System and method of waster water reduction and product recovery

A method for recovery of reusable constituents from a waste stream comprising at least a first constituent with a first relative volatility and a second constituent having a second relative volatility lesser than the first constituent, comprising the steps of:

• a. delivering the waste stream to a vapor thermocompression evaporation unit;
• b. transferring heat to the waste stream to vaporize a significant fraction of the first constituent without appreciably vaporizing the second constituent, resulting in a vaporized fraction of the first constituent and an intermediate stream comprising the second constituent and the unvaporized first constituent;
• c. compressing the vaporized fraction of the first constituent;
• d. circulating the compressed vaporized fraction of the first constituent to transfer heat therefrom to the waste stream within the vapor thermocompression unit;
• e. delivering the intermediate stream to a film evaporator;
• f. forming the intermediate stream into film flow to aid with heat transfer to the stream;
• g. transferring heat to the intermediate stream film to vaporize substantially all of the first constituent without appreciably vaporizing the second constituent, resulting in a vaporized fraction of the first constituent and a product stream comprising the second constituent substantially free of the first constituent;
• h. compressing the vaporized fraction of the first constituent from the film evaporator;
• and
• i. circulating the compressed vaporized fraction of the first constituent from the film evaporator to transfer heat therefrom to at least one of the waste stream in the vapor thermocompression unit and the intermediate stream within the film evaporator.

A system for recovery of hydrocarbon constituents from a waste stream comprising water and a hydrocarbon fraction having at least one hydrocarbon constituent, the hydrocarbon fraction being less volatile than the water, comprising:

• a. a preheater to transfer heat to the waste stream;
• b. a vapor thermocompression evaporator, comprising:
• i. a heat absorbing section with an inlet for receiving the waste stream, means for vaporizing a significant fraction of the water without appreciably vaporizing the hydrocarbon, a vapor outlet for exhausting the water vapor, and a liquid outlet for discharge of an intermediate stream comprising the hydrocarbon and unvaporized water;
• ii. a heat releasing section, with an inlet for receiving water vapor having a higher energy than the waste stream, an outlet for discharging condensed water to the preheater, and means for condensing the water vapor and transferring heat from the condensing water vapor to the heat absorbing section to vaporize the water from the waste stream, wherein the condensed water circulates through the preheater to preheat the incoming waste stream;
• iii. a first vapor compressor in communication with the vapor outlet of the heat absorbing section for compressing the water vapor and delivering the compressed water vapor to the heat releasing section inlet and into the heat releasing section to be used as fluid from which heat is transferred to the waste stream in the heat absorbing section;
• c. a film evaporator, comprising:
• i. a heat absorbing section having an inlet in communication with the liquid outlet of the heat absorbing section of the vapor thermocompression evaporator for receiving the intermediate stream, means for vaporizing substantially all of the water without appreciably vaporizing the hydrocarbon in which the intermediate stream is formed into a film, a vapor outlet for exhausting the water vapor from the intermediate stream, and a liquid outlet for discharging a product stream comprising the hydrocarbon substantially free of water;
• ii. a heat releasing section, with an inlet for receiving water vapor having a higher energy than the intermediate stream, an outlet for discharging condensed water, and means for condensing the water vapor and transferring heat from the condensing water vapor to the heat absorbing section to vaporize the water from the intermediate stream;
• and
• d. a second vapor compressor in communication with the vapor outlet of the heat absorbing section of the film evaporator for compressing the water vapor from the intermediate stream and delivering the compressed water vapor to the heat releasing section of at least one of the vapor thermocompression evaporator and the film evaporator to transfer heat to the respective heat absorbing section.