Many industrial processes release valuable water vapor. Often, this vapor is condensed or discharged, even though it still holds a significant amount of energy.
With Mechanical Vapor Recompression (MVR), this vapor is mechanically compressed, raising both its temperature and its pressure. The vapor can then be reused as a heat source within the same production process. The result? Lower energy consumption, fewer fossil fuels, and significantly higher energy efficiency.
The Callens Group designs, builds, and integrates MVR installations that are fully tailored to your production process, available vapor streams, and heat demand.
When is Mechanical Vapor Recompression (MVR) worthwhile?
Mechanical Vapor Recompression (MVR) is especially well suited to production processes that release large volumes of water vapor or where products are evaporated, concentrated, or dried. That makes the technology a strong fit for the food industry, the paper and cardboard industry, the chemical and pharmaceutical sector, wastewater treatment, and other energy-intensive sectors where evaporation processes play a central role.
Instead of condensing this vapor and letting its energy go to waste, it is mechanically compressed and reused as a heat source within the same production process. This reduces the need for primary heat sources such as steam or natural gas and raises the energy efficiency of the entire installation.
Reasons to choose an MVR installation:
You run a production process that continuously generates large volumes of process vapor.
You want to make the most of residual energy.
You want to reduce your steam or natural gas consumption.
You want to lower your CO2 emissions from your production process.
Min–Max flow
0.75 m³/h to 30 m³/h
Max pressure
20 barg
Technical specifications of an MVR installation
An efficient MVR installation starts with a thorough analysis of your production process. Our specialists examine the vapor flow rate, the vapor temperature, the required temperature lift, the process pressure, and the operating hours.
On that basis, we design an installation that makes the most of the available process vapor while guaranteeing reliable, energy-efficient operation.
Benefits
Mechanical Vapor Recompression (MVR)
MVR helps companies get the most out of their process energy. By reusing vapor as a heat source, less fresh steam has to be produced while the energy efficiency of the entire installation goes up.
Maximum use of process vapor
A large part of the required process heat is recovered internally.
Lower steam consumption
By reusing the vapor, you reduce the need for fresh steam.
Lower CO2 emissions
Thanks to lower fossil fuel consumption, your installation’s climate impact drops.
Lower energy costs
A large part of the required process heat is recovered internally.
Higher energy efficiency
MVR converts electrical energy into usable process heat with high efficiency.
Fully tailored
The MVR installation is tailored to your existing production environment and energy supply.
How do you integrate an MVR installation into your production process?
An MVR installation does not replace your existing evaporator; it seamlessly integrates with it. The mechanically compressed vapor is reused as a heat source within the same process, which sharply reduces the need for fresh steam.
To make this possible, our specialists study how the MVR installation can work best alongside existing evaporators, heat exchangers, condensation systems, and control technology. In doing so, we not only look at the technical integration, but also at the impact on your site’s overall energy balance.
The result is an integrated solution that lowers steam consumption, raises energy efficiency, and safeguards the continuity of your production process.
Partnership
Why work with the Callens Group?
60 years of experience in EPCS projects
An independent integrator focused on your specific needs
Flexible project execution
Short decision-making lines and a personal approach
Unique service & maintenance support
Always close to customers with 13 locations
Maximizing energy efficiency does not start with choosing a technology. It starts with mapping out your specific environment and goals.
Questions? We have the answers.
Mechanical Vapor Recompression (MVR) is a technique that mechanically compresses process vapor. This compression raises the pressure and temperature of the vapor, allowing it to be reused as a heat source within the same production process. That way, the available energy is put to maximum use and the need for fresh steam is reduced.
MVR is used mainly in industrial evaporators, drying installations, distillation processes, evaporation plants, and other processes that continuously generate water vapor. The technology is applied in the food, the chemical and the paper industry, and in other energy-intensive sectors.
Curious whether your production environment is a good fit for MVR? Our experts are happy to find out for you.
That depends on the process, the available vapor, and the operating hours. Because process vapor is reused as a heat source, consumption of fresh steam and fossil fuels can be reduced considerably. In many applications, this makes MVR one of the most energy-efficient techniques for industrial process heat.
Yes. The Callens Group takes care of the entire process: from energy analysis and feasibility study to engineering, installation, commissioning, service, and maintenance. Our specialists review the complete process installation to optimally integrate the MVR solution and achieve maximum efficiency. That gives you a single point of contact for your entire emission reduction project.
You can find more information about the different steps in our workflow here.
For a potato processing company, the Callens Group engineered an MVR system (Mechanical Vapor Recompression) that recovers heat from potato dryer drums and feeds it back into the process. The system captures the energy from evaporating moisture during the drying of mashed potato and upgrades it to steam at 8 barg (175°C). To achieve this, we developed a link between the existing potato dryer drums and MVR technology, an application that had never been realized in this context before. The installation reaches a COP of 4.
What burning question is on your mind? Contact our experts.
