MIT International Journal of Mechanical Engineering Vol. 2, No. 2, Aug. 2012, pp.

(105-108) 105
ISSN No. 2230-7680 © MIT Publications

Design of Wiped Film Evaporator (WFE)

System With Recovery of Working Fluid For
Herbal Products
Vijaykumar C. Patel Prof. Alkesh Mavani
Mechanical Department, Research Student Mechanical Department
L.D.R.P Institute of Technology & Research L.D.R.P. Institute of Technology & Research
Gandhinagar-382015, India Gandhinagar-382015, India
email: vp7259@gmail.com email: alkeshmavani@yahoo.com

ABSTRACT
Now-a-day, the entire world is taking interest in herbal products. These products are perishable in nature & storage of
them required tremendous effect.
In cold storage plant, to store such products required lots of power consumption. The electrical energy is costlier & produced
using fossile fuel, which is one of the causes for pollution. In case of failure of power supply, the chances of distruction
of such commodity is possible therefore this recover of this problem on design of Wiped Film Evaporator with Computer
Aided Tools (CAE) for analysis of WFE for OSWAL INDUSTRIES LTD., BILESHWARPURA, DIST. MEHSANA
Keywords: Component; Herbal Products, Evaporator

INTRODUCTION value of the product otherwise lost; pollution;

The process by which any substance is converted from a liquid
state into, and carried off in, vapor; as, the evaporation of
water, of ether, of camphor. The transformation of a portion 3. Make efficient use of the available energy. This may
of a fluid into vapor, in order to obtain the fixed matter
contained in it in a state of greater consistence. That which
is evaporated; vapor [1].
Equipment used in evaporation, the process of boiling a
liquid in order to reduce its volume it is called Evaporator.
FUNCTION OF AN EVAPORATOR
The main function of an evaporator is to concentrate a solution
or to recover a solvent. The evaporator design consists of three
principal elements: heat transfer, vapor-liquid separation, and
efficient utilization of energy. For evaporators to be efficient,
the equipment selected and used must be able to accomplish
several things.
1. Transfer large amounts of heat to the solution with
a minimum amount of metallic surface area. This
requirement, more than all other factors, determines
the type, size, and cost of the evaporator system.
2. Achieve the specified separation of liquid and
vapor and do it with the simplest devices available.
Separation may be important for several reasons:
fouling and corrosion of the equipment downstream
with which the vapor is contacted.
take several forms. Evaporator performance often
is rated on the basis of steam economy, pounds of
solvent evaporated per pound of steam used. Heat
is required to raise the feed temperature from its
initial value to that of the boiling liquid, to provide
the energy required to separate liquid solvent from
the feed, and to vaporize the solvent. The greatest
increase in energy economy is achieved by re-using
the vaporized solvent as a heating medium. Energy
efficiency may be increased by exchanging heat
between the entering feed and the leaving residue
or condensate. When this method is used, each
evaporator is known as an effect.
4. Meet the conditions imposed by the liquid being
evaporated or by the solution being concentrated.
Factors that must be considered include product
quality, salting and scaling, corrosion, foaming,
product degradation, holdup, and the need for special
types of construction. Between the entering feed
and the leaving residue or condensate. When this
method is used, each evaporator is known as an
effect [4].
MIT International Journal of Mechanical Engineering Vol. 2, No. 2, Aug. 2012, pp. (105-108)
ISSN No. 2230-7680 © MIT Publications
Types of Evaporator [7]
Evaporators are broadly classified to four different categories:
• Evaporators in which heating medium is separated from the
evaporating liquid by tubular heating surfaces.
• Evaporators in which heating medium is confined by coils,
jackets, double walls etc.
• Evaporators in which heating medium is brought into direct
contact with the evaporating fluid.
• Evaporators in which heating is done with solar radiation.
The different types of evaporators
1. Horizontal tube evaporators
I. Horizontal spray film evaporators
2. Short tube vertical evaporators
I. Basket type evaporators
II. Inclined tube evaporators
3. Long tube vertical evaporators
I. Rising or climbing film evaporators
II. Falling film evaporators
III. Rising falling film evaporators
4. Forced circulation evaporators
5. Plate evaporators
6. Mechanically aided evaporators
I. Agitated vessels
II. Scraped surface evaporators
III. agitated thin film evaporators (WFE)
Wiped Film Evaporator Principle
The wiped film evaporator (WFE), also known as an
agitated thin-film evaporator (ATFE) is a device often used
to purify liquids with viscosities up to 105 poise, to separate
temperature-sensitive mixtures, or in general to provide short
residence times in heated zones. Unfortunately, the heat and
mass transfer mechanisms involved in wiped film evaporators
are poorly understood. Users of the technology must rely on
equipment vendors and experience for guidance.
Wiped filmed evaporators are designed to spread a thin
layer or film of liquid on one side of a metallic wall, with
heat supplied to the other side. The unique feature of this
equipment is not the thin film itself, but rather the mechanical
wiping device for producing and agitating the film. This
mechanical concept permits the processing of high-viscosity
liquids, liquids with suspended solids, or situations requiring
liquid rates too small to keep the thermal surface of a falling-
film evaporator uniformly wet.
Most WFEs are vertical cylinders (Figure 1) where the
feed material is distributed to the inner surface. As the liquid
flows downward, axially arranged blades or roller wipers
distribute the liquid as a thin film, which is constantly mixed.
This type of equipment can operate at very low pressure
and provides minimum pressure drop [4].
106
Thin-film evaporation is applied in heat exchangers
called thin-film or thin-layer evaporators. Actually thin-layer
evaporators may be considered as heat and mass exchangers,
since molecules from liquid phase are transferred to gas
phase during process of vaporization and the movement
of molecules from gas phase to liquid phase is probable
during process of condensation. These kinds of devices are
commonly applied in chemical, pharmaceutical and food
industries since 1950. Vertical thin-layer evaporator, example
of which is presented in Fig.1, is characterized by small
pressure drop and short residence time of the phases in the
apparatus, which means also that there is short contact time
of the liquid with hot surface of the evaporator wall. These
features of the evaporator cause that it is applied for the
concentration of heat sensitive liquid solutions especially
with high viscosity. Because of low value of pressure
drop during gas flow inside the evaporator the boiling
temperature of liquid, which is evaporated, depends only
on its composition and does not depend on liquid position
in the evaporator, which is of great importance in case of
evaporation at low pressure. There are two main types of
the thin-layer evaporator, which will be considered below,
namely: static type thin-layer evaporator and mechanically
agitated thin-layer evaporator. All types are constituted by
vertical cylinder heated from the outside, inside which liquid
flows off gravitationally on the heated surface. During that
flow vaporization of liquid takes place.
CALCULATION
Feed Inlet = 791.5 kg/hr
Feed Inlet Temp. = 30°C
B P of Feed Solution = 196°C at ATM. Pressure
Specific Heat of feed Solution = 0.58 kcal/kg °C at 32°C
0.44 kcal/kg °C at 196 °C
Latent Heat of Ethylene Glycol = 204 kcal/kg
kcal
Q = 178205.5
hr
Thermic Fluid Circulation Rate:
kg
m = 11138
hr
Density of Thermic Fluid is 730 kg/m3 at feed conditions
m3
m = 15.25
hr
POWER CONSUMPTION
Feed Pump
Feed Rate : 791.5 kg/hr
Density : 1070 kg/m3
Diff. Head : 15 m
MIT International Journal of Mechanical Engineering Vol. 2, No. 2, Aug. 2012, pp. (105-108) 107
ISSN No. 2230-7680 © MIT Publications

HHP = 0.043 Effective Heat Transfer Height: 4300-500 (Required for

distribution Plate) =3800 mm
043
BHP = 0 ◊ ◊ 4 = 0.11 HP Number of Blades in each row: 3800/250 =15 Nos.
0
Blades are welded 90° apart to the inner rotating cylinder.
Thermic Fluid Circulation Pump Hence the required blades are as under :
Feed Rate : 30.51 m3/hr Total Blades: 15 × 4 = 60 Nos.
Density : 730 kg/m3
Diff. Head : 15 m POWER CALCULATION
HHP = 0.511 Considering Gland losses, transmission losses and gear box
511 losses to 50%. Hence the agitator power consumption will
BHP = 0 ◊ ◊ 4 = 1.5 HP
0 reduced to 50% efficiency.
Th1 = 250°C Total Power Required HP = 20.06 HP
Tc1 = 30°C
mh = 11138 kg/hr = 3.1 kg/sec JACKET THICKNESS CALCULATIONS
mc = 791.5/3600 = 0.22 kg/s Total Length : 7000 mm
= 0.075 kg/s (Total dissolved solids) Jacket ID : 700 mm
Design Temp : 300 °C
Log Mean Temperature Difference (LMTD)
Method Design Pressure : 5 bar(g)
MOC of Material is SS304 and properties are as under
Cph = 0.64 at 250°C & 3 bar(g)
Cpc = 0.58 at 30°C Composition as : Cr : 18% and Ni : 8%
Ch = mh × Cph =3.1 × 0.64=1.984 kcal/s °C Design Stress : 113.2 N/mm2 at 300 °C
Cc = mc × Cpc =0.22 × 0.58 =0.147kca/s °C Joint Efficiency : 0.85
Cmin = 0.147 Corrosion Allowance : Nil (As it is SS304)
Cmax = 1.984 Thickness is calculated as under:
C* = 0.147/1.984 = 0.065 ≤ 1 ts = 19 mm
ΔTlm =Log mean temperature difference (LMTD) Jacketed Vessel with Agitator cost : Rs.21.16 lacs
ΔTl = Thi – Tci = 250 – 30 = 2200 C
ΔT2 = Tho – Tco = 225 – 200 = 250 C
ΔTlm = 89.6 C
U = 280 kcal/hr-m2-C (Assumed)
F = Fouling factor = 1 (From TEMA Standard)
A = 7.1 m2
Depending on the velocity criterion ID of WFE shall be
calculated as under:
Maximum allowable vapor velocity is 3 m/s and min
velocity is 1 m/s. For Design assumed minimum possible
velocity i.e. 1 m/s.
Ethylene Glycol Evaporation rate is 1000 kg/hr, density
of solvent is 1100 kg/m3 hence the volumetric flow rate is
901 m3/hr i.e. 0.25 m3/s
ID = 400 mm
Height of WFE (H) = 3.8 m
Figure 1: Wiped film evaporator
AGITATOR DESIGN
CONCLUSION
Number of Blade Calculations
It can be concluded that use of WFE (Wiped Film Evaporator) is
Blade Size: 250 mm H × 70 mm W × 12 mm Thk. simple & effective. It is widely used in dairy, pharmaceuticals,
MIT International Journal of Mechanical Engineering Vol. 2, No. 2, Aug. 2012, pp. (105-108) 108
ISSN No. 2230-7680 © MIT Publications

petrochemicals, food industries etc. where high sensitivity & Ch = Hot fluid flow steam heat capacity rate, kcal/kg °C
optimum temperature control is essential along with removal CC = Cold Fluid Flow Steam heat capacity rate, kcal/kg °C
of volatile components from non volatile material.
Ch =mh × Cph
It is used for preservation of permissible commodities &
Cc =mc × Cpc
herbal products for long time duration with keeping their
natural composition unchanged. C* = Cmin/Cmax
total heat transfer rate Q betntwo fluids.
ACKNOWLEDGMENT Q = UAFΔTlm
ΔTlm = Log mean temperature difference (LMTD)
In the pursuit of this academic endeavour, I feel I have been
singularly fortunate. I should fail in my duty if I do not record DT 1 - DT 2
my profound sense of indebtedness and heartfelt gratitude Ê DT 1 ˆ
Ln Á
to my supervisor Prof. AlkeshMavani& Prof. KedarBhojak Ë DT 2 ˜¯
who inspired and guided me in the pursuance of this work.
Q = UAFΔT
I owe a depth of gratitude to Prof. A.R. PATEL, H.O.D. of
M.E. Thermal Engineering, L.D.R.P. Institute of Technology F=VxA
& Research, Gandhinagarand all other faculties for all the n ¥ N 3 ¥ D5 ¥ Sp.Gr
Power ( HHP) =
facilities provided during the course of my tenure. (394)5

n : Number of Impellers
APPENDIX
N : RMP = 60 rpm
Some Important Equations D : Diameter of Impellers in inch
Total Heat Load = Sensible Heat + Latent Heat Sp. Gr. : 1.07 (Specific Gravity of Feed Inlet)
Q = (m x cp x ∆T) + (λxm)
È Ê m3 ˆ ˘ REFERENCES
Í ÁË hr ˜¯ ¥ Diff Head ¥ Sp.Gr.˙
HHP = Î ˚
[1] http://www.brainyquote.com/words/ev/evaporation162073.
274
html#ixzz1iOVheoiS
087
BHP = 0 ◊ [2] http://www.wxhysh.com/products/prod9.htm
Pump Eff .
[3] http://www.dalalengineering.com/wiped_film_evaporator.aspx
22
BHP = 1◊ [4] Jacinto Lopez-Toledo, “Heat and Mass Transfer Characteristics
Pump Eff . of a Wiped Film Evaporator”The University Of Texas At Austin
Th1 = Hot Fluid Temperature (Inlet Temperature) [5] Janusz Dziak, “Mass & Heat Transfer During Thin Film
Evaporation of Liquid solution” Wroclaw University of
= Thermic Fluid at 3 bar Technology, Poland.
Tc1 = Cold Fluid Temperature (Inlet Temperature) [6] R.K.Shah and Dusan P. Sekulic“Fundamentals of Heat
= Herbal & Glycol Solution Exchanger Design” Published by John Wiley & Sons, Hoboken,
New Jersey.
Cmin = Smaller of the two magnitudes of Ch & Cc
[7] V.Jaishree“Optimization of a multiple Effect Evaporator
Cmax = Smaller of the two magnitudes of Ch & Cc System” Department of Chemical Engineering, National
Institute Of Technology, Rourkela, India.