In modern B2B chemical processing, starch refining, alcohol production, and waste treatment plants, achieving the balance between thermal efficiency, regulatory compliance, and operational reliability is paramount. As a premier CE certified evaporator dryer manufacturer and supplier, Jiangsu Zongheng Concentrating and Drying Equipment Co., Ltd. (formerly Yixing Yangxi Light Industry Machinery Factory, established in 1992) design-engineers thermodynamic and fluid mechanical processing systems built for continuous uptime. This whitepaper analyzes the mechanical principles, metallurgy configurations, thermodynamic energy integrations, and global compliance regulations surrounding modern falling-film evaporators, forced circulation evaporation systems, bundle dryers, and airflow flash drying equipment.
Under the European Union Pressure Equipment Directive (PED 2014/68/EU) and ASME Section VIII rules, evaporation and drying columns are categorized under high-risk mechanical operations. Our engineering methodologies integrate advanced computational fluid dynamics (CFD) modeling, finite element analysis (FEA) for pressure vessel shell design, and thermodynamic cycle simulations to achieve steam reduction factors exceeding 30% compared to legacy architectures.
Engineered for highly heat-sensitive fluids, falling film evaporators ensure extremely short liquid residence times. Fluid is distributed uniformly across the internal surfaces of vertical tubes, flowing downward as a thin liquid film. Co-current vapor velocity aids descending flow, minimizing fouling and degradation.
For high-viscosity, crystallizing, or severe-fouling applications. High-efficiency axial flow pumps push the liquid through heat exchanger tubes at high velocities (up to 3 m/s). Boiling is suppressed within the tube bundle by hydrostatic head, occurring only when the fluid enters the separation chamber.
An indirect heating solution utilizing steam-fed tube bundles rotating inside a stationary housing. Designed for continuous mass heat transfer of free-flowing materials. The steam is distributed inside the tubes while the material occupies the shell space, avoiding direct air contact.
Mechanical Vapor Recompression (MVR) represents the pinnacle of thermodynamic design in modern liquid concentration systems. Traditional multi-effect evaporators consume large volumes of live boiler steam. In contrast, an MVR system compresses the boiled-off vapor utilizing a high-performance centrifugal fan or roots compressor. Compressing the vapor increases its saturation temperature and pressure, allowing it to be recycled back into the same evaporator effect as the heating medium.
The energy balance comparison between standard thermal technologies highlights the immense operational cost (OPEX) savings achieved with MVR integrations:
| Technology Type | Steam Consumption (per Ton Evaporation) | Electrical Consumption (per Ton Evaporation) | Cooling Water Demand | OPEX Index |
|---|---|---|---|---|
| Single Effect Evaporator | ~1.1 - 1.2 Tons | < 5 kWh | High (100%) | 100% (Base) |
| 3-Effect Thermal Evaporator | ~0.35 - 0.40 Tons | ~8 kWh | Medium (35%) | 40% |
| 5-Effect Thermal Evaporator | ~0.20 - 0.24 Tons | ~12 kWh | Low (20%) | 28% |
| MVR Evaporator System | ~0.03 - 0.05 Tons (Startup only) | 15 - 22 kWh | Minimal (< 2%) | 12% - 15% |
For global chemical plants operating in high utility-cost jurisdictions (such as the EU and North America), transitioning to MVR technology yields payback periods of less than 18 months. By reducing fossil-fuel boiler reliance, MVR installations minimize scope 1 carbon emissions, aligning plants with current ESG mandates and net-zero goals.
Industrial drying requires uniform heat distribution, strict residence time management, and optimized gas-solids separation. Jiangsu Zongheng manufactures two primary industrial drying configurations to suit distinct material kinetics:
The MQG Airflow Dryer operates on the principle of co-current flash drying. Moist solids are dispersed into a high-velocity stream of hot gas (air or combustion gases). The drying process occurs in a matter of seconds during pneumatic conveying. Through precise changes in tube diameters, pressure differentials generate turbulent fluidization, forcing continuous surface moisture evaporation without overheating the inner core of the particles. This rapid, thermal-sensitive process is ideal for starch, food proteins, and chemical crystals.
For dense, non-free-flowing, or organic materials requiring extended residence times (such as corn gluten meal, spent grains, or DDGS), the ZXG Tube Bundle Dryer is the industry standard. The machine operates on indirect heat transfer, utilizing saturated steam passed through a bundle of concentric tubes. As the bundle slowly rotates, shovels lift the material, cascading it over the hot tubes. Moisture is swept away by a minimal flow of carrier gas, reducing downstream air pollution filtration costs.
Established in 1992, Jiangsu Zongheng Concentrating and Drying Equipment Co., Ltd. (formerly Yixing Yangxi Light Industry Machinery Factory) has evolved from a regional pressure vessel manufacturer into a globally recognized B2B process engineering partner. Over 30 years, our facility has maintained strict compliance with Chinese Special Equipment Licensing, ASME U Stamp requirements, ISO 9001 quality systems, and European CE PED certifications.
Established as Yixing Yangxi Light Industry Machinery Factory, covering 15 mu of land with 45 employees, supplying primary distillation and light industry evaporation units.
Implemented standardized international quality protocols, securing ISO9001 certification and expanding design scopes for chemical vessels.
Recognized as a Jiangsu Provincial High-Tech Enterprise, marking major investments in advanced heat transfer and aerodynamic fluid design patents.
Secured the Special Equipment Manufacturing License of the People's Republic of China (License No.: TS2232C42) for high and medium pressure vessels.
Acquired the ASME "U" Stamp authorization from the American Society of Mechanical Engineers, certifying products for North American B2B installations.
Acquired International Quality System Certification (Certificate No.: 45021) and designed dedicated evaporative concentration lines for CE compliance markets.
Currently employing over 120 staff including 3 senior engineers and 20+ specialized engineers. Factory area covers 54,000+ square meters with 22,000+ square meters of dedicated processing workshops.
Located in Zhoutie Town, Yixing City—the industrial heart of China’s steel fabrication and environmental engineering cluster—Jiangsu Zongheng leverages localized supply chains. Our 54,000 m² facility is fully equipped with heavy plate rolling machines, automatic tube-to-tubesheet orbital welding equipment, multi-axis CNC machining centers, and an in-house non-destructive testing (NDT) facility (including X-ray and ultrasonic testing).
By keeping all manufacturing processes in-house, we eliminate subcontractors and control every aspect of pressure vessel production. This vertical integration allows us to offer shorter lead times and higher price-to-performance ratios than European and American competitors, without compromising on quality.
Fouling, scaling, and chloride-induced stress corrosion cracking (SCC) are major challenges in concentration plants. We build equipment using high-performance alloys tailored to process fluids:
B2B procurement of heavy processing plant machinery requires engineering support before, during, and after the sale. At Jiangsu Zongheng, we provide comprehensive project engineering services:
Utilizing Aspen Plus and Aspen HYSYS, we simulate custom mass balances, thermal balances, and fluid dynamics. This ensures your evaporator or dryer achieves its specified output and energy performance under your exact operating conditions.
To reduce onsite assembly times, we can deliver systems as modular skids. Structural steel support frames, piping, valves, instrumentation, and wiring are pre-assembled in our facility and tested prior to shipping, minimizing field installation costs.
Our experienced process engineering team is ready to design a custom evaporation or drying system tailored to your exact process parameters.
Zongheng