EVAPORATION:

Evaporation is the partial removal of water from liquid food by boiling. For instance, liquid
products can be concentrated from 5% dry solids to 72%, or even higher, depending on the
viscosity of the concentrates. Evaporation is used to pre-concentrate food, to increase the
solid content of food, to change the colour of food and to reduce the water content of a liquid
product almost completely, e.g. as in edible oil drying.
Reduction of the water content by evaporation reduces weight and volume of the product,
cutting storage and transportation costs, and improving the storage stability of the product.

The basic factors that affect the rate of evaporation are the:

➢ rate at which heat can be transferred to the liquid.

➢ quantity of heat required to evaporate each kg of water.
➢ maximum allowable temperature of the liquid.
➢ pressure at which the evaporation takes place.
➢ changes that may occur in the foodstuff during the course of the evaporation
process.

EVAPORATORS:

An evaporator is a heat exchanger designed whose purpose is to heat a given compound and
separate water through evaporation.
Traditionally, evaporators are used in industrial processes. An example is the food sector,
where water is eliminated from foods to increase the concentration of the solid part, obtain
the desired taste and texture and increase shelf life.
CONSTRUCTION OF AN
EVAPORATOR:
The typical evaporator is made up of three
functional sections:
➢ The heat exchanger
➢ Vacuum
➢ The evaporating section
➢ The separator
➢ Condenser

In many evaporators, all three sections are

contained in a single vertical cylinder.
Steam, vapour or exhaust gases from other
drying operations, are usually used as the
heating medium.

➢ The heat exchanger:

The heat exchanger is enclosed in a large chamber and transfers heat from the heating
medium, usually low pressure steam, to the product usually via indirect contact surfaces.

➢ The vacuum:
The vacuum keeps the product temperature low and the difference in temperatures high.

➢ The evaporating section:

Here the liquid boils and evaporates.

➢ The separator:
The vapour separator removes entrained solids from the vapours, channelling solids back to
the heat exchanger and the vapours out to the condenser.

➢ The condensor:

It is sometimes a part of the actual heat exchanger, especially in older vacuum pans, but more
likely a separate unit in newer installations. The condenser condenses the vapours from inside
the heat exchanger and may act as the vacuum source.

PRINCIPLE OF OPERATION OF AN EVAPORATOR:

The driving force for heat transfer is the difference in temperature between the steam in the
coils and the product in the pan. The steam is produced in large boilers, generally tube and
chest heat exchangers. The steam temperature is a function of the steam pressure. Water boils
at 100° C at 1 atm., but at other pressures the boiling point changes. At its boiling point, the
steam condenses in the coils and gives up its latent heat. If the steam temperature is too high,
burn-on/fouling increases so there are limits to how high steam temperatures can go. The
product is also at its boiling point. The boiling point can be elevated with an increase in
solute concentration. This boiling point elevation works on the same principles as freezing
point depression.

TEMPERATURE RATES:

Since food products are heat sensitive, it’s necessary to work at low temperatures. This is
achieved by boiling the liquid part under vacuum. Evaporation normally occurs in the range
of 50-100oC, although it can be as high as 130oC in the sugar industry.

Important practical considerations in evaporators:

➢ maximum allowable temperature, which may be substantially below 100°C.

 ➢ promotion of circulation of the liquid across the heat transfer surfaces, to
attain reasonably high heat transfer coefficients and to prevent any local
overheating,

➢ viscosity of the fluid which will often increase substantially as the

concentration of the dissolved materials increases.

➢ tendency to foam which makes separation of liquid and vapour difficult.

Evaporator selection:
The rapid development of the process industries and of new products has provided many
liquids with a wide range of physical and chemical properties all of which require
concentration by evaporation. The type of equipment used depends largely on the method of
applying heat to the liquor and the method of agitation. Heating may be either direct or
indirect. Direct heating is represented by solar evaporation and by submerged combustion of
a fuel. In indirect heating, the heat, generally provided by the condensation of steam, passes
through the heating surface of the evaporator. Some of the problems arising during
evaporation include: (a) High product viscosity. (b) Heat sensitivity. (c) Scale formation and
deposition. Equipment has been developed in an attempt to overcome one or more of these
problems. In view of the large number of types of evaporator which are available, the
selection of equipment for a particular application can only be made after a detailed analysis
of all relevant factors has been made. These will, of course, include the properties of the
liquid to be evaporated, capital and running costs, capacity, holdup, and residence time
characteristics.

CLASSIFICATION OF EVAPORATORS ON ENERGY SAVING EVAPORATION

SYSTEMS:

➢ Single-effect evaporator
➢ Multiple effect evaporator
➢ Vapour recompression evaporators

➢ SINGLE EFFECT EVAPORATORS:

Definition:
In a single-effect evaporator, steam provides energy for
vaporization and the vapor product is condensed and removed
from the system.
It is made up of three functional sections:

➢ The heat exchanger

➢ The evaporating section:
Here the liquid boils and evaporates.
➢ The separator:
 Where vapour leaves the liquid and passes off to condenser or other equipment.

In many evaporators all these three sections are contained in a single vertical cylinder.

Construction:

➢ In the centre of cylinder there is steam heating section.

➢ The steam heating section has pipes passing through it in which the evaporating liquor
rises.
➢ At the top of the cylinder the baffles which allow the vapours to escape but check
liquid droplets which may accompany the vapours from the liquid surface. This type
of evaporator is called conventional evaporator.

Mechanism:

In the heat exchanging section called the calandria

in this type of evaporator, steam condenses in the
jacket and the liquid being evaporated boils on the
inside of the tubes and in the space above the upper
tube plate.

The circulation of liquids greatly affects the

evaporation rates but circulation rates and pattern
are very difficult to predict in any detail.

As evaporation proceeds the remaining liquors

become more concentrated and because of this the
boiling temperature rises.

Also the viscosity of the liquid will increase, often

quite substantially, this affects circulations and heat
transfer coefficients leading again to lower rates of
boiling.
Single-effect evaporators are often used when the required capacity of operation is relatively
small and/or the cost of steam is relatively cheap compared to the evaporator cost. However,
for large-capacity operation, using more than one effect will markedly reduce steam costs.

ADVANTAGES AND DISADVANTAGES OF SINGLE EFFECT EVAPORATOR:

ADVANTAGES DISADVANTAGES
High heat transfer rates at high temperature Large floor, space and weight
differences leads to quick process.
Ease of cleaning Poor heat transfer at low temperature
differences
Relatively inexpensive. Not use for thermolabile products.

APPLICATION:

Evaporators are an important unit operation and find application in many different industries.
Evaporators find use in such applications as caustic soda processing in the chemical industry,
ammonium nitrate in the fertilizer industry, Bright dip acid (phosphoric) in steel mills, as well
as applications in the aluminum industry, paper mills, distilleries, and others.
It is also used in:
➢ The concentration of milk to produce condensed milk.
➢ Concentration of juices
➢ Concentration of NaCl, NaOH from aqueous solutions to produce salt.
➢ Ether recovery from fat extraction.

MULTIPLE EFFECT EVAPORATOR :-

Definition:
Two or more evaporator units can be run in sequence to
produce a multiple effect evaporator. It is an apparatus for
efficiently using the heat from steam to evaporate water. It
is an important procedure adopted to economize the
consumption of energy. 1kg of steam can evaporate more
water, depending on the number of effects and operating
pressures.
Construction:
Each effect would consist a heat transfer surface, a vapour separator, as well as a vacuum
source and a condenser. For concentrating a process liquid it comprises of:
➢ A plurality of evaporator effects arranged in series.
➢ Each effect includes a process liquid inlet and a process liquid outlet, a heating fluid
inlet and heating fluid outlet.
➢ Heat exchange means in each effect for passing process liquid in heat exchange
relationship with heating fluid for evaporating water out of process liquid and where
in evaporated water from one effect serves as heating fluid for adjacent effect.
➢ An evaporative condenser provided with liquid inlet means for receiving process
liquid from one of evaporator effects, and liquid outlet means for transmitting process
liquid to another evaporator effects. Means for receiving heating fluid vapour and for
passing heating fluid vapour in heat exchange relationship with cooled process liquid
in a cooling circuit , for condensing heating fluid vapour.

Working Principle:
Water is boiled in a sequence of vessels, each held at a lower pressure than the last. The
boiling point of water decreases as pressure decreases, the vapour boiled off in one vessel can
be used to heat the next. Generally the first vessel (at highest pressure) requires an external
source of heat.
Mechanism:

Each effect operates at a lower pressure and temperature

than the effect preceding it so as to maintain a
temperature difference and continue the evaporation
procedure.

Due to heat transfer the liquid temperature increases and

reaches the boiling point . during this process, vapour
will be generated from the liquid feed.

So formed vapours displaces the air in the upper part of

1st evaporator.

Moreover the vapour also displaces the air in the steam

space of the 2nd evaporator.

after complete displacement of air of second evaporator,

the second valve is closed

The vapour of 1st evaporator transmits its heat to the

liquid of second evaporator and gets condensed.

Condensate is removed through the second condensate

valve . these steps continue in the 3rd evaporator.

Types of multiple effect evaporators:

There are four types of MEE, based upon feeding methods:
➢ Backward feeding
➢ Forward feeding
➢ Mixed feeding
➢ Parallel feeding

➢ Backward feeding:
In the backward-feed operation for a triple-effect evaporator, the fresh feed enters the last
and coldest effect and continues on until the concentrated product leaves the first effect.
This method of reverse feed is advantageous when the fresh feed is cold, since a smaller
amount of liquid must be heated to the higher temperatures in the second and first effects.
However, liquid pumps are used in each effect, since the flow is from low to high
pressure. This method is also used when the concentrated product is highly viscous. The
 high temperatures in the early effects reduce the viscosity and give reasonable heat-
transfer coefficients.
➢ Forward feeding:
In forward-feed operation, the fresh feed is added to the first effect and flows to the next in
the same direction as the vapor flow. This method of operation is used when the feed is hot or
when the final concentrated product might be damaged at high temperatures. The boiling
temperatures decrease from effect to effect. This means that if the first effect is at P1= 1 atm
abs pressure, the last effect will be under vacuum at a pressure P3.
➢ Mixed feeding:
When feed moves forward with fresh feed entering at the 2nd or 3rd effect is called as mixed
type feeding. The final evaporation is done at the highest temperature so economies are still
better than forward feed, but fewer pumps are required than in a backward feed arrangement.
It is used in solutions having considerable change in viscosity with temperature over
concentration range.
➢ Parallel feeding:
Parallel feed in 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 of operation is mainly used when the feed is almost
saturated and solid crystals are the product, as in the evaporation of brine to make salt.

Advantages and disadvantages of multiple effect evaporator:

Advantages Disadvantages
1. Suitable for large scale and Not suitable for cold in forward feeding
continuous operation arrangement.
2. Highly economical when compared In backward feed arrangement, as the liquid
to single effect moves from low pressure side to high
pressure side, pumping is required.
3. Multiple effects are now used to
minimize the energy input required
to evaporate or boil off undesirable
water content.
4. The total evaporation achieved in
these systems is approximately the
number of effects times the energy
input to the first effect.

VAPOUR RECOMPRESSION EVAPORATORS:

Also known as mechanical vapor recompression, thermal recompression or vapor
recompression evaporators, these units have gained widespread acceptance in a variety of
applications including foods, drugs, dairy products, and pulp and paper as well as for
desalting brackish water or seawater. Vapor recompression is accomplished by mechanical
compressors or steam-jet ejectors, depending on the volume and quality of vapors to be
handled, and the pressure level required in the steam chest. Inherently, water vapor has a high
specific volume of 26.8 ft/lb at 14.7 psia.
The boiling creates vapours which can be recompressed for high steam economy. This can be
done by adding energy to the vapour in the form of a steam jet, thermo compression or by a
mechanical compressor, mechanical vapour recompression.

Thermo Compression (TC)

Involves the use of a steam-jet booster to recompress part of the exit vapours from the first
effect. Through recompression, the pressure and temperature of the vapours are increased. As
the vapours exit from the first effect, they are mixed with very high pressure steam. The
steam entering the first effect calandria is at slightly less pressure than the supply steam.
There is usually more vapours from the first effect than the second effect can use; usually
only the first effect is coupled with multiple effect evaporators.

Mechanical Vapour Recompression (MVR)

Whereas only part of the vapour is recompressed using TC, all the vapour is recompressed in
an MVR evaporator. Vapours are mechanically compressed by radial compressors or simple
fans using electrical energy.

There are several variations; in single effect, all the vapours are recompressed therefore no
condensing water is needed; in multiple effect, can have MVR on first effect, followed by
two or more traditional effects; or can recompress vapours from all effects.

Industrial applications:

Process heat-sensitive materials, e.g., fruit juices and similar applications in dairy and
pharmaceutical plants.

• Crystallize solids having inverse solubility curves (solubility decreases with increasing
temperature), such as sodium sulfate and sodium carbonate.

• Produce potable water from brackish or salt water in remote locations where either electric
power is unavailable (engine-driven compressors must be used) or where considerations other
than cost have a higher priority (for example, scarcity of freshwater resources).

CLASSIFICATION OF EVAPORATORS ON THE BASIS OF CIRCULATION:

Evaporators with tubular heating surfaces are prominent in the industry. Circulation of the
liquid past the surface may be induced in terms of boiling (natural circulation) or by using
pumps (forced circulation). The latter may or may not involve boiling in the heating surface.
 ➢ NATURAL CIRCULATION EVAPORATORS:

Definition:
Natural circulation in an evaporator is caused by the
thermal difference between the heating medium and the
liquid. This thermal change is called "thermo-siphon
action". Sufficient heat must be available to provide the
necessary thermal difference to cause circulation. these
evaporators depend on natural physical forces in lieu of
pumps for their operation.

Construction:
Natural Circulation evaporation is essentially based upon
natural convection currents manipulated through the
system piping to create circulation. Circulation through convection is achieved through
bubble formation. Bubble are of lower density and rise through the liquid to promote upward
lift into the evaporating vessel.
Physically Natural circulation evaporators use a short tube bundle within the batch pan or by
having an external shell and tube heat exchanger outside of the main vessel.

Working principle:
The movement of the liquid results from convection currents set up by the heating process.

Mechanism:

In an evaporator It facilitates the The amount of

using tubing, after the separation of the evaporation that takes
place depends on the
water begins to boil, liquid and the vapor temperature difference
bubbles will rise and at the top of the between the steam and
cause circulation heating tubes. the solution.
TYPES OF NATURAL CIRCULATION EVAPORATORS:
The types of natural circulation evaporators are:
➢ Batch type pan evaporators
➢ Short tube evaporators
➢ Rising/climbing film evaporators
➢ Falling film evaporators

➢ BATCH TYPE PAN EVAPORATORS:

Also known as the steam jacketed kettle or

evaporating pan is an evaporator that can be used for
the bulk evaporation of water from aqueous
liquids. They are the oldest type of industrial
evaporators.

Construction:
It is constructed in the form of a hemispherical shaped shell
usually made of
➢ stainless steel
➢ copper
➢ aluminium
➢ enamelled iron
and a steam jacket. The hemispherical shape gives the best surface/volume ratio for heating
and the largest area for the disengagement of vapour.

Working principle:
Steam flows through the space between the outer and inner pans at a slightly elevated
pressure. The hot steam causes heat to pass through the inner pan, by conduction, to the
solution that is to be evaporated. As the temperature of the solution rises, so solvent
molecules are evaporated. The pan can be permanent mounted and the product is emptied
through an outlet at the bottom of the pan, or the pan can be mounted in such a way that it can
be tilted so that the product can be poured out.
Mechanism:

The
the movement
steam is concentrated
of the liquid
introduced liquid is
The dilute results from
through the collected
solution is convection
steam inlet into through the
taken in the pan currents set up
the jacket to outlet placed at
by the heating
heat the pan. the bottom of
process.
the pan.

Advantages and disadvantages of batch type pan evaporators:

ADVANTAGES DISADVANTAGES

1. Pans can be constructed for small Heat transfer area per unit volume in a pan
to large batch operations is small.

2. Easy to operate, maintain and has Residence time of product is very long
simple construction. usually several hours

3. Low cost of installation and Have small convective heat transfer

maintenance. coefficient

4. Wide variety of materials of It is not ideal for thermolabile materials as

construction (e.g., Copper, the liquid matter is heated constantly and
aluminum, stainless steel) is normally open to the atmosphere
atmosphere.
 5. Can be manually stirred and
product removal is fast and easy
With an open pan is open the solvent
vapours can move around the room
causing discomfort among workers and
because the vapours are not force vented,
this may slow down the evaporation
process.

Uses:
➢ Concentrating liquor and aqueous and thermos-stable liquors eg: cooking pickles,
liquorice extract etc.
➢ Used for concentration of jams and jellies and also for some pharmaceutical products.

SHORT TUBE EVAPORATORS:

This is a very common evaporator in the industry, it is often
known as the standard evaporator.

CONSTRUCTION:
➢ The evaporator is a cylindrical vessel. The lower
portion of the vessel consists of a nest of tubes with
the liquor inside and steam outside. This assembly is
called the calendra.
The specifications of calendra are as follows:
➢ Length of tube: 1-2m
➢ Diameter of tubes: 40-80mm
➢ Diameter of evaporator: 2.5m
➢ Number of tubes:1000
The feed inlet is at the top of calendra. The product outlet is placed at the bottom of the
evaporator. Steam inlet and outlet is placed from the side of the calendria.

Principle:
The driving force for flow of liquid through the tubes is the difference in density between the
liquid in the downcomer and two-phase mixture in the tubes.

Mechanism:
 The liqour in the tubes the mixture of liquid The product is collected
is heated by the steam and vapour shoot up the through the product
and begins to boil. tubes outlet.

Advantages and disadvantages of short tube evaporator:

ADVANTAGES DISADVANTAGES

1. These evaporators can be used with A large area is required since the units are
scaling liquids, since evaporation squat.
takes place inside the tubes

2. Fairly high heat-transfer coefficients Heat-transfer coefficients are sensitive to

are obtained with thin liquors (i.e., the temperature difference and liquor
water or dilute solutions of 1-5 cP). viscosity

3. Units are relatively inexpensive, Due to large liquid holdup, these

provided that they are made of evaporators cannot be used with heat-
carbon steel or cast iron. sensitive materials.

4. Use of tubular calendria increases Complicated design

the heating area possibly by a factor
of 10 to 15 compared to that of an
external jacket.

Uses:
Short-tube vertical evaporators are suitable for
➢ noncorrosive (e.g., evaporation of cane sugar),
➢ clear
➢ non crystallizing liquors.
RISING/CLIMBING FILM EVAPORATORS:
The rising-film evaporator is the original version of the
long-tube vertical evaporator. This is known as the
first “modern” evaporator used in the industry.

Construction:
➢ consist of a heat exchanger isolated from the
vapour separator.
➢ The heat exchanger, or calandria, consists of 10
to 15 meter long tubes in a tube chest which is
heated with steam.
➢ the liquid to be evaporated is introduced to the
bottom of the tube, a film of liquid forms on
the walls and rises up the tubes, hence known as climbing film evaporator.

Working principle:
Vapor traveling faster than the liquid flows in the core of the tube causing the liquid to rise up
the tube in a film. This type of flow can occur only in a portion of the tube.

Mechanism:

As the fluid
moves up the
The liquid inside
tube, more vapor
the tubes is
Steam condenses is formed, This leads to a
brought to a boil,
on the outside resulting in a thinner and more
with the vapor
surfaces of the higher central- rapidly moving
generated
vertical tubes. core velocity that liquid film.
occupying the
forces the
core of the tube.
remaining liquid
to the tube wall.

Advantages and disadvantages of rising film evaporator:

 ADVANTAGES DISADVANTAGES

1. Large area for heat transfer. Expensive, construction is quite

complicated.

2. Suitable for heat sensitive materials. Cleaning and maintenance is quite difficult.

3. Used for foam forming liquids. Not for viscous, salting and scaling liquids.

4. Less space required. Heat transfer is difficult to predict; pressure

drop is higher than for falling-film types.

5. Since feed enters at the bottom, the the units are sensitive to changes in loads
feed liquor is distributed evenly to and feed conditions, and turndown is
all tubes. limited to 2:1.

Uses:
➢ Major uses of rising-film evaporators include concentrating black liquors in pulp-and-
paper mills
➢ concentrating nitrates, spin-bath liquors, electrolytic tinning liquors, etc.
➢ insulin, liver extracts, vitamins, foaming liquids, corrosive solutions can be
concentrated.

FALLING FILM EVAPORATORS:

The falling film evaporators are the most widely used in the
food industry. Falling-film evaporators evolved as a means to
solve the problems associated with the rising-film types.
Specifically, the hydrostatic head necessary for the operation of
rising-film units leads to problems with some heat-sensitive
products.

Construction:
➢ The heating unit consists of steam-jacketed tubes,
having a length to diameter ratio of about 140 to 1.
➢ the tube diameters are rather greater, about 8 cm.in
length and 20-50mm in diameter.
Mechanism

Flow of vapor They are

the film is and liquid separated in a
the feed liquor moving in the may be either chamber
is introduced direction of co-current, in the where
at the top tube gravity rather which case concentrate concentrate is
sheet, and than against vapor-liquid and liquid taken out
flows down it, a thinner separation leaves the through
the tubewall and faster- takes place at bottom. product outlet
as a thin film. moving film the bottom, or and vapour
results counter from vapour
current. outlet.

Advantages and disadvantages of falling film evaporator:

ADVANTAGES
1. Relatively low cost
2. Large heating surfaces in one body
3. Low product hold up
4. Small floor space requirement
5. Good heat transfer coefficients at
significantly low temperature
differences
DISADVANTAGES
High head room requirement
Generally not suited for scaling or salting
liquids
Recirculation is usually required.
The design of such evaporator is
complicated.
Uses:
➢ Falling-film evaporators are employed for processing food and dairy products, and for
desalting seawater.
➢ Used in brine concentration.
➢ Manufacturing of gelatin.
➢ Used for heat- sensitive liquids.
➢ Concentration of yeast extracts.
➢ Used in extracts of tea and coffee.

FORCED CIRCULATION EVAPORATORS:

Forced circulation evaporators are that type of
evaporators which works under forced circulation which
is a type of circulation which largely depends on pumps
instead of natural density differences for water circulation
in evaporators.
They use some kinds of pumps which pump the food:
➢ Between plates
➢ Through tubes
➢ Creates the film of products using scraper
assemblies inside cylindrical heat exchanger.

Construction:
➢ Heating unit consists of steam jacketed tubes.
➢ Inlets are provided for steam and feed.
➢ Outlets are provided for vapour, concentrated products, non-condensed gases and
condensate.
➢ Pump is connected near the inlet.
➢ It involves a non contact heat exchanger.

Working principle:
Force is used to drive the liquid through the evaporator tubes thus producing high tube
velocities. A high efficiency circulating pump, designed for large volume and sufficient head,
is used to supply the force. Proper design results in controlled temperature rise, controlled
temperature difference and tube velocities that give optimum heat transfer.

Mechanism:
 liquid is Hence When liquid
This leads to
circulated boiling leaves the
forced flashing of
through the doesnot tube and
circulation super heated
tubes at high takes place enters the
creates liquor. thus
pressure by as boiling vapour head,
agitation. evaporation
means of point is pressure falls
is affected.
pump. elevated. suddenly.

Advantages and disadvantages of forced circulation evaporators:

ADVANTAGES
1. Forced-circulation evaporators are
the most versatile of all evaporators.
2. High heat-transfer coefficients can
be achieved for problem liquors
3. They possess rapid evaporation
rate.
4. Shows less scaling, fauling or
salting than natural evaporators.
5. Suitable for high viscous
preparation.
DISADVANTAGES
High capital cost
High operating cost
More power supply is required.
Corrosion-erosion can occur, due to high
circulation velocities.
plugging of tubes where liquor enters can
be a problem in salting services where the
salt deposits detach and accumulate at the
bottom.

Uses:
➢ These systems are used in producing common salt, caustic soda and other crystalline
products.
➢ Used for products with suspended solids
➢ Used for viscous liquids.
TYPES OF FORCED CIRCULATION EVAPORATORS:
There are mainly two types of forced circulation evaporators:
➢ Mechanical (or agitated) thin film evaporators
➢ Plate evaporators

➢ AGITATED THIN FILM EVAPORATORS:

These are essentially large-diameter jacketed tubes, in which the product is
vigorously wiped by one of several different blade configurations
(rollers, wipers, fixed clearance blades or pitched blades for high
viscosity applications) being renewed on the inside of the evaporator
wall while being exposed to heating and vacuum conditions.

Construction:
➢ The Agitated Thin Film Evaporator consists of a jacketed shell
having a machined surface on the inner side.
➢ The rotor assembly consisting of different configuration of blades
depending upon the nature of product is mounted in the shell.
➢ Feed inlet is provided at the top side.
➢ Specially designed feed distributor is integral with the rotor at the top side.
➢ The rotor is also fitted with an entrainment separator. Generally the vapour outlet is
provided on the top side of the shell.

The different types of blade configurations available are:

Fixed blade rotor

Spring loaded rotor
Cylindrical wiper rotor
Centrifugal blade rotor

The construction of the evaporator is such that different types of rotors can be mounted in the
same equipment for different products. The evaporators having surface area up to 50sq.m.
can be supplied.

Working principle:

The liquid feed is distributed on the heated wall of the evaporator to form a uniform thin film
with the help of suitable configuration of blades. The volatile component or the component
with lower boiling point gets evaporated and is vacuumed out of the evaporator, while the
component with higher boiling point flows down the wall and is collected at the bottom. The
vapours are passed through a condenser and collected separately.
Mechanism:

high pressure
the blades steam is used
the liquid is
keep the liquid as the heating
spread on the
the liquid is violently medium to
walls into a
normally fed agitated and obtain high
thin film by
to the top thus promotes wall
rotating
high rates of temperatures
blades.
heat transfer for reasonable
evaporation.

Advantages disadvantages of agitated thin film evaporator:

ADVANTAGES
1. Low residence time
2. High heat transfer coefficient due to
turbulence impelled by rotor.
DISADVANTAGES
High operation cost as only single effect is
possible
High capital and maintenance cost

3. Less product decomposition Low processing capacity

resulting in higher yield.

Uses:

➢ For viscous foods

➢ For heat sensitive foods
 ➢ For those who are liable to foam or foul evaporator surfaces. Eg: fruit pulps,
tomato paste, meat extracts, honey, cocoa mass, coffee etc).
➢ Commonly used in concentration of milk and fruit juices.

PLATE EVAPORATOR:
Plate evaporators are often used as an alternative design for tubular evaporators.

Construction:
➢ A plate-and-frame configuration employs special plates,
with alternate product and heating channels.
➢ The plates are sealed by gaskets located within specially
designed slots that do not require adhesives.
➢ These gaskets can be inserted and removed without
special tools.

Mechanism:

Intensive heat
Defined plate The wide inlet
transfer causes
distances in duct and the
Product and the product to Residual
conjunction upward
heating media boil while the liquid and
with special movement
are vapor formed vapors are
plate shapes ensure
transferred in drives the separated in
generate optimum
counterflow residual the
strong distribution
through their liquid, as a downstream
turbulence, over the total
relevant rising film, centrifugal
resulting in cross-section
passages. into the vapor separator.
optimum heat of the heat
duct of the
transfer. exchanger.
plate package.

Advantages and disadvantages of plate evaporators:

ADVANTAGES DISADVANTAGES
• 1. Use of different heating media – due to Turbulent flow causes large pressure drop

plate geometries, the system can be heated

with both hot water as well as with steam.
2. High product quality
3. Little space required
4. Easy installation requiring
little time
5. Flexible evaporation rates
6. Ease of maintenance and
cleaning
Narrow spaces between the plates can
cause rapid fouling thus required frequent
cleaning.
Deteriorating gaskets are difficult to
remove.
Limited to high pressure, high temperature
or aggressive fluids.

Uses:

➢ For liquids containing only small amounts of undissolved solids and with no tendency
to fouling.
➢ For temperature-sensitive products, for highly viscous products or extreme
evaporation conditions, a product circulation design is chosen.
➢ Dairy and food processing industries.
➢ Pasteurization of milk.

CLASSIFICATION OF EVAPORATORS ON MODE OF OPERATION:

➢ Batch evaporators
➢ Semi- batch evaporators
➢ Continuous evaporators
➢ Continuous batch evaporators
➢ BATCH EVAPORATORS:
Batch evaporators are utilized for small quantities of product which require large
residence times. Filling, evaporation and emptying of the vessel occur at three
separate stages which generates unwanted changeover times. A batch evaporator
should be large enough to handle the entire amount of the feed and the heating
element should be located as low enough not to be uncovered when the volume is
reduced to that of the product.
 ➢ SEMI-BATCH EVAPORATOR:

Semi-batch operation is more commonly used than batch operation where a continuous
supply of feed is taking place in order to keep the liquid level a constant compensating for the
loss of water due to evaporation. However, product is withdrawn once only when the desired
concentration has been achieved.

➢ CONTINOUS EVAPORATORS:

continuous evaporators have continuous feed and discharge.

➢ CONTINOUS-BATCH EVAPORATORS:

Continuous-batch mode also has a continuous feed but unlike semi-batch, it has a continuous
discharge over at least part of the cycle.