EVAPORATION

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CONTENT
1. Type of Evaporation equipment and Methods
2. Overall Heat Transfer Coefficient in Evaporators
3. Calculation Methods for Single Effect Evaporators
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3. Calculation Methods for Single Effect Evaporators
4. Calculation Methods for Multiple Effects Evaporators
5. Condenser for Evaporator
6. Evaporation using Vapor Recompression
Topic Outcomes
Define Evaporation process
Describe and determine the processing
factors that involved in evaporation process
identify the types of evaporators and identify the types of evaporators and
distinguish the suitable evaporator for
certain operations
Describe other specific types of evaporators
that are used in certain industries
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EVAPORATION
Heat is added to a solution to vaporize the solvent, which is usually water.
Case of heat transfer to a boiling liquid.
Vapor from a boiling liquid solution is removed and a more concentrated
solution remains.
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solution remains.
Refers to the removal of water from an aqueous solution.
Example: concentration of aqueous solutions of sugar. In these cases the
crystal is the desired product and the evaporated water is discarded.
Foaming or frothing
Pressure and temperature
Scale deposition
Materials of construction
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Processing Factors
Concentration in
the liquid
solubility
Temperature sensitivity
of materials
Scale deposition
PROCESSING FACTORS
(1) Concentration
dilute feed, viscosity , heat transfer coefficient, h
concentrated solution/products, , and h .
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(2) Solubility
concentration , solubility , crystal formed.
solubility with temperature .
(3) Temperature.
heat sensitive material degrade at higher temperature & prolonged
heating.
(4) Foaming/frothing.
caustic solutions, food solutions, fatty acid solutions form
foam/froth during boiling.
entrainment loss as foam accompany vapor.
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(5) Pressure and Temperature
pressure , boiling point .
concentration , boiling point.
heat-sensitive material operate under vacuum.
(6) Material of construction
minimize corrosion.
TRAY
Growing
PACKING
Growing foam
leaves tower
Lean soln
Sweet gas Sweet gas
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LI
TRAY
Growing
foam slows/
stops liquid
from
flowing
down
LI
PACKING
Foam effects
less severe, but
can cause some
channeling
Sour gas
Sour gas
Rich soln Rich soln
Lean soln
Forming Effects
Type of Evaporation
Equipment
Horizontal tube type
Vertical tube type
Long tube vertical type
Forced-circulation type
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Forced-circulation type
Open kettle or pan
Open-pan solar evaporator
Falling-film-type evaporator
Agitated-film evaporator
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Wiped film evaporator
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Operating parameters Operating window
Feed rate kg/h 20 - 100.000
Evaporation rate kg/h up to 40.000
Heating temperature C up to 380
1)
Pressure on process side barg -1 to 30
Product viscosity at operating temperature mPas up to 70.000
Residence time min < 1
2)
Evaporation ratio (concentrate/feed) up to 1:50
3)
Through put % 20 - 100
3)
1)
evaporators with electrical inductive heating up to 600 C
2)
in horizontal evaporators longer residence times possible
3)
depending on evaporator type
Effect of Processing Variables on Evaporator Operation
(1) T
F
T
F
< T
bp
, some of latent heat of steam will be used to heat up the cold
feed, only the rest of the latent heat of steam will be used to vaporize
the feed.
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Is the feed is under pressure & T
F
> T
bp
, additional vaporization
obtained by flashing of feed.
(2) P
1
desirable T [Q = UA(T
S
T
1
)]
A & cost .
T
1
depends on P
1
will T
1
.
(3) P
S
P
S
will T
S
but high-pressure is costly.
optimum T
S
by overall economic balances.
(4) BPR
The concentration of the solution are high enough so that the
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The concentration of the solution are high enough so that the
c
P
and T
bp
are quite different from water.
BPR can be predict from Duhring chart for each solution such
as NaOH and sugar solution.
(5) Enthalpyconcentration of solution.
for large heat of solution of the aqueous solution.
to get values for h
F
and h
L
.
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feed, F
T
F
, x
F
, h
F
.
vapor,V to condenser
T
1
, y
V
, H
V
P
1
T
1
heat-exchanger
tubes
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steam, S
T
S
, H
S
concentrated liquid, L
T
1
, x
L
, h
L
condensate, S
T
S
, h
S
T
1
Simplified Diagram of single-effect evaporator
steam, T
feed, T
F
vapor T
1
(1)
T
1
(2)
T
2
(3)
T
3
vapor T
2
vapor T
3
to vacuum
condenser
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steam, T
S
concentrate
from first
effect.
concentrate
from second
effect.
concentrated
product
condensate
Simplified diagram of forward-feed triple-effect evaporator
steam, T
S
feed, T
F
vapor T
1
(1)
T
1
(2)
T
2
(3)
T
3
vapor T
2
vapor T
3
to vacuum
condenser
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Simplified diagram of backward-feed triple-effect evaporator
concentrated
product
condensate
The feed (usually dilute) enters at T
F
and saturated steam at T
S
enters the heat-exchange section.
Condensed leaves as condensate or drips.
The solution in the evaporator is assumed to be completely
mixed and have the same composition at T
1
.
SINGLE EFFECT EVAPORATORS
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mixed and have the same composition at T
1
.
The pressure is P
1
, which is the vapor pressure of the solution at
T
1
.
Wasteful of energy since the latent heat of the vapor leaving is
not used but is discarded.
Are often used when the required capacity of operation is
relatively small, but it will wasteful of steam cost.
CALCULATIONS
a) vapor, V and liquid, L flowrates.
b) heat transfer area, A
c) overall heat-transfer coefficient, U.
CALCULATION METHODS FOR SINGLE-EFFECT
EVAPORAT
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c) overall heat-transfer coefficient, U.
d) Fraction of solid content, x
L
.
(1) To calculate V & L and x
L
,
- solve simultaneously total material balance &
solute/solid balance.
F = L + V total material balance
F (x
F
) = L (x
L
) solute/solid balance
(2) To calculate A or U,
- No boiling point rise and negligible heat of solution:
calculate h
F
, h
L
, H
v
and .
where, = (H
S
hs)
h = c
P
(T T
ref
)
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h = c
P
(T T
ref
)
where, T
ref
= T
1
= (as datum)
c
PF
= heat capacity (dilute as water)
H
V
= latent heat at T
1
solve for S:
F h
F
+ S = L h
L
+ V H
V
solve for A and U:
q = S = U A T = UA (T
S
T
1
)
(3) To get BPR and the heat of solution:
1) Calculate T
1
= T
sat
+ BPR
2) Get h
F
and h
L
from Figure 8.4-3.
3) Get
S
& H
V
from steam tables for superheated vapor or
H = H + 1.884 (BPR)
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H
V
= H
sat
+ 1.884 (BPR)
4) Solve for S:
F h
F
+ S = L h
L
+ V H
V
5) Solve for A and U:
q = S = U A T = UA (T
S
T
1
)
A continuous single-effect evaporator concentrates 9072 kg/h of a
1.0 wt %salt solution entering at 311.0 K (37.8 C) to a final
concentration of 1.5 wt %. The vapor space of the evaporator is at
101.325 kPa (1.0 atm abs) and the steam supplied is saturated at
143.3 kPa. The overall coefficient U = 1704 W/m
2
.K.
Example 8.4-1: Heat-Transfer Area in Single-Effect Evaporator
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Calculate the amounts of vapor and liquid product and the heat-
transfer area required. Assumed that, since it its dilute, the solution
has the same boiling point as water.
U = 1704 W/m
2
P
1
= 101.325 kPa
F = 9072 kg/h
T
F
= 311 K
x
F
= 0.01
h
F
.
V = ?
T
1
, y
V
, H
V
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U = 1704 W/m
2
T
1
A = ?
S , T
S
, H
S
P
S
= 143.3 kPa
L = ?
T
1
, h
L
x
L
= 0.015
S, T
S
, h
S
Figure 8.4-1: Flow Diagram for Example 8.4-1
Solution
Refer to Fig. 8.4-1 for flow diagram for this solution.
For the total balance,
F = L + V
9072 = L + V
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For the balance on the solute alone,
F x
F
= L x
L
9072 (0.01) = L (0.015)
L = 6048 kg/h of liquid
Substituting into total balance and solving,
V = 3024 kg/h of vapor
Since we assumed the solution is dilute as water;
c
pF
= 4.14 kJ/kg. K
From steam table, (A.2-9)
At P
1
= 101.325 kPa, T
1
= 373.2 K (100 C).
H
V
= 2257 kJ/kg.
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H
V
= 2257 kJ/kg.
At P
S
= 143.3 kPa, T
S
= 383.2 K (110 C).
= 2230 kJ/kg.
The enthalpy of the feed can be calculated from,
h
F
= c
pF
(T
F
T
1
)
h
F
= 4.14 (311.0 373.2)
= -257.508 kJ/kg.
Substituting into heat balance equation;
F h
F
+ S = L h
L
+ V H
V
with h
L
= 0, since it is at datum of 373.2 K.
9072 (-257.508) + S (2230) = 6048 (0) + 3024 (2257)
S = 4108 kg steam /h
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S = 4108 kg steam /h
The heat q transferred through the heating surface area, A is
q = S ()
q = 4108 (2230) (1000 / 3600) = 2 544 000 W
Solving for capacity single-effect evaporator equation;
q = U A T = U A (T
S
T
1
)
2 544 000 = 1704 A (383.2 373.2)
Solving, A = 149.3 m
2
.
Example 8.4-3: Evaporation of an NaOH Solution.
An evaporator is used to concentrate 4536 kg/h of a 20 % solution of
NaOH in water entering at 60 C to a product of 50 % solid. The pressure
of the saturated steam used is 172.4 kPa and the pressure in the vapor
space of the evaporator is 11.7 kPa. The overall heat-transfer coefficient
is 1560 W/m
2
.K.
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is 1560 W/m .K.
Calculate the steam used, the steam economy in (kg vaporized/kg steam)
used, and the heating surface area in m
2
.
U = 1560 W/m
2
P
1
= 11.7 kPa
F = 4536 kg/h
T
F
= 60 C
x
F
= 0.2
h
F
.
S = ?
V, T
1
, y
V
, H
V
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U = 1560 W/m
2
T
1
A = ?
S = ?
T
S
, H
S
P
S
= 172.4 kPa
L, T
1
, h
L
x
L
= 0.5
S, T
S
, h
S
Figure 8.4-4: Flow Diagram for Example 8.4-3
Solution
Refer to Fig. 8.4-4, for flow diagram for this solution.
For the total balance,
F = 4536 = L + V
For the balance on the solute alone,
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For the balance on the solute alone,
F x
F
= L x
L
4536 (0.2) = L (0.5)
L = 1814 kg/h of liquid
Substituting into total balance and solving,
V = 2722 kg/h of vapor
To determine T
1
= T
sat
+ BPRof the 50 % concentrate product, first
we obtain T
sat
of pure water from steam table. At 11.7 kPa, T
sat
=
48.9 C.
From Duhring chart (Fig. 8.4-2), for a T
sat
= 48.9 C and 50 %
NaOH , the boiling point of the solution is T
1
= 89.5 C. hence,
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NaOH , the boiling point of the solution is T
1
= 89.5 C. hence,
BPR = T
1
- T
sat
= 89.5-48.9 = 40.6 C
From the enthalpy-concentration chart (Fig.8.4-3), for
T
F
= 60 C and x
F
= 0.2 get h
F
= 214 kJ/kg.
T
1
= 89.5 C and x
L
= 0.5 get h
L
= 505 kJ/kg.
For saturated steam at 172.4 kPa, from steam table, we get
T
S
= 115.6 C and = 2214 kJ/kg.
To get H
V
for superheated vapor, first we obtain the enthalpy at T
sat
=
48.9 C and P
1
= 11.7 kPa, get H
sat
= 2590 kJ/kg. Then using heat
capacity of 1.884 kJ/kg.K for superheated steam. So H = H + c BPR
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1 sat
capacity of 1.884 kJ/kg.K for superheated steam. So H
V
= H
sat
+ c
P
BPR
= 2590 + 1.884 (40.6) = 2667 kJ/kg.
Substituting into heat balance equation and solving for S,
F h
F
+ S = L h
L
+ V H
V
4535 (214) + S (2214) = 1814 (505) + 2722 (2667)
S = 3255 kg steam /h.
The heat q transferred through the heating surface area, A is
q = S ()
q = 3255 (2214) (1000 / 3600) = 2 002 000 W
Solving for capacity single-effect evaporator equation;
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Solving for capacity single-effect evaporator equation;
q = U A T = U A (T
S
T
1
)
2 002 000 = 1560 A (115.6 89.5)
Solving, A = 49.2 m
2
.
Steam economy = 2722/3255
= 0.836