Skamols goals in implementing the Vapor Compression System
Skamol is a Denmark-based global leader in insulation systems for industrial and building applications. The company specializes in using unique materials such as diatomaceous earth (moler), vermiculite, and calcium silicate to create innovative insulation solutions. Since May 2023, Skamol and its four production plants have been part of Etex. Their purpose is to protect the planet by reducing energy consumption and emissions of greenhouse gases.

PILLER and Skamol had a common goal in this project: to make the process efficient and cost-effective by saving energy and reducing CO₂. That’s where the process of Mechanical Vapor Recompression (MVR) and PILLER’s expertise in compression systems meet Skamol’s requirements: The VapoStation installed here is, as usual with PILLER, a one-off that precisely meets our customer’s process requirements. The experts from both teams came together and identified the solution in the compressor system with 6 VapoFans.

How the VapoStation works
The process here is a classic drying process that is specifically aimed at drying insulation boards. By recovering the process steam, it can be fed back into the process for heating (open loop). The state-of-the-art system is specifically designed to meet the unique needs: This VapoStation is engineered to compress approximately 4 tons of steamCompression raises the saturated temperature from 100°C to 150°C. In total, the System delivers 2.7 MW of thermal energy to the process – with an electrical consumption of 0.48 MW and a COP (Coefficient of Performance) of 5.6.

The VapoStation stands out with its small footprint and flexible installation and its operating point monitoring (OPM) system, which ensures smooth operation of the unit. In this case, the controlled water injection is also regulated by the OPM system. In addition to its core functions, this system incorporates several other groundbreaking innovations, further enhancing its efficiency and performance.

The team was therefore able to carry out all tests on the system on site and verify the target results before the official commissioning. The final successes are now being pursued in ongoing operations, and we look forward to further collaboration and future projects.