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EVAPORATION
Compilation of Lectures and Solved Problems
CHEMICAL ENGINEERING SERIES 2
EVAPORATION
EVAPORATION
A unit operation that involves the concentration of a solution consisting of a non-volatile solute
and a volatile solvent
1. Single Effect Evaporators – used when the required capacity of operation is relatively small
and/or cost of steam is relatively cheap compared to the evaporator cost.
Vapor, V where:
TV
HV - Mass flow rates of feed,
PV vapor, and steam
respectively
- Temperatures of feed,
product and vapor,
Steam, S P I respectively
TS - Liquid enthalpy of feed
λS
and product, respectively
Condensate
TS2 - Vapor enthalpy
TI - Operating temperature
Feed, F
xF - Operating pressure
TF - Mass fraction of solute in
hF Product, P
CP, F xP
feed and product
TP respectively
hP
Solute Balance:
Enthalpy Balance:
Heat Balance:
( )
must be evaluated at or
If vacuum pressure is given,
CHEMICAL ENGINEERING SERIES 3
EVAPORATION
2. Forward Feed Multiple Effect Evaporators – fresh feed is added to the first effect and flows
to the next in the same direction as the vapor flow. This is used when the feed is hot or when
the final concentrated product might be damaged at high temperatures
VI VII VIII
P1, T1 P2 ,T2 P 3 , T3
Steam, S
TI TII TIII
F
LI LII
P
3. Backward Feed Multiple Effect Evaporators – fresh feed enters the last and coldest effect
and continues until the concentrated product leaves the first effect. This is used when the
fresh feed is cold. This type of evaporation would requires liquid pump for each effect since
flow is from low to high pressure
VI VII VIII
P1, T1 P2 ,T2 P 3 , T3
Steam, S
TI TII TIII
LI LII
F
P
4. Mixed Feed Multiple Effect Evaporators – fresh feed enters any of the available effects and
continues not necessarily to the effect next to it.
5. Parallel Feed Multiple Effect Evaporators – involves the adding of fresh feed and the
withdrawal of concentrated product from each effect. The vapor from each effect is still used
to heat the next effect. This method is used mainly when the feed is almost saturated and
solid crystals are the product, as in the evaporation of brine to make salt.
CHEMICAL ENGINEERING SERIES 4
EVAPORATION
Evaporator Capacity
Where:
- Rate of heat transfer through the heating
surface of an evaporator
- Over-all heat transfer coefficient
- Heat transfer surface area
- Over-all temperature drop
2. Steam Economy – number of kilograms vaporized per kilogram of steam fed to the unit
Boiling point Evaluation (BPE) of a solution is the increase in boiling point over that of water
Dϋhring’s Rule – the boiling point of a given solution is a linear function of the boiling point of
th
pure water at the same pressure. Figure 16.3 (Unit Operations 7 edition by McCabe and
Smith)
( )
∑
CHEMICAL ENGINEERING SERIES 5
EVAPORATION
PROBLEM # 01:
A triple effect forward feed evaporator is being used to evaporate a sugar solution containing 5 wt
% solids to a concentrated solution of 80 %. The boiling point rise of the solutions (independent
2
of pressure) can be estimated from BPR °C = 1.78x + 6.22x , where x is wt fraction of sugar in
solution. Saturated steam at 205.5 kPa (121.1°C saturation temperature) is being used. The
pressure in the vapor space of the third effect is 13.4 kPa. The feed rate is 10,000 kg/h at
26.7°C. The heat capacity of the liquid solutions is 4.19 – 2.35x, kJ/kg·K. The heat of solution is
considered to be negligible. The coefficients of heat transfer have been estimated as U 1 = 3123,
2
U2 = 1987, and U3 = 1136 W/m ·K. if each effect has the same surface area, calculate the area,
the steam rate used and the steam economy.
SOLUTION:
V1 V2 V3
P1, T1 P2 ,T2 P 3 , T3
Steam, S
TI TII TIII
F
L1 L2
L3
Step 1:
rd
From steam table, at 13.4 kPa (pressure of the vapor space at 3 effect)
rd
For the 3 effect with x = 0.80
( ) ( ) ( )
( )
Step 2:
Consider solute balance around the system:
( )( *
Where:
( )( )
nd
For the 2 effect:
( )( )
Step 3:
st nd
To solve for BPR for the 1 and 2 effects:
st
1 effect:
( ) ( ) ( )
nd
2 effect:
( ) ( ) ( )
∑ ∑
∑ ( )
Estimate ΔT for each effect using equation 8.5-6
∑ ( )* +
∑ ( )* +
∑ ( )* +
Calculate actual boiling point of solution for each effect using the estimated ΔT
CHEMICAL ENGINEERING SERIES 7
EVAPORATION
( )
( )
( ) ( )
( )( )( ) ( ) ( )( )( ) ( )
nd
For 2 effect:
( ) ( )
( )
( )
( )( )( ) ( )( )
( )( )( ) ( )
rd
For 3 effect:
( ) ( )
( )
( )
( ) ( )
( )( )( ) ( )( )
( )( )( ) ( )( )
Equate and
Step 5:
Solve for heat transfer area for each effect:
st
For 1 effect:
( *( *
( *( )
nd
For 2 effect:
( *( *
( *( )
rd
For 3 effect:
( *( *
( *( )
Since areas are not close, then another trial should be done
TRIAL 2:
Conduct new material balance using the computed L values
CHEMICAL ENGINEERING SERIES 9
EVAPORATION
( )( )
( )( )
st nd
To solve for BPR for the 1 and 2 effects:
st
1 effect:
( ) ( ) ( )
nd
2 effect:
( ) ( ) ( )
∑ ∑
∑ ( )
( )( *
( )( *
( )( *
Adjust to attain total ΔT of 63.53
( )( *
( )( *
Calculate actual boiling point of solution for each effect using the estimated ΔT
( )
( )
( ) ( )
( )( )( ) ( ) ( )( )( ) ( )
nd
For 2 effect:
( ) ( )
( )
( )
( )( )( ) ( )( )
( )( )( ) ( )
rd
For 3 effect:
( ) ( )
( )
From steam table, at TV2 = 87.61°C
( )
( ) ( )
CHEMICAL ENGINEERING SERIES 11
EVAPORATION
( )( )( ) ( )( )
( )( )( ) ( )( )
Equate and
Step 5:
Solve for heat transfer area for each effect:
st
For 1 effect:
( *( *
( *( )
nd
For 2 effect:
( *( *
( *( )
rd
For 3 effect:
( *( *
( *( )
Areas are almost equal, therefore new assumptions are valid:
ANSWERS:
Area of each effect:
Steam Requirement
Steam Economy:
CHEMICAL ENGINEERING SERIES 12
EVAPORATION
PROBLEM # 02:
A solution with a negligible boiling point rise is being evaporated in a triple effect evaporator using
saturated steam at 121.1°C. The pressure in the vapor of the last effect is 25.6 kPa abs. The
2
heat transfer coefficients are U1 = 2840, U2 = 1988, and U3 = 1420 W/m ·K and the areas are
equal. Estimate the boiling point in each of the evaporators.
SOLUTION:
VI VII VIII
T1 T2 T3 p3 = 25.6
Steam, S
121.1 C kPa abs
TI TII TIII
F
LI LII
P
∑
CHEMICAL ENGINEERING SERIES 13
EVAPORATION
( )( )
( )
( )( )
( )
( )( )
( )
CHEMICAL ENGINEERING SERIES 14
EVAPORATION
PROBLEM # 03:
A forced-circulation evaporator is to
concentrate 60,000 kg/h of 44 percent NaOH to
65 percent using steam at 3 atm pressure. The
feed temperature and the condensing
temperature are both 40°C. The density of the
3
feed solution is 1,450 kg/m . If the over-all
2
heat transfer coefficient is 2,000 W/m ·°C,
calculate (a) the steam requirement, in kg/h; (b)
the heat transfer area required.
SOLUTION:
( )( *
[ ( *( )]
( *( * ( *( *
( *( *
( )
( )
( )( )
CHEMICAL ENGINEERING SERIES 16
EVAPORATION
PROBLEM # 04:
Calculate (a) the steam required in lb/h; (b) heating surface per effect; (c) economy in lb per lb of
steam; and (d) the latent heat to be removed in the condenser
th
(Source: Unit Operations of Chemical Engineering, 7 edition, McCabe and Smith)
SOLUTION:
I II III CONDENSER
c b a
F= 35,000 gal/h
P xF = 0.17
xP= 0.38 TF = 60 F
CHEMICAL ENGINEERING SERIES 17
EVAPORATION
( )( )
( *
Solute balance:
( )( )
Solute balance:
( )( )
Solute balance:
( )( )
TEMPERATURE DISTRIBUTION
Δ
rd rd
Temperature of vapor leaving the 3 effect corresponds to the pressure in the 3 effect
( )( ) ( )( )
( )( ) ( )( )
( )
( )
Feed 60
Feed to “b” 91
Feed to “c” 134
CHEMICAL ENGINEERING SERIES 19
EVAPORATION
st
Consider heat balance around 1 effect:
( )
Consider heat balance around the second effect and heater “c”
st nd
Note that the vapor coming from 1 effect will be used to heat the heater and the 2 effect
( ) ( )
( )
For x = 0.17, Cp = 0.952 BTU/lb·°F
From steam table, at T2 = 144 °F, λ = 1011.64 BTU/lb
( ) ( )( )( )
Consider heat balance around the third effect and heater “b”
nd rd
Note that the vapor coming from 2 effect will be used to heat the heater and the 3 effect
( ) ( )
Equate and
Substitute and
( ) ( )
CHEMICAL ENGINEERING SERIES 20
EVAPORATION
From equation
( )
( )
( )
( *( *
Δ ( *( )
( )
( *( *( )
( *( * ( *
Δ ( *( )
( )
( *( *( )
( *( * ( *
( *( )
Since surface of each effect is not the same, therefore, previous assumptions need to be re-
adjusted
To adjust ΔT:
( *
( )( *
( )( *
( )( *
CHEMICAL ENGINEERING SERIES 21
EVAPORATION
SECOND TRIAL:
Recompute using the adjusted ΔT:
STREAM DESIGNATION TEMPERATURE,
°F
st
1 Effect
Steam Feed to E-I 230
Liquor from E-III 106
Vapor to E-II 170
Product 185
nd
2 Effect
Feed from H- c 160
Vapor to E-III 143
Liquor to E-III 144
rd
3 Effect
Vapor to condenser 101
Liquor to E-I 106
Feed 60
Feed to “b” 91
Feed to “c” 133
st
Consider heat balance around 1 effect:
( )
Consider heat balance around the second effect and heater “c”
st nd
Note that the vapor coming from 1 effect will be used to heat the heater and the 2 effect
( ) ( )
( )
For x = 0.17, Cp = 0.952 BTU/lb·°F
From steam table, at T2 = 143 °F, λ = 1012.23 BTU/lb
( ) ( )( )( )
CHEMICAL ENGINEERING SERIES 22
EVAPORATION
Consider heat balance around the third effect and heater “b”
nd rd
Note that the vapor coming from 2 effect will be used to heat the heater and the 3 effect
( ) ( )
Equate and
Substitute and
( ) ( )
From equation
( )
( )
( )
( *( *
( *( )
( )
( *( *( )
( *( * ( *
( *( )
( )
( *( *( )
( *( * ( *
CHEMICAL ENGINEERING SERIES 23
EVAPORATION
( *( )
Since surface of each effect is not the same, therefore, previous assumptions need to be re-
adjusted
To adjust ΔT:
( *
( )( *
( )( *
( )( *
Since there will be no change in ΔT’s, therefore, assumptions are correct:
( )
( )
ECONOMY:
( )
( )
( *( *( )
From steam table, at T3 = 101 °F, λ = 1036.44 BTU/lb
( *( *
( )
CHEMICAL ENGINEERING SERIES 24
EVAPORATION
PROBLEM # 05:
SOLUTION:
Consider sucrose balance
( )( )
( )
( )( *( )
( )( *
2
From steam table at 8.8 kg/cm gage
( )
* +
CHEMICAL ENGINEERING SERIES 25
EVAPORATION
PROBLEM # 06:
SOLUTION:
( )
( )
( *
From the steam table, @ 460 mm Hg,
( *( *( )
( )( *
CHEMICAL ENGINEERING SERIES 26
EVAPORATION
( )
( )
( )( )
( )
CHEMICAL ENGINEERING SERIES 27
EVAPORATION
PROBLEM # 07:
SOLUTION:
( )( )
( )( *
( *( * ( *( * ( *( *
CHEMICAL ENGINEERING SERIES 28
EVAPORATION
( )
For steam at 50 psig
( *( )
( )
( )
CHEMICAL ENGINEERING SERIES 29
EVAPORATION
PROBLEM # 08:
( )
( )( *( )
( )
Assume barometric pressure of 1 atm or 29.921 in Hg
The vapor will be condensed first before lowering to 100°F, thus, Cp of the liquid water
should be used
( )
( ) ( )( )
( )
From figure 16.3 (McCabe and Smith), for 40% NaOH solution and T 1 of 124.37°F
( )( *
( *( * ( *( * ( *( *
( )
For steam at 20 psig
( *( )
CHEMICAL ENGINEERING SERIES 31
EVAPORATION
PROBLEM # 09:
4,500 kg/h of a 10% wt sugar solution is to be concentrated to 30% wt. Feed enters at 21°C.
Saturated steam at 110°C is available and the temperature in the condenser is 43°C. Specific
heat of the solutions may be taken as constant at 4 J/g·°C. Determine (a) heating surface
required, (b) steam consumption, and (c) steam economy, for each of the following cases:
2
I. Single effect, OHTC = 2,840 W/m ·°C
2
II. Double effect, forward feed; U1 = 2,270, U2 = 1,700 W/m ·°C
2
III. Double effect, backward feed; U1 = 2,270, U2 = 1,700 W/m ·°C
SOLUTION:
( )( *
T1 = 43 C
Steam, S T1
110 C
Sugar soln TI
F=4,500 kg/h
xF = 0.10
TF= 21 C
P
xP = 0.30
Consider heat balance:
Temperature of vapor leaving the evaporator is the same as the condenser temperature
( )
( *( *( )
CHEMICAL ENGINEERING SERIES 32
EVAPORATION
( *( *
Δ ( )
( )( )
( )
( )
( )
VI VII
T2 = 43 C
T1 T2
Steam, S
110 C
TI TII
Sugar soln
F=4,500 kg/h P
PI
xF = 0.10 xP = 0.30
TF= 21 C
Initial Assumptions:
( *
st
Consider material balance around the 1 effect
Δ Δ ( ) Δ ( *
Ts = 110 C
ΔTI Δ
Δ ( )( *
TI
Δ Δ ( ) Δ ( *
ΔTII
Δ
TII = 43 C Δ ( )( *
( )
nd
Enthalpy balance around the 2 effect:
st
Enthalpy balance around the 1 effect:
( )
Equate and
( )
( ) ( )
( )
( ) ( )( )
( ) ( )( )
( )( ) ( )( ) ( )
( ) ( )( )
( )
Equate and
( *( *
( )( )
( )( )
CHEMICAL ENGINEERING SERIES 36
EVAPORATION
( )
( )
( )
VI VII
T2 = 43 C
T1 T2
Steam, S
110 C
TI TII
PI
Sugar soln
P F=4,500 kg/h
xP = 0.30 xF = 0.10
TF= 21 C
Initial Assumptions:
( *
st
Consider material balance around the 1 effect
CHEMICAL ENGINEERING SERIES 37
EVAPORATION
Δ Δ ( ) Δ ( *
Ts = 110 C
ΔTI Δ
TI Δ ( )( *
Δ Δ ( ) Δ ( *
ΔTII
Δ ( )( *
TII = 43 C
( )
nd
Enthalpy balance around the 2 effect:
st
Enthalpy balance around the 1 effect:
Equate and
( )
( )
CHEMICAL ENGINEERING SERIES 38
EVAPORATION
( ) ( )( )
( ) ( )( )
( ) ( ) ( )( ) ( )( )
( )( )
( )
Equate and
( *( *
( )( )
CHEMICAL ENGINEERING SERIES 39
EVAPORATION
( )( )
( )
( )
( )
CHEMICAL ENGINEERING SERIES 40
EVAPORATION
PROBLEM # 10:
Glycerine is to be concentrated from 12% to 72% in a single-effect evaporator. The inlet steam
used is at 25 psig and comes out at 170°F. The vapor space in the evaporator has 25 inches Hg
vacuum. Ten metric tons of glycerine per hour are fed at 85°F. The concentrated product is at
125°F. Calculate the amount of water evaporated in kg/h.
SOLUTION:
Vapor,
V
( )( *
PROBLEM # 11:
A feed of 4,535 kg/h of a 2.0 % wt salt solution at 311 K enters continuously a single effect
evaporator and is being concentrated to 3%. The evaporation is at atmospheric pressure and the
2
area of the evaporator is 69.7 m . Saturated steam at 383.2 K is supplied for heating. Since the
solution is dilute, it can be assumed to have the same boiling point as water. The heat capacity
of the feed can be taken as Cp = 4.10 kJ/kg·K. Calculate the amounts of vapor and liquid product
and the over-all heat transfer coefficient.
th
(Source: Principles of Transport Processes and Separation Processes, 4 edition, by
Geankoplis)
SOLUTION:
Vapor,
V
Steam, S P = 1 atm
383.2 K
F=4535 kg/h TI
xF = 0.02
TF= 311 K
P
xP = 0.03
( )( *
Since the evaporator operates at 1 atm, operating temperature will be the the
temperature corresponding to 1 atm or water boiling point (373 K)
( )
( *( *( )
( *( *
( )
( )( )
CHEMICAL ENGINEERING SERIES 43
EVAPORATION
PROBLEM # 12:
2
An evaporator having an area of 83.6 m and U = 2270 Vapor,
2 V
W/m ·K is used to produce distilled water for a boiler feed.
Tap water having 400 ppm dissolved solids at 15.6 °C is fed
to the evaporator operating at 1 atm pressure abs.
Saturated steam at 115.6°C is available for use. Calculate Steam, S P = 1 atm
115.6 C
the amount of distilled water produced per hour if the outlet
liquid contains 800 ppm solids. xF = 0.04 TI
TF= 15.6 C
(Source: Principles of Transport Processes and Separation
th
Processes, 4 edition, by Geankoplis) P
xP = 0.08
SOLUTION:
Assume that the boiling point of the solution is 100°C (1 atm operating pressure)
( )
( )( )( )
( )
( )
For water, Cp = 4.1868 kJ/kg·°C
( )( *( )
( )( *
( )
CHEMICAL ENGINEERING SERIES 44
EVAPORATION
PROBLEM # 13:
SOLUTION:
( )( *
For 20 kPa evaporator vapor space pressure, the temperature of the vapor (from steam table)
[ ( )]
From steam table, at 60.06°C, ⁄ , ⁄
CHEMICAL ENGINEERING SERIES 45
EVAPORATION
( *[ ( ⁄ )( )]
( *( * ( *( *
( )
( )
( *( *( )( )
( )( )
CHEMICAL ENGINEERING SERIES 46
EVAPORATION
( *( * ( *( *
( )
( )
( *( *( )( )
( )( )
CHEMICAL ENGINEERING SERIES 47
EVAPORATION
PROBLEM # 14:
Vapor,
In order to concentrate 4,536 kg/h of an NaOH solution V
containing 10 wt % NaOH to a 20 wt % solution, a single
2
effect evaporator is being used with an area of 37.6 m . PV = 51.7 kPa (abs)
The feed enters at 21.1 °C. Saturated steam at 110 °C is
Steam, S
used for heating and the pressure in the vapor space of 110 C
the evaporator is 51.7 kPa abs. Calculate the kg/h of
steam used and the over-all heat transfer coefficient. NaOH soln TI
F=4,536 kg/h
xF = 0.10
(Source: Principles of Transport Processes and TF = 21.1 C
th P
Separation Processes, 4 edition, by Geankoplis)
xP = 0.20
SOLUTION:
( )( *
For 51.7 kPa evaporator vapor space pressure, the temperature of the vapor (from steam table)
[ ( )]
From steam table, at 82.06°C, ⁄ , ⁄
( *[ ( ⁄ )( )]
CHEMICAL ENGINEERING SERIES 48
EVAPORATION
( *( * ( *( *
( )
( )
( *( *( )( )
( )( )
CHEMICAL ENGINEERING SERIES 49
EVAPORATION
PROBLEM # 15:
Vapor,
V
An evaporator is concentrating F kg/h at 311 K of a 20 wt %
solution of NaOH to 50%. The saturated steam for heating PV = 13.3 kPa (abs)
is at 399.3 K. The pressure in the vapor space of the Steam, S
399.3 K
evaporator is 13.3 kPa abs. The over-all heat transfer
2 2
coefficient is 1,420 W/m ·K and the area is 86.4 m . NaOH soln TI
F
Calculate the feed rate F of the evaporator. xF = 0.20
TF = 311 K
P
(Source: Principles of Transport Processes and Separation xP = 0.50
th
Processes, 4 edition, by Geankoplis)
SOLUTION:
( )( )
For 13.3 kPa evaporator vapor space pressure, the temperature of the vapor (from steam table)
[ ( )]
From steam table, at 51.39°C, ⁄ , ⁄
( )[ ( ⁄ )( )]
( )
( )( * ( )( *
( )
( )( )( )
CHEMICAL ENGINEERING SERIES 51
EVAPORATION
PROBLEM # 16:
SOLUTION:
( )( )
For 15.3 kPa evaporator vapor space pressure, the temperature of the vapor (from steam table)
Since no BPE
( )
CHEMICAL ENGINEERING SERIES 52
EVAPORATION
( *( *( )
( *( *
( )
( )( )