EvapCare™ for Heat-Sensitive and Viscous Products: A Guide to the Right Evaporator
- jesusrangel3
- Jun 20
- 2 min read
Introduction
Processing heat-sensitive and viscous products presents unique challenges in industrial separation and purification. The choice of the right evaporator is crucial to ensure product quality, maximize yield, and maintain process efficiency. Sulzer’s EvapCare product line offers specialized film evaporators designed to handle even the most demanding applications.
This article will guide you through selecting the best evaporator for your heat-sensitive or viscous products.
The Challenges of Heat-Sensitive and Viscous Products
Heat-sensitive products can degrade or lose valuable properties when exposed to high temperatures or prolonged heating. Viscous materials, on the other hand, require effective mixing and film formation to prevent fouling and ensure efficient evaporation.
Both scenarios demand gentle, efficient, and robust evaporation solutions.
Overview of EvapCare Evaporator Types
Sulzer’s EvapCare portfolio includes three main types of film evaporators, each tailored to specific product and process needs:
Falling Film Evaporator (EvapCare-F)
Best for: Low-viscosity, heat-sensitive products with minimal fouling tendency.
How it works: Liquid flows as a thin film inside heated vertical tubes, driven by gravity. The proprietary liquid distribution system ensures even coverage and gentle evaporation.
Key benefits: High heat transfer, short residence time, low pressure drop, and suitability for vacuum operations.
Wiped Film Evaporator (EvapCare-W)
Best for: Continuous processing of heat-sensitive, viscous, or fouling products.
How it works: A mechanical rotor distributes and mixes the liquid film on the heated surface, minimizing fouling and maximizing heat transfer.
Key benefits: High heat flux, low residence time, robust design, and easy cleaning. Available with different rotor types for specific needs, including glass-lined options.
Short Path Evaporator (EvapCare-S)
Best for: Extremely heat-sensitive compounds and high molecular weight substances.
How it works: Features a vertical condenser inside the wiped evaporation chamber, minimizing the distance between heating and condensing surfaces. Enables evaporation at ultra-low pressure, preserving product quality.
Key benefits: Very low pressure drop, no liquid hold-up, and suitability for high-boiling-point components.
How to Select the Right Evaporator
Choosing the optimal evaporator depends on several factors:
Product viscosity and fouling tendency
Thermal sensitivity of the product
Desired purity and concentration levels
Required throughput and operating pressure
Sulzer supports you through feasibility studies, lab and pilot trials, and expert process design to ensure the best match for your application. In some cases, combining different evaporator types in one process delivers the most economical and effective solution.
Case Studies
Example 1: Pharmaceutical Industry
A pharmaceutical manufacturer needed to concentrate a heat-sensitive API without degradation. The falling film evaporator provided gentle evaporation and preserved product quality.
Example 2: Oleochemical Processing
For a viscous, fouling-prone feedstock, the wiped film evaporator’s robust design and continuous mixing enabled efficient processing and easy cleaning.
Example 3: High Molecular Weight Compounds
A biotech company required purification of a high-boiling, thermally sensitive compound. The short path evaporator allowed for ultra-low pressure operation, achieving high purity and yield.
Conclusion
Selecting the right evaporator is essential for processing heat-sensitive and viscous products. Sulzer’s EvapCare range offers tailored solutions falling film, wiped film, and short path evaporators to meet the unique demands of your application. With expert support, pilot testing, and proven performance, you can optimize your process and achieve superior results.
Contact Us
Ready to find the perfect evaporator for your process?
Contact Sulzer today for expert advice and customized solutions.
