66

Wiped Film Evaporator

CHAPTER

9
Wiped Film
Evaporator
9.1 Overview
We are using wiped film evaporator in our process to remove heavy residue
from the used oil feed which also contains lube oil (our desired product), diesel, and sulfur
compounds.
The key to efficient, economical concentration, distillation or
devolatilization of a product is selecting the technique best suited to the process. Tubular
evaporators of batch or continous types, such as forced circulation, rising film and falling
film, have been widely used successfully with a variety of materials. However, they have
been less successful with heat sensitive, viscous, fouling or high boiling liquids. Degradation
due to long residence times, fouling of the heat transfer surface, plugging of tubes, and low
heat transfer coefficients and high pressure drops due to high viscosities are common
operating problems.

9.2 Wiped Film Technology 1

Wiped film evaporation has been very successful with difficult- to- handle
products. Simply stated, the method quickly separates the volatile components using indirect
heat transfer and mechanical agitation of the flowing product film under controlled
conditions.

Fig 9.1
 67
Wiped Film Evaporator

The separation is normally done under vacuum conditions to maximize ∆T while maintaining
the most favorable product temperature, and to maximize recovery. A variety of wiped film
evaporator designs are commercially available today. Wiped film evaporators can be either
vertical or horizontal, and can have cylindrical or tapered thermal bodies and rotors. The
majority of wiped film evaporators in operation today are the vertical design with a
cylindrical fixed clearance rotor. The vertical wiped film evaporator consists of two major
assemblies: 1. A Heated Body (Jacketed Cylindrical Shell) 2. A Rotor

Fig 9.2
 68
Wiped Film Evaporator
Two-third of the cylindrical shell of the evaporator is jacketed with heating
fluid whereas the remaining part is unjacketed. The jacketed section is vaporization zone
whereas unjacketed section is the vapor disengagement zone.The feed enters unit tangentially
above the heated zone and is distributed evenly over the inner circumference of the body wall
by the rotor. Product spirals down the wall while the bow wave developed by the rotor blades
generates highly turbulent flow and optimum heat flux. In jacketed portion the evaporation of
the volatile components occurs, the vapors formed from the agitated-thin film, rise upward
and enter the vapor disengagement zone. Here the vapor velocity is decreased and the
entrained liquid droplets are disengaged from the vapors. These liquid droplets are sent back
to the heated surface by the rotor blades. Liquid-free vapors (diesel, lube, sulfur compounds)
escape through outlet at the top of the evaporator and are sent to the condenser. The residue is
taken from the bottom outlet.
Continous washing by the bow wave minimizes fouling of the thermal wall
where the residue is most concentrated. The combination of short residence time, high
turbulence and surface renewal permits the wiped film evaporator to successfully handle
viscous, heat-sensitive, and fouling streams.
Wiped film evaporators have a wide processing flexibility, and a single
system can often be designed to process different products under varied operating conditions.
Wiped film technology is a good choice for process or products containing vaporizable or
partly vaporizable components that must be removed to improve quality, yield/recovery,
operating economy or environmental containment.

9.2.1 Advantages of Wiped Film Evaporator

9.2.1aNo Product Degradation due to:

1.Short residence time.
2.Positive flow conditions, no back mixing.
3.High product film turbulence induced by the rotor blades, protecting the product from
local over exposure to elevated temperatures.
4. High product film turbulence prevents also surface fouling of particles, permitting
thus the processing of suspensions and slurries.
5. Self-cleaning effect.

9.2.1b High Evaporation Capacity (>95%), due to:

1. Centrifugal action of the rotor blades permitting normal evaporating conditions at
high temperature differences.
2. Appropriate selection material combinations giving a low thermal wall resistance.

9.2.1c Highest Product Quality and Yield due to:

1. Continous single pass operation i.e. no recirculation.
 69
Wiped Film Evaporator
2. Built-in separator section eliminating contamination of the product vapors with the
liquid droplets.
3. Counter-current flow of liquid and vapors (allowing maximum separation efficiency
for single stage operation).

9.2.1d Easy operation and maintenance, due to:

1. Adaptation to optimum conditions.
2. Fast response to changing operating conditions, due to minimum product holdup
3. Simple cleaning procedure (flushing the evaporator with appropriate liquid).
4. Evaporator design permitting easy access to all important parts for inspection and
maintenance.
9.3 Heating Fluid 2
In the evaporator the temperature of the used oil feed is to be increased from
o o
186 C to 320 C, and for that a utility fluid is needed for heating purposes. We are using
Paratherm (a heating oil) as our heating fluid in the evaporator. The reasons for preferring
this heating fluid over steam or other heating fluids are :
1. Our operating temperature is very high i.e. 320oC
2. Due to vacuum, high pressure steam cannot be used

9.3.1 Advantages of Paratherm over other Heating Fluids

9.3.1a Non-Fouling

Unlike conventional heat transfer fluids, the Paratherm will not cause hard
carbon formation on heated surfaces. Conventional heat transfer fluids, when severely
overheated, will produce sooty carbon at the film layer. Much of this carbon immediately
adheres to the heated surface and bakes on, forming a crust.

9.3.1b Non-Toxic
The Paratherm fluid is completely non-toxic. It is certified by the FDA and
USDA, by Canadian Agriculture and Health & Welfare and by New Zealand MAF for use
with food and pharmaceuticals. It also carries the NSF's H1incidental food contact rating and
is certified kosher by the Orthodox Union (O-U), the world’s premier kosher certifying
agency.

9.3.1c Low Vapor Pressure

The Paratherm fluid has an extraordinarily low vapor pressure – less than 1/3
of an atmosphere at its maximum operating temperature. This and the fluid’s exceptionally
low pressure drop permit the designer considerable latitude in the choice of lower-cost
equipment.
9.3.1d Low-Viscosity
Paratherm’s viscosity is among the lowest of available high temperature heat transfer fluids.
This means that less horsepower is needed for a given duty, and that a smaller pump and
motor can be specified.
 70
Wiped Film Evaporator

9.4 Material Balance

Temp = 320 oC
Temp=186oC
Vapors 3757kg/hr
Temp =
(Lube+Diesel+Residue+Sulfur
Comp)
320oo C
Feed 4117kg/hr
Lube 3847kg P = 0.2
Diesel 11kg kpa Temp = 320 oC
Residue 197kg
Sulfur Comp 62kg (Residue + Lube)
360 kg/hr
Fig 9.2


Since in the evaporator the vapors produced are in equilibrium with the liquid
and temperatures of both top vapors and the bottom liquid is the same, so we
can perform flash calculations for the material balance 3

since we know that Zi = Lxi + Vyi

& L= 1 – V
so Zi = xi(1-V) + Vyi
Substituting xi = yi/Ki and solving for yi
yi = Zi Ki
& 1+ V(Ki - 1)
∑ yi = ∑ Zi Ki
1+ V(Ki - 1)
From Material Balance we found the amount of individual components in the vapor and
liquid streams Table 9.1
Components Amount in Vapor Amount in bottom Liquid (kg)
(kg)

Lube Oil 3647 200

Diesel 11 0
Sulfur Compounds 62 0
Heavy Residue 37 160
 71
Wiped Film Evaporator

9.5 Energy Balance:

∆H1 ∆HV

Evaporator

∆HL

∆H2

Fig 9.3

Heat In - Heat out + Heat Generated - Heat Consumed = 0

Reference Conditions: T=25 oC , P = 101.3kpa

∆H2 - ( ∆HL + ∆Hv ) = Consumed - Generated

no heat is generated & consumed within the evaporator,
So Heat In = ∆H2 = ( ∆HL + ∆Hv )
now ∆HL = mlCpl ∆Tl
and Cpl = Heat capacity of liquid= 2.9888 kj/kg K

so
∆HL = 88 kwatt
and
∆Hv = mv£
Where £ = Latent heat of vaporization =315.45 kj/kg
and mv = mass flow of vapors = 3757 kg/ hr
∆Hv =330 kwatt
so
Heat duty required = ∆H2 = ∆HL + ∆Hv = 418 kwatt
Heat Load
Heat Duty required = 418 kwatt

9.6 Mass Flow of Paratherm

 72
Wiped Film Evaporator
Paratherm : (T1) 350o C (T2) 330 oC
Used Oil : (t2) 320 oC (t1) 186 oC
Since Q = mCph ∆T
Cph = Heat capacity of Paratherm = 4.12 kj/kg K , mh= mass flow of paratherm

Therefore mh = 5073 kg/hr

9.7 Heat Transfer Area

L.M.T.D = t = ((T1-t2)-(T2-t1)) / ln(T1-t2/T2-t1)
= (350-320)-(330-186) / ln(350-320/330-186)
L.M.T.D = 73 oC
Assume Overall Heat Transfer Coefficient U = 258 W/m2 K
Area, A = Q/U ∆ T

so Area = 23 sq.meter

9.8 Length of Evaporating Section

For Vertical Columns, the Rule of Thumb 4 is
L/D = constant= 3 - 5
Take L/D=3 L = 3D
Since A= πDo L so 23 = πDo (3Do )
so Do =1.56 m
 Now A= π×Do × L so 23 = π × 1.56 × L

Therefore L = 4.70 m
we use 20mm = 0.02m thick wall 5
Internal Diameter . Di =Do - 2t = 1.56- 2(0.02)
Di = 1.52 m

9.9 Jacket Design

At steady state hj (T-Tw) = U (T-t)
where T= (350+330) /2 = 340o C & t = 320 oC
and hj = Jacket side heat transfer coefficient
Assume hj = 286 watt/m2K
So 286 (340-Tw) = 258 (340-320)
So wall Temp = 322 oC
Spacing between the shell wall & jacket wall = ∆s = 0.23m , It is calculated as
follows:

For turbulent flow , Re = 4500

also Re = (Deq G)/ µ = Deq (mh/ S)
 73
Wiped Film Evaporator
where S = flow area , m2 , mh = mass flow of paratherm , kg/hr
Deq= Equivalent Diameter of Jacket, m
Deq/ S = Re × µ = 0.39
mh
also Deq = 4 × hydraulic radius= 4 rh
And rh = flow area/wetted perimeter
so Deq = 4(d02-di2) π/4
π(d0+di)
Deq = (d0-di)
now S = (d02-di2) π/4
So Deq/ S = (d0-di) = 4
2 2
(d0 -di ) π/4 π (d0+di)
0.39 = 4
π (d0+di)
(d0+di) = 3.27
Since di = 1.52m
So d0 = 3.27-1.52= 1.75m
So ∆s = (d0-di) =1.75 -1.52

∆s = 0.23m
also Deq = (d0-di) = 0.23m

9.9.1 Physical properties of Paratherm at 340 oC: 6

ρh =Density of paratherm = 691kg/cubic m , µh = Viscosity = 0.01 pa.sec
kh = Thermal conductivity = 0.94 W/m.K Ch = Heat Capacity = 4.12kj/kg K
Volumetric flow rate of paratherm= qh= mh / ρh = 5073/691 = 7.34 m3
Velocity of Paratherm in the jacket = uh = qh/aj
Where aj = cross-sectional area of the channel
= π/4 D2eq= 0.0126 m2
So uh = 7.34/0.0126 =582 m/hr = 0.16m/sec
Now Re 0.8 = [(ρh× Deq × uh )/µ]0.8
So Re 0.8 = 530
at Tw= 322 oC
µw= 0. 011 pa.sec
So ( µh/µw)0.14 = 0.90
Pr0.4 = (Cph ×µh / kh)0.4
So Pr0.4 = 2.83

Where Pr = Prandl number

& Nu = (hj × Deq/kh)
Nu = hj × 0.143
where Nu = Nussselt Number
But
 74
Wiped Film Evaporator
Nu = 0.027 × Re 0.8 × Pr0.4 × ( µh/µw)0.14
So
hj = 283watt/m2.K
So our assumed value of hj is validly justified

9.10 Evaporator Shell Design:

Physical properties of Used Oil (40 oAPI ) at 320 oC

ρ = Density = 830kg/m3 , k =Thermal conductivity = 0.138watt/m.K
Cp =Heat capacity = 2.531 kj/kg K µ = Viscosity = 0.01121 pa.sec

9.10.1 Evaporating Film Coefficient :

hb = 570 × (k0.875/µ0.18) × (ρ × Cp/tf)0.125
so hb = 785 watt/m2.K

9.10.2 Calculation of Resistance Due to Wall Thickness :

The material of construction of evaporator shell is carbon steel for which
thermal conductivity = kw = 55 watt/m2.K

Dirt Coefficient : 7
For Jacket Side:
hjd = 5050 watt/m2.K (Heat Transfer Fluid )
For Shell Side :
hsd = 2525 watt/m2.K ( Boiling Organics )

9.10.3 Overall Heat Transfer Coefficient:

1/ U = 1/hj + 1/hjd + (D0 ×ln(D0 /Di)/ 2×kw)
So 1/ U = 0.00389

Therefore U = 257 watt/m2.K

 Since calculated value of U is close enough to our supposed value so our calculations
are correct

9.10.4 Total Height of Evaporator 8

Since L = 2/3 Lt
So Lt = 3/2 L = 3/2 × 4.70 = 7 m

9.10.5 Height of Separating Section

Lr = Lt – L = 7 - 4.70 = 2.3m
 75
Wiped Film Evaporator

9.10.6 Residence Time

Since Mass Flow Rate of Used Oil, m = 5073 kg/hr
Volumetric Flow Rate of Used Oil,
q = m/ρ = 9.11 m3/hr
Area of Cross Section of Film,
af = π ×L ×Tf = 0.01m2
Film Velocity uf = q / af = 0.25 m/sec

Residence Time t = L/ uf = 18 sec

9.11 Rotor Design

Film thickness in the Shell = Tf = 0.05 in = 0.0012m
so Diameter of Rotor = Dr = Di – 2 Tf = 1.51m
Tip Speed = Ts = 6.5 m/sec
Rotational Speed , n = Ts/π × Dr = 1.4 rps
No. of Blades = B = 4

Time for deposition and Recollection of thin film:

tf = 1 / n×B = 0.17 sec

9.11.1 Power
Re = (n× D2r ×ρ)/ µ = 240861
For this rotor blade power number is a function of Reynolds No. and is ,
9
Power Number , Np = 1.26(Re)0.0296 = 1.26(240861)0.0296
So Np = 1.81
Power, P = Np ×n3 × D5r ×ρ
therefore
Power, P= 4.7 Kwatt = 6.3 hp

Specification Sheet
Equipment Wiped Film Evaporator
 76
Wiped Film Evaporator
Function To separate lube oil from used oil feed

Operating Pressure 0.2 kPa

Operating Temperature 320 oC

Heat Load 418 kwatt

Area of Heat Transfer 23 m2

Inner Diameter of Shell 1.52 m

Wall Thickness 0.02 m

Total Height of Evaporator 7m

Diameter of Rotor 1.51 m

No. of Blades 4

Power Requirement 6.3 kwatt

Material of Construction Carbon Steel

References:
1. Jacinto Lopez-Toledo,Heat and Mass Transfer Characteristics of Wiped Film
Evaporator, Research paper presented at the University of Texas, August 2006,Austin
 77
Wiped Film Evaporator
2,6. Paratherm Corporation, www.paratherm.com

3,8. LCI Corporation, www.lcicorp.com

4. F.L.Avens,Equipment Design Handbook for Refineries and Chemical Plants,

2nd Ed, Vol.2, Gulf Publishing Company, USA

5. Paratherm Corporation, www.paratherm.com

7. Ernest E. Ludwig, Applied Process Design for Chemical and Petroleum Plants,
3rd Ed, Vol.1, Gulf Publishing Company, USA

9. “Design Model of Wiped Film Evaporator”, Chemical Engineering Science,

Vol.50, No.3, Elsevier Publishing Ltd, Great Britain, 1995