Evaporator Design

Glycerol FOR 3 EFFECT

We considered 2 effect vertical evaporator design

Given data:
Mass flowrate(w_F) I. Conc(%) F.Conc(%) Temp(K) Steam_press(1st eff) Vacuum_press(3rd eff)
3000 kg/h 5 75 293 103.66 Kpa 100 mm Hg
0.833333 kg/s
Solution:

Total solid Total product Total Evaporation to be done T_steam(entering) T_steam(3rd effect) T_diff
150 kg/h 200 kg/h 2800 kg/h 373.4118 K 324.034 K 49.3778 K
0.041667 kg/s 0.055555556 kg/s 0.777778 kg/s temperature from (sat.)steam table

U_assumed(avg)
1500 W/m²K

Assume nominal diameter 2 in Sch No 80 Steel pipe

TUBE OD 2.38 in 0.060452 m
ID 1.939 in 0.04925 m
length 2 m

Assuming equal evaporation rate in all 2 effects

w1 0.388889 kg/s w1 is evaporation rate in 1st effect Outlet from 1st effect w_F-w1 0.444444 kg/s
w2 0.388889 kg/s w2 is evaporation rate in 2nd effect Outlet from 2nd effect w_F-w1-w2 0.055556 kg/s

Conc_gly in outlet from 1st effect(wt%) 9.375

Conc_gly in outlet from 2nd effect(wt%) 75

From BPR table of glycerol

BPR for 1st effect 0.7 K BPR1
BPR for 3rd effect 13.85 K BPR3

Sum of BPR for glycerol soln(s) 14.55 K

Effective temp diff (T_diff- s) 34.8278 K

Assume heat transfer rate to be equal for each effect,

Q1=Q2
We know U1=U2=1500 W/m2K
U1A1Δt1=U2A2Δt2=U3A3Δt3
Assume all areas be equal,
Δt1=Δt2
Δt1 17.4139 K
Δt2 17.4139 K

Actual boiling point in each effect

1st effect T1 = T_steam-Δt1 355.9979 K
2nd effect T2 = T1-BPR1-Δt2 337.884 K

For ho calculation: For hi calculation:

Using properties for each effect in above equation:

ho1 5442.35 W/m²K hi1 6721.04 W/m²K
ho2 5135.99 W/m²K hi2 2350.87 W/m²K
ho3 4824.96 W/m²K hi3 1989.01 W/m²K

Using the equation for U,

U1 2334.715789 W/m²K
U2 1284.065801 W/m²K
U3 1128.26347 W/m²K

Thus,
Estimated U for 1st effect(U1) 2334.71579 W/m²K
Estimated U for 2nd effect(U2) 1284.0658 W/m²K
Estimated U for 3rd effect(U3) 1128.26347 W/m²K

Assume heat transfer from steam to soln is equal in all 2 effects

Q1=Q2
Also, heat transfer area for all 2 effects are equal, A1=A2
We have,
U1A1Δt1=U2A2Δt2
U1Δt1=U2Δt2
2334.71579Δt1=1284.0658Δt2
Δt1 7.125861 K
Δt2 12.95639 K
λs = latent heat of steam = 2257.86 kJ/kg 2257.86 kJ/kg
Actual boiling point in each effect HF = enthalpy of feed at inlet temp(293 ⁰C) = 0.575 kcal/kg⁰C * 25 60.0875 kJ/kg
1st effect T1 = T_steam-Δt1 366.2859 K H1 = enthalpy of steam leaving 1st effect at T1 = H2s+Cpsteam(BPR1)
2nd effect T2 = T1-BPR1-Δt2 352.6295 K H1 = 2666.0 kJ/kg +1.884 kJ/kgK * BPR1 2500.119 kJ/kg
h1 = enthalpy of outlet at T1 = CP1(T1-0) = 0.069 kcal/kg⁰C * T1 105.6442 kJ/kg

Heat balance
1st effect λ1 = latent heat of steam at
at 366 K = H1 - h2s
367.135K 2272.423 kJ/kg
w_sλs + w_FHF = w1H1 + (w_F-w1)h1 H2 = enthalpy of steam leaving 2nd effect = H3s+Cpsteam(BPR2)
59.476w_s - 63.075w1 = 1 -->eqn(1) H2= 2646.6 kJ/kg + 1.884kJ/kgK*BPR2 2672.593 kJ/kg
h2= enthalpy of outlet at T2 = CP2(T2-0)= 0.0585kcal/kg⁰C*T2 85.49151 kJ/kg

2nd effect
w1λ1 + (w_F-w1)h1 = w2H2 + (w_F-w1-w2)h2
134.1186w1 - 154.0572w2 + 1 = 0 -->eqn(2)
Also, Heat transfer rate in each effect
w1+w2 = 0.7778 -->eqn(4) Q1 = w_sλs 1025.2942 kJ/s U1A1Δt1
Q2 = w1λ1 937.01069 kJ/s U2A2Δt2
Solving these equations,
w_s 0.4541 kg/s
w1 0.41234 kg/s
w2 0.36546 kg/s

Area of each effect Deviation_area

A1 61.6278657 m2 4.4989712 %
A2 56.32136388 m2 A1+A2+A3 117.9492 m2 4.4989712 %
ΣAi/2 58.97461 m2

Cost Estimation

Steam Economy
Σwi 0.7778 kg/s Steam Economy 1.7128386
w_s 0.4541 kg/s

Total Area 117.9492

Purchasing Cost of Evaporator

a 17000
b 13500
n 0.6
Aavg 58.97461479
For single effect
Ce a + bS^n 172859.341

Purchasing cost for 2 effects = 2*Ce 345718.7

Annual Cost Calculation

P 345718.6824
n 5
i 0.1 10 %

A 91199.71748
Amount to be paid annually to repay the principal 91199.72

Steam Cost Calculation

Steam flow rate 0.4541 kg/s

Steam cost 2 Rs/Kg
Time of Running
10Hr for 300Day/yr 10800000 sec
Steam Cost Per Yr 9808560

Electricity Cost Calculation

Consumption/Day 40 KW/hr
Electricity Rate 4.5 Rs/hr
Total Electricity cost 540000 Rs
Total fixed cost 91199.71748 Rs
Total Operating cost 10348560 Rs
Total Cost for running plant 10439759.7 Rs/year