DESIGN AND SIMULATION OF MULTI-EFFECT FORCED

CIRCULATION EVAPORATOR USING VAPOR RECOMPRESSION

Department of Mechanical Engineering

National Institute of Technology, Hamirpur (HP)

Completed under the guidance of

Mr. Vivek Verma, CMD
Mr. Surjit Paul, Team Leader
Mr. Jitender Sharma, Team Leader
SPRAY ENGINEERING DEVICES LIMITED
C-82, Industrial Area, Phase-7, Mohali, Punjab 160055

Submitted by:
Jayant Kumar Jain (16334)
Mukesh Kumar (16341)
Sidharth Rana (16339)
Shubham Vijay (16335)
CONTENTS

S No. Particulars Page No

1. Introduction 3-4

2. Evaporators and its Types 5-9

3. Low Temperature Evaporator

a. Introduction 10
b. Salient Features 11
c. Design Features 12

4. Forced Circulation Evaporator

a. Introduction 13
b. Constructional Features 14-15
c. Process 16-18

5. Design Considerations
a. Design for Shaft & Couplings 18-21
b. Design of Shell under External Pressure 22-25
c. Design of Impeller 26-30
d. Design of Calandria 31-37

6. References 38
1.INTRODUCTION

Evaporators are used in a process industry to concentrate solutions

consisting of a non-volatile solute and volatile solvent, like foods,
chemicals, etc. Dilute solutions contain a large amount of water,
and the cost of processing such solutions involves a high equipment
cost. The evaporation process proceeds by evaporating a part of
the solvent from the solution to increase its concentration. This
evaporation is carried out by using steam as the heating medium.

The material of construction of an evaporator may be any kind of

steel. Special materials like copper, stainless steel, nickel,
aluminium may be used depending upon the specific properties of
the solution to be concentrated.

When a single evaporator is used for concentration, the vapour

issuing out of it is condensed and discarded. This type of operation
is called single-effect evaporation. When a number of effects are
used in series, such that the vapour coming out of one effect is
used as a heating medium in the steam chest of the next effect, it is
called multiple effect evaporation. Single effect evaporation is
simple but fails to utilize the steam effectively, while multiple effect
evaporators evaporate more quantity of water per kilogram of
steam consumed in the evaporation process.
3
This brings about a saving in the steam cost, but at the same time,
the cost of material and installation of the evaporator system
increases because of the large number of effects involved. The
various process industries where evaporation plays a pivotal role
are food and pharmaceuticals, pulp and paper, sugar, chlor-alkali,
desalination of water etc. The most important application of
evaporators is in the food and beverage industry. Evaporation of
water from foods and beverages like milk products, fruit juices,
various extracts, enables them to last for a longer period of time or
helps in maintaining the required consistency, like in case of coffee.
Evaporation eliminates excess moisture from pharmaceutical
products, thereby improving product stability and enabling easy
handling of the product. Preservation of long-term activity and
stabilization of enzymes is brought about by evaporating excess
moisture. In the pulp and paper industry, sodium hydroxide is
recovered in the Kraft process by evaporation.

Evaporation differs from the other mass transfer operations such as

distillation and drying. In distillation, the components of a solution
are separated depending upon their distribution between vapour
and liquid phases based on the difference of relative volatility of
the substances. Removal of moisture from a substance in presence
of a hot gas stream to carry away the moisture leaving a solid
residue as the product is generally called drying.

4
2.EVAPORATORS AND ITS TYPES

Evaporation is a process of concentrating a given solution by

heating it to vaporize water. Exposing the solution to a higher
surface area or heating it to a higher temperature reduces the time
needed to achieve a desired concentration. But increasing the
temperature of operation or the residence time in an evaporator
might degrade the solution. So, in order to avoid thermal
degradation of the solution, the operating temperature, as well as
the residence time should be kept as low as possible. This
requirement has led to the development of many types of
evaporators.

The different types of evaporators are:

A. Horizontal tube evaporators: -These were the first kind of

evaporators that came into use and have the simplest of designs. It
contains a shell and a horizontal tube within it, such that the
heating medium is confined within the tubes and the liquid to be
evaporated is in the shell. They have very limited use in present day
applications, they are mostly used for fluids that have low viscosity
and are non-scaling. They have a very low initial investment.

5
B. Horizontal spray-film evaporators: -They are modified horizontal
tube evaporators in which the liquid is distributed by a spray
system and falls down the tubes by the action of gravity. They give
the following advantages:

 Easy removal of non-condensable vapours

 Uniform distribution of the liquid
 Vapour is easily separated from the liquid
 Convenient operation even with scaling fluids.

C. Short tube vertical evaporators: - They are better known as

Calandrias. Liquid circulates past the heating surface by boiling, i.e.
natural circulation. The first short tube evaporator was built by
Robert. They consist of tubes inside a shell. The tubes may be 2 to 3
inches in diameter and 4 to 10 feet long. A down comer is present
at the centre which enables the flow of liquid from the top to the
bottom tube sheet.

D. Long tube vertical evaporators: - They are the most versatile

and economical evaporator systems. The tubes herein are 1 to 2
inch in diameter and 12 to 30 feet long. They may be operated as
once-through or recirculating systems. In once-through
evaporators, the liquid has a residence time of few seconds only.
6
Recirculation type evaporators may be batch type or continuous. In
a recirculating evaporator, a particular level in the vapour body has
to be maintained, and a deflector is provided to prevent
entrainment in the vapour body. There is a non-uniform
temperature distribution in the tubes and this makes prediction of
the tube side temperature difficult. Due to the appreciable length
of the tubes, the effect of hydrostatic pressure head cannot be
ignored.

E. Climbing film evaporators: They are operated under vacuum, in

order to lower the boiling point of the solution and thus increase
the temperature difference driving force. The working principle
behind this is the ‘thermo-siphon’ principle. The liquid rises up in
the core of the tube in the form of a thin film, because the liquid
flows faster than the vapour. Such a flow of the liquid is against
gravity and thus it is highly turbulent. This is useful during
evaporation of highly viscous and fouling solutions. They give high
heat transfer rates and have a low contact time. They are most
ideal for concentration of heat sensitive materials like juices,
pharmaceuticals etc. They provide low cost operation. They have
the least cost per unit capacity available.

7
F. Falling film evaporators: - In falling film evaporators, the liquid
enters the tubes from the top, gets heated and flows downstream
as a film, and leaves from the bottom. The tubes in these type of
evaporators are about 2 to 10 inch in diameter. The vapor that is
evolved from the liquid also moves downward with the liquid and is
removed from the bottom of the unit. They have a liquid-vapor
separator at the bottom and a distributor for uniform distribution
of the feed liquid at the top. Once-through falling film evaporators
have a minimum time of exposure to the heated surface, and thus
can be used for concentration of highly heat sensitive liquids. They
are also effective in handling highly viscous liquids. Recirculating
evaporators distribute the liquid to the tubes by moderate recycling
of the liquid from the bottom to the top of the tubes. Recirculating
systems allow larger volume of flow through the tubes as compared
to the once-through evaporators. The device is suitable for scale-
forming solutions as boiling occur on the surface of the film.

G. Forced circulation evaporators: - Natural circulation evaporators

give uneconomically low heat transfer coefficients with viscous
liquids since the velocity of liquid entering the tubes is low, only
about 0.3 to 1.2 m/s. Forced-circulation evaporators provide for a
centrifugal pump which forces the liquid through the tubes at a

8
higher velocity, about 2 to 5.5 m/s. Sufficient static head is provided
to the tubes to ensure that the liquid does not boil over the heating
surface, in order to avoid the fouling characteristics of the liquid. It
has a shell and tube heat exchanger, with vertical or horizontal
tubes. There is a significant reduction in the cost of evaporation of
viscous liquids by using forced circulation evaporators, despite the
added cost of pumping. Because of the high liquid velocities, they
take very short residence times and are good for moderately heat
sensitive liquids. Forced circulation evaporators are also used for
evaporating salting liquors, or those that have foaming tendency.

H. Plate type evaporators: - Plate evaporators consist of corrugated

and framed plates that are suitable for scaling liquids, since the
scales can be easily flaked off the plates. They provide relatively
larger surface areas than other type of evaporators. The liquid is
pumped between the thin plates, and the heating medium is
provided between the mating surfaces. They have a single pass
operation and thus a short contact time with the heating surface,
making them suitable for heat-sensitive liquids. The product quality
is better than other evaporators. They have a low liquid hold-up
and produce minimal waste. They can be easily scaled up, and need
low installation cost due to their compact size and light weight.

9
3.LOW TEMPERATURE EVAPORATOR

a. Introduction

Low temperature evaporator is an innovative system to

recover clean water along with concentrated solution
separately, by processing industrial/domestic waste
water/solution of wide variety. Low temperature evaporator
is used to concentrate various fluids by evaporating excess
water up to 85%-99% depending on boiling point elevation
(BPE) of fluid. All excess water is recovered as clean water or
condensate separately along with concentrated fluid.

Low temperature evaporator is comprised of highly energy

efficient plate evaporator and mechanical vapour Re-
compression(MVR), to evaporate excess water by the use of
compressed vapour generated from solution itself.

 Enhances the capabilities of processing viscous fluid.

 Plate evaporator ensures betters HTC with optimal
energy consumption.
 MVR recycles steam required for evaporation thus
eliminates continuous use of external heating source
during operation.

10
  High pressure compressed vapours enters in evaporator
calandria which evaporates the excess water and
generates low pressure vapours.
 Low pressure vapours are then compressed by MVR and
recycled in Low Temperature Evaporator resulting in
highly energy efficient process.

b. Salient Features

Low temperature evaporator offers high flexibility and precise

over process parameters especially to deal with heat sensitive
liquor concentration.

 No need of stem generation unit, heat reject units and

chemicals
 Suitable for handling wide variety of fluid/wastewater
 High flexibility & precise control over process
parameters
 Operation at low ΔT.
 Minimal electric power consumption
 Elimination of subsequent degradation due to thermal
injury
 Prevention of ground water table depletion
 Highly energy efficient
 Elimination of regular heating source
11
  Reduced manpower requirement
 Low capex and opex
 Plug and play system
 Eco-friendlier

c. Design Features

Low temperature evaporator is a vertical cylindrical

vessel consists of inbuilt high efficiency compressor/
turbofan impeller at the top, which discharges
compressed vapors at 360° in the space surrounding the
plate heat exchanger, which is placed at the middle
plate heat exchanger. This design has small foot print
area which delivers the highest evaporation. Top
mounting of the MVR impeller on the evaporator
eliminates the need for separate foundation and vapour
ducting to interconnected evaporator along with less
pressure drops of recycling vapors.

 Peripheral ductless steam/compressed vapour entry to

plate heat exchanger.

12
  Efficient feed inlet distribution system to ensure proper
wetting of the entire heating surface.

 Compact design with less foot print area.

4.FORCED CIRCULATION EVAPORATOR

a. Introduction

Forced Circulation Evaporator is a fundamentally unique multi-

effect evaporator comprising tubular heat exchangers and
agitator placed at the bottom to utilize waste water of steam
turbines, pans & evaporators in sugar, food, power plant and
other processing industries for sustainable environmental
development. It is the arrangement in which processes like
circulation, vaporization, condensation, heat exchange occurs in
the single shell.

The natural circulation evaporators are not suitable under some

situations such as:

• highly viscous solutions due to low heat transfer coefficient

• solutions containing suspended particles

13
 • for heat sensitive materials

All these problems may be overcome when the liquid is

circulated at high velocity through the heat exchanger tubes to
enhance the heat transfer rate and inhibit particle deposition.

b. Constructional Features

 Shell: The outer structure of the FCE evaporator is a

cylindrical thick shell mounted on a skirt. Feed water is filled
inside the calandria to suitable levels leaving sufficient space
for vapor, above the surface of feed water. Openings like
Manhole, Sight and Light Glass, NCG outlet, Steam inlet,
condensate outlet, feed inlet, feed outlet are provided on the
shell.

 Skirt: It provides support and platform to the shell.

 Blower and Booster Aassembly: FCE operates at full vacuum

which is created in the shell by blower and booster assembly.
Blower & booster collects the vapor from the shell, creates
14
 vacuum, and pumps the vapor into calandria after
compressing it. The temperature of the vapor is raised by
compressing it up to the required ΔT for heat transfer.

 Calandria: Calandria used for FCE is the assembly of large

number of tubes fitted in two parallel plate having holes. The
shape of the calandria can be illustrated by the figure. Ends of
a tube are locked into holes on the plate of calandria by

expansion. Calandria is the heat exchange ground in FCE

where the outer surface of calandria tubes is exposed to
compressed vapor having sufficient ΔT to raise the
temperature of feed water upto the critical temp of
evaporation at vacuum pressure. Tube sheet arrangement in
calandria is made in the triangular fashion to increase the
contact of hot vapor with tube surface and hence maximum
heat transfer.

Noncondensible gases are vented through the coiled tube

arrangement. The arrangement has tiny holes on the
periphery of circular tubes to collect the vapour mixture.NCGs
collected in circular tubes are then transferred to the main
pipe fitted vertically in calandria.The suction pump is installed
to suck the NCGs out of the shell.

Condensate is collected at the bottom of the calandria. 15

  Circulator Arrangement: Agitator is placed in the shell to
circulate the feed water through the tubes of calandria and
hence enable the uniform heat transfer to feed water.Agitator
provides thrust force to push the feed water from the upper
side of the shell to the lower part and then into tube sheet
arrangement.Circulation creates a rising film type heat
exchanger.

c. Process

Thrust force provides pressure difference to attain sufficient

velocity to cross tube sheet segment during heat exchange,
hence the cycle continues. An overhead electric motor
mounted on a long-suspended shaft is used as the prime
mover for agitator. The motor is mounted on the top of the
shell.

Feed liquid is pumped into the shell till the required level
above calandria is achieved.All the inlet and outlet valves are
closed at this point and complete system is operated under
full vacuum conditions.Vacuum is created by booster and
blower assembly.

16
Feed water starts evaporating at lower temperatures due to
drop in boiling point at vacuum pressure. Vapor cloud over
the feed water is sucked to blower & booster assembly and is
compressed where its temperature rises and a temperature
difference is created with respect to feed water. Vapor gets
converted to steam which is then pumped into the calandria.

Heat is transferred to feed water which is present in the tubes

to raise its temperature. Ultimately this leads to the
vaporization of feed water and create more vapor. In the
process of heat exchange, steam loses its enthalpy and gets
condensed to the bottom of calandria in interfacial space of
tubes and shell and collected as fresh water.NCGs are vented
through pipe arrangement out of the shell.

17
The Figure shows the complete assembled view of the Forced Circulation Evaporator

18
5.DESIGN CONSIDERATIONS
a. Design for Shaft & Couplings

Shaft material- Stainless Steel (𝑆𝑢𝑡 = 505 𝑀𝑃𝑎 = 505 𝑁⁄𝑚𝑚2

𝑆𝑦𝑡 = 215 𝑀𝑃𝑎 = 215 𝑁⁄𝑚𝑚2 )

𝑙𝑒𝑡 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 = 𝐹𝑂𝑆 = 1.5

𝑺𝒔𝒚 𝟎.𝟓𝑺𝒚𝒕 107.5
Shear stress= 𝝉 = = = = 71.66 𝑁⁄𝑚𝑚2
𝑭𝑶𝑺 𝑭𝑶𝑺 1.5

Power delivered by motor = 22 𝐾𝑊

Power losses by motor gearbox assembly= 5%

𝐃𝐞𝐥𝐢𝐯𝐞𝐫𝐞𝐝 𝐦𝐨𝐭𝐨𝐫 𝐩𝐨𝐰𝐞𝐫 = 𝐦𝐨𝐭𝐨𝐫 𝐩𝐨𝐰𝐞𝐫 × (𝟏-loss%)

5
= 22 × (1 − ) = 20.9 𝐾𝑊
100

Rpm of motor = 3000

Gear ratio = 32.5 (gear box customised value)

∴ Rpm of rotating shaft = 3000 ÷ 32.5 = 92

𝜔 = 2𝜋 × 92 ÷ 60 = 9.6342 𝑟𝑎𝑑/𝑠𝑒𝑐

𝑷 = 𝝎𝑻 = 9.6342 × 𝑇

20.9 × 1000
𝑇= = 2,169.35500 𝑁𝑚 = 2169355 𝑁𝑚𝑚
9.6342
19
 For rotating solid shaft,

𝑻 = (𝝅/𝟏𝟔) × 𝝉 × 𝒅𝟑

2169355 = (𝜋/16) × 71.66 × 𝑑3

𝑑 = 53.6 𝑚𝑚

But standard value of shaft diameter= 𝟔𝟎 𝒎𝒎

-Design for Couplings

Shaft diameter is 60 mm.

a. Outside diameter of hub (dh)= 2d=120 mm
b. Length of hub or effective length of key (lh ) =1.5d = 90 mm
c. Pitch circle diameter of bolts (D) = 3d = 180 mm
d. Thickness of flanges (t)= 0.5d = 30 mm
e. Outer diameter of flanges = 4d = 240 mm

(for shaft diameter 40 to 100 mm)

The number of bolts (N) = 4

-Design for Bolts

External torque = Resisting torque

𝐷
𝑇 =𝑃× ×𝑁
2
20
where,

T = torque transmitted by the coupling (N-mm)

P = force acting on each bolt (N)
D = pitch circle diameter of bolts (mm)
N = number of bolts

180
2169355 = 𝑃 × ×4
2

𝑃 = 6025.98 𝑁
𝑃
Direct shear stress in the bolt = 𝜏 = 𝜋 where d diameter of
4
𝑑2

bolts.
𝜋 2
71.66 × 𝑑 = 6025.98
4

𝑑 = 10.3 𝑚𝑚 = 12 𝑚𝑚

And numbers of bolts = 4

The diagrams showing the individual effects of torque on the

shaft of impeller: -

21
Name Type Min Max Name Type Min Max
Stress VON: von 9.600N/m^2 6.245e+008N/m^2 Displacement URES: Resultant 0 mm 2.415 mm
Displacement Node: 196 Node: 10401
Mises Stress Node: 9407 Node: 1423

Name Type Min Max

Strain ESTRN: Equivalent 5.832e-006 2.749e-003
Strain Element: 3483 Element: 2134

22
b. Design of Shell under External Pressure
NOTATION
A =factor “A,” strain, from ASME Section TI, Part D, Subpart 3,
dimensionless
B = factor “B,” allowable compressive stress, from ASME
Section 11, Part D, Subpart 3, psi
D = inside diameter of cylinder, in.
Do =outside diameter of cylinder, = 2000 mm
E = modulus of elasticity, psi = 200 GPa = 29.6*106 psi
L = for cylinders-the design length for external pressure =
7350 mm
P = design internal pressure, psi
Pa= allowable external pressure, psi
Px = design external pressure, psi
t =thickness of cylinder, in

Factor “A’ falls to the left of the material line, hence the
following equation is used to determine the
allowable external pressure:

2AE
pa =
3(D0 ∕ t)

CASE 1: Assuming t = 6 mm
L/ Do = 3.675, Do/t = 333.33
Factor A = 0.000045
Pa1 = 2.66 psi ,
23
 CASE 2: Assuming t = 8 mm
L/ Do = 3.675, Do/t = 250
Factor A =0.000090
Pa = 7.104 psi

CASE 3: Assuming t = 10 mm
L/ Do = 3.675, Do/t = 200
Factor A =0.00015
Factor B =2250
Pa1 = 14.5 psi

Hence the value of external pressure is close to atmospheric

pressure when the thickness of the shell is taken to be 10 mm.

24
25
c. Design of Impeller
In order for a mixing impeller to perform optimally, correct
location and liquid coverage is essential. Incorrect position of
mixing impeller may hamper mixing performance and be
detrimental to the performance life of the mixer drive. D/T is
the ratio of impeller diameter to tank diameter. For most
mixing applications, it ranges from 0.20 to 0.60. A D/T that is
too small may leave areas unmixed. A D/T too large may
choke off the up flow between the impeller and the tank wall.

 Taking D/T ratio =0.5, Tank Diameter – 2000 mm

-Impeller Diameter, D=1000 mm =39.37 IN

 Horsepower can be calculated for most mixer (turbulent flow)

applications as follows:

SHP = (Np N 3 D5 SG)/1.53*1013 -(1)

NP = Power Number of impeller

N = Impeller speed (RPM)
D = Impeller diameter (IN)
S.G. = Specific Gravity

27
 Rpm of motor = 3000

Gear ratio = 32.5 (gear box customised value)

∴ Rpm of rotating shaft = Impeller Speed= 3000/32.5 = 92

Considering TDS Level to be 50 %,

Specific Gravity of the Feed water - 1.217

Dynamic Viscosity 𝜇 = 3.5 × 10-3 Pa-s

And Volume Flow Rate inside the Evaporator, V = 1000 kg/h

=0.277 kg/s

π 2
Contact area inside the tubes, A= 792× (
4
× 0.035 )

=0.762 m2

We know that
Volume Flow Rate =Density (𝜌) ×Contact Area(𝐴) ×
Velocity(v)
v = 3×10-4 m/s

Also,
Reynolds’ Number (Ra) = 𝜌vd/ 𝜇 --(2)
=1217× 3 ×10-4 ×1/3.5 × 10-3
=104.3

28
Corresponding value of the power number is obtained from
the Graph given below: -

Ne~0.9

Using equation 1,
SHPi= 5.27 kW
Considering various efficiencies into account like,
Impeller Efficiency = 0.70
Motor Efficiency = 0.80
Gearbox Efficiency = 0.80
Bush Efficiency = 0.80

29
SHPr = 5.27 /(0.8*0.7*0.8*0.8)
=14.7 Kw say 22 kw

30
31
d. Design of Calandria
a. Calandria Internal Shell

-Inner Diameter -1000 mm

-Outer Diameter-1020 mm

b. Calandria Outer Shell Diameter -2000 mm

c. Length of Calandria -3000 mm

-Effective Length for Heat Transfer-2975 mm

Heating Area required for the operation of 1000 kg/h is given to be

250 square metre.

Now, Outer Diameter of Calandria Tubes -35 mm

Inner Diameter of Calandria Tubes-33.80 mm

Considering the heat transfer rate,

250 = N*(π×0.0338×2.975)

N=792

Where N=number of Calandria tubes

31
 The initial design of Calandria included various rings mounted on
the internal shell which further collected the Non-Condensable
Gases(NCGs) to a single tube, the opening of which was provided
above the top surface of Calandria.

Diameter of holes for collection of NCG- 6 mm

As the NCG outlet has Nominal Bore of 50 mm, the number of rings
to be provided on the Calandria (Nr) and the number of holes on
each ring (Nh) are calculated as follow: -

Assuming constant velocity throughout the exit pipe,

Flow rate at the exit=π(50/2)2V1

Flow rate at the inlet of holes=π (6/2)2v2

V1,V2 be the velocity of NCG at respective points,

Considering Equation of Continuity,

π (50/2)2V1 = π (6/2)2v2 (Nr*Nh)

(Nr×Nh) ≈ 70

32
Number of Rings -10
Number of Holes-7

The holes are provided in a zig-zag manner on the

alternate tubes. The image of the mentioned design is shown
below:

33
The new design of Calandria include tubes rather than rings,
keeping hole diameters same, on the periphery of Calandria’s
internal shell. The total number of holes for collecting NCG is taken
to be 72, such that total number of tubes is 12 having 6 holes over
its length. The NCG is collected in a jacket placed at the middle of
the down take. All tubes have their openings into this jacket and 6
holes are provided in such a manner that 3 of them are above this j
acket and 3 below this. The tubes are simply welded to upper and
lower plate of the down take and at the bottom, extra openings are
provided for collection of condensate. Two additional support rings
are provided equally along the length of the down take for
supporting the tubes.

34
Comparison: -

a. MASS CALCULATIONS

Material Used – Stainless Steel (Ferritic)

Old Design
Collecting Rings (*10) = 20.04 kg
Supporting Strips (*8) =27.15 kg
Collecting Pipe = 20.2 kg

Total mass ≈ 68 kg

New Design
Collecting Tubes (×24) = 20 kg
Collecting Pipe = 12.13 kg

Supporting Rings(×2) = 4.08 kg

Total mass ≈ 36 kg

35
b. Weld lengths: -

Old design:

Supporting Strips (*8) 2*8*3000*0.50mm =24m

Collecting Pipe (both side weld) 2*3000mm = 6m

Teck welds and main exit pipe welds 1m

Total Weld length ≈ 31m

New Design

Supporting Rings(×2) 4*π*1020*0.5mm=6.4m

( Non continuous welding with 50% effective welding requirements)

Collecting Pipe
2*π*1020+2*π*1130mm=13.5m

Tubes
24*π*35mm=2.63m

Teck welds and main exit pipe welds 1m

≈ 23.5m

Percentage reduction (31-23.5)/31 = 24%

36
The major advantages of the new design include: -

1.Reduction in the raw material

As shown in the previous section, the mass requirement in the new

design is almost half the older design, hence the raw material required
for the NCG outlet structure reduces by a substantial amount.

2.Reduction in the amount of Welding: -

Amount of welding required is reduced up to 24%. Required data is

shown in the previous section. Welding length directly affects labour
requirement and fabrication cost.

3. Machining time might reduce. New design uses straight tubes instead
of rounded hollow tubes which significantly reduces the overall
machining time to bend the tubes to make circular NCG arrangement.

Cost Reduction: Above mentioned factors can reduce the cost up to

25-40% in combined effect.

37
6.REFERENCES

1. CHEMICAL ENGINEERING DESIGN-DESIGN OF EVAPORATORS by NPTEL

2.THESIS ON Design and simulation of a multiple-effect evaporator using

vapour bleeding by MONALISHA NAYAK, NITR

3. PRINCIPLES OF FLUID MIXING by BRAWN MIXER, INC.

4. Mechanical Agitator Power Requirements for Liquid Batches by John

Frank Pietranski

5.Pressure Vessel Design Manual by Dennis Moss

38