgCO2eq/m3 liquid waste treated 25,10 Percentage of emissions avoided with respect to incineration of the liquid waste -­97,7% The first value represents an average between the various industrial uses considering machine usage of 24h/d, 330 d/y, for 10 years, road transport of the machinery 1000 km from the manufacturer's production site and road transport of the chemical products for a distance of 100 km from the customer’s site. The data for comparison with incineration was weighted for machine efficiency, i.e. the ratio between the initial liquid waste to be treated and the residual concentrate to be disposed of.

12 Chemical products Chemical products are required during the normal operation of the machine. In order to obtain the best performances together with minimum consumptions, the manufacturer recommends using "Hydrex" chemical products. "Hydrex" is the VEOLIA brand that meets the chemical products requirements of the wastewater treatment and process water production. Notes -­ For details concerning machine safety and installation, refer to the use and maintenance manual. -­ The data in this document are indicative. VWT Italia reserves the right to change any data without prior notice. The front-­page photograph is not representative of all versions or all models.