HT Unit 4 .1

UNIT 4 EVAPORATION AND RADIATION
Theory of evaporation - single effect and multiple effect evaporation – Design calculation for
single and multiple effect evaporation. Radiation heat transfer - Black body radiation, Emissivity,
Stefan - Boltzman law, Plank’s law, radiation between surfaces.
EVAPORATION
Evaporation-definition
✓ Evaporation is an operation that is carried out in the industry as a means of concentration
a weak liquor/solution by vaporizing a portion of the solvent.
✓ The weak liquor/solution is composed of a non-volatile solute and a solvent.
Introduction:
✓ The objective of evaporation is to concentrate a weak solution (consisting of a non-volatile
solute and a volatile solvent).
✓ It differs from drying, distillation, crystallization.
✓ Evaporation is generally followed by crystallization and drying.
✓ Evaporation is carried by supplying heat to a solution to vaporize the solvent.
✓ The common heating medium (heat source) is generally a low pressure steam but in some
situations other sources that might be used are: solar energy, fuel, electricity, hot oil and
flue-gas.
✓ The heat is utilized to –
(i) Increase the temperature of the solution to its boiling point and
(ii) Supply the latent heat of vaporization of the solvent.
Examples of evaporation:
✓ Concentration of aqueous solutions of sugar, sodium chloride, sodium hydroxide, glycerol,
milk and fruit juices.
✓ Manufacture of sugar from sugar cane by evaporation and crystallization, manufacture of
common salt by evaporation of sea water.
Evaporator Types:
Evaporators may be operated either as once through or circulation units.
Once through Evaporators
✓ In once through operation, the feed liquor passes through the tubes only once, releases the
vapor, and leaves the unit as thick liquor.
1
✓ Once through evaporators are especially useful for heat – sensitive materials. with a
single rapid passage through the tubes, the thick liquor is at the evaporation temperature
but a short time and can be quickly cooled as soon as it leaves the evaporator.
✓ Agitated film evaporator are always operated once through; falling film and rising film
evaporators can also operated in this way.
Circulation evaporators
✓ In circulation evaporators a pool of liquid is held within the equipment. Incoming feed
mixes with the liquid from the pool, and the mixture passes through the tubes.
✓ Unevaporated liquid discharged from the tubes returns to the pool, so that only part of the
total evaporation occurs in one pass.
✓ Circulation evaporators are not well suited to concentrating heat – sensitive materials.
✓ Circulation evaporators, however, can operate over a wide range of concentration
between feed and thick liquor in a single unit, and well adapted to single effect
evaporation.
✓ They may operate either with natural circulation, with the flow through the tubes induced
by density differences, or forced circulation, with flow provided by a pump.
✓ All forced circulation evaporators are operated in this way, rising film evaporators are
usually circulation units.
✓ Natural circulation evaporators are commonly employed for simpler evaporation
operations singly or in multiple effect e.g. horizontal tube evaporator, vertical tube
evaporator etc.,
✓ While forced circulation evaporators are commonly employed for salting, viscous and scale
forming solutions.
✓ These units may be provided with an external horizontal or vertical heating element.
✓ Evaporators used in process industries can be classified as:
(i) Natural circulation evaporators , and
(ii) Forced circulation evaporators
✓ Long tube vertical evaporators
(i) Upward flow (climbing film or rising film)
(ii) Downward flow (Falling film)
✓ Agitated film evaporators
Open pan evaporator/Jacketed pan evaporator:
✓ The simplest method of concentrating a solution is by use of jacketed pans, in which the
condensing steam is used in the jacket for evaporating a part of the solvent.
✓ Such type of evaporator is particularly suitable when small quantities are to be handled.
✓ These are available in a great variety of materials. Pans of stainless steel, copper, aluminum
etc., are widely used in the food process industries. Mild steel jacket may be welded to the
pan.
✓ Pan is made of a single sheet of metal for small size, or several sheets joined by
welding/brazing.
2
✓ A jacket is welded to the pan.
✓ The jacket is provided with a steam inlet at the top while a condensate drain is provided at
its bottom.
✓ The pan is provided with an outlet at the bottom for draining its contents.
✓ The solution to be concentrated is taken into the pan and steam is admitted in the jacket.
✓ Evaporation is carried out for a predetermined time to achieve a desired concentration
level.
✓ The thick liquor is then drained from the outlet.
Horizontal tube evaporator:
✓ It is the oldest type of evaporator consists of a vertical cylindrical shell incorporating a
horizontal square tube bundle at the lower portion of the shell.
✓ Channels are provided on either ends of the tube bundle for introduction of steam and
withdrawal of condensate.
✓ Shell is closed by dished heads at both ends.
✓ A vapor outlet is provided on the top cover and a thick liquor outlet is provided at the
bottom.
✓ Feed point is located at a convenient point.
3
✓ In this evaporator, as evaporation occurs outside the tube, it eliminates scale formation
problems inside the tubes.
✓ Small diameter tubes than any other types are used.
✓ Steam gets condensed by transferring its latent heat and condensate is removed from an
outlet provided at the bottom of the opposite steam chest.
✓ Heat given out by the condensing steam will be gained by a solution in the evaporator and
the solution boils.
✓ Vapors formed are removed from the top while the thick liquor is removed from the bottom.
✓ In this evaporator, the steam is inside the tubes and the liquor to be concentrated surrounds
the tubes.
✓ Steam which is admitted through one of the steam chest/channel flows through the tubes.
Main advantage:
(i) Very low heat room requirements and
(ii) Large vapor-liquid disengaging area.
Calendria-type / standard vertical tube evaporator / Short tube evaporator:
Construction;
✓ It consists of a vertical cylindrical shell incorporating (at the lower portion) a short vertical
tube bundle with horizontal tube sheets bolted to shell flanges.
✓ Vapor outlet is provided at the top cover while thick liquor discharge is provided at the
bottom.
✓ Usually, the tube bundle is not more than 150 cms high and tube diameter (outside) not
more than 75 mm (25 mm to 75 mm).
✓ In this evaporator, the solution to be evaporated is inside the tubes and steam flows outside
the tubes in the steam chest.
✓ Condensate is withdrawn at any convenient point near the lower tube sheet, while non-
condensable gas (such as air) is vented to the atmosphere from a point near the top tube
sheet.
4
✓ A down take is provided at the center of tube bundle with flow area about 40 to 100 percent
of the total cross-sectional area of tubes for circulating cooler liquid back to the bottom of
the tubes.
Working:
✓ Thin liquor is introduced to the tube side and steam into the steam chest.
✓ The liquor covers the top of tubes. Heat transfer to the boiling liquid inside the tubes takes
place from condensing steam on the outside of tubes.
✓ The vapours formed will rise through the tubes come to a liquid surface from which they
are disengaged into the vapour space and removed from the vapour outlet.
✓ Circulation of the cold liquor is promoted by the central down take and the concentrated /
thick liquor is removed from the bottom of the evaporator.
Advantages:
(i) Relatively inexpensive
(ii) As scaling occurs inside the tubes, it can be easily removed by mechanical or
chemical means.
(iii) Provide moderately good heat transfer at reasonable cost.
(iv) Can be put into more rigorous services than horizontal tube evaporators.
(v) Requires low heat room.
Disadvantages:
(i) Floor space required is large.
(ii) Liquid hold-up in the evaporator is large.
(iii) Since there is no circulation, these are not suitable for viscous liquid.
✓ This is best suited for clear liquids, non-corrosive liquids and mild scaling solution-needing
mechanical cleaning, as tubes are short and of large diameter.
Upward flow (Climbing or Rising film) evaporator:
Construction:
✓ A long tube evaporator consists of a long tubular heating element incorporating tubes 25
mm to 50 mm in diameter and 4 to 8 meters in length (a simple one pass vertical shell and
tube heat exchanger).
✓ The tubular heating element projects into a vapour space / separator for removing entrained
liquid from the vapour.
✓ The upper tube sheet of the tubular exchanger is free and a vapour deflector is incorporated
in the vapour space just above it.
✓ A return pipe connecting the vapour space to the bottom of the exchanger is provided for
natural circulation of the unvaporised liquid.
✓ It is provided with inlet connections for feed , steam and outlet connections for vapour ,
thick liquor , condensate , etc.,
✓ In this evaporator, the liquor to be concentrated is in the tubes and condensing steam
surrounds the tubes.
5
Working:
✓ In this evaporator, feed enters the bottom of the tubes, gets heated by condensing steam,
starts to boil part way up the tubes and the mixture of vapour and issues from the top of
tubes and finally impinges at high velocity on a deflector.
✓ The deflector acts both as a primary separator and a foam breaker.
✓ The separator liquid enters the bottom of exchanger (by gravity) and part of this liquid is
taken out as a product.
✓ The long tube vertical evaporator competes most favorably with forced circulation
evaporators as compared to other natural circulation evaporators.
Advantages:
✓ Low cost, small floor space, good heat transfer coefficients, low liquid hold-up and large
heat transfer surface in one body.
Disadvantage:
✓ High headroom requirements and unsuitable for salting, scaling liquids.
✓ It is suitable for clear liquids, effective for concentrating forming liquids (liquids that tend
to foam), corrosive solutions and large evaporation loads.
✓ It is widely used for the production of condensed milk.
✓ The falling film version of the long tube evaporator (falling film evaporator) is widely used
for concentrating highly heat sensitive materials (fruit juices-orange juice) which require a
minimum exposure time to a heated surface.
✓ In this evaporator, liquid is fed at the top of the tube through a distributor, flows downward
inside the tubes along the tube walls as a film and leaves the bottom.
✓ Vapour formed is carried downward with the liquid vapour –liquid separation takes place
at the bottom (in a liquid-vapour separator).
✓ The tubes of this evaporator are usually 50 to 250 mm in diameter.
6
Downward flow (falling film) evaporator:
SAME FOR ABOVE PAGE ONLY THE DIAGRAM FLOW DIRECTION CHAGED (feed
flow is downward direction)
Forced Circulation Evaporators:
✓ Whenever we are dealing with concentration problems involving solutions of high
viscosities, of scale forming tendencies there is no alternative but to use forced circulation
evaporators as increasing the velocity of flow of liquor through the tubes increases
remarkably liquid film heat transfer coefficients and high velocity resulting by use of a
centrifugal pump prevents the formation of excessive deposits on the heat transfer surfaces.
✓ In a natural circulation evaporator, the liquid enters the tube at a velocity of 0.3 to 1 meter
per second.
✓ In the forced circulation evaporator, smaller diameter tubes are used then in the natural
circulation evaporator, generally not larger than 50 mm.
Forced circulation evaporators with horizontal external heating element:
Construction:
✓ In consists of a circulating pump , a separating space (separator ), an evaporator body with
a vapour outlet at the top , a deflector plate, an outlet for the discharge of thick liquor and
an external heating surface.
✓ A horizontal shell and tube heat exchanger having two passes on both shell and tune sides.
Working:
✓ Centrifugal pump forces liquids through the tubes at a high velocity and the liquid is heated
as it passes through the tubes due to heat transfer from condensing steam on the shell side.
✓ Boiling does not take place in the tube as they are under sufficient static head which raises
the boiling point above that in the separating space, so there is no boiling in the tubes.
7
✓ The liquids / solution becomes superheated and flashes into a mixture of vapour and liquid
just before entering a separator due to reduction in the static heat when it flows from the
exchanger to the separator.
✓ The two-phase mixture impinges on a deflector plate in the separating space, and the
vapours are removed from the top, and the liquid is returned to the centrifugal pump.
✓ Part of liquid / solution leaving the separating space is withdrawn as concentrated liquor
and makeup feed is continuously introduced at the pump inlet.
✓ In the case of forced circulation evaporator with vertical heating element, a single pass
shell and tube heat exchanger is used.
Advantage of forced circulation evaporators:
✓ High heat transfer coefficient is obtained even with viscous material.
✓ Positive circulation and close control of flow.
✓ Whenever there is tendency to form scale or deposit salts, use of forced circulation units
prevents the formation of excessive deposits due to high velocities.
Disadvantages:
✓ High cost and power required for circulating pump.
✓ The forced circulation evaporators are commonly employed for crystalline product,
viscous, salting, scaling, corrosive and foaming solutions/liquors.
Agitated film evaporator:
Construction:
✓ This is a modified falling – film evaporator with a single jacketed tube containing an
internal agitator.
Working:
✓ Feed enters at the top of the jacketed section and is spread out into a thin, highly turbulent
film by the vertical blades of the agitator.
✓ Concentrate leaves from the bottom of the jacketed section, vapor rises from the
vaporizing zone into an unjacketed separator, which is somewhat larger in diameter than
the evaporating tube.
8
✓ In the separator the agitator blades throw entrained liquid outward against stationary
vertical plates. The droplets coalesce on these plates and return to the evaporating section.
✓ Liquid free vapor escapes through outlets at the top of the unit.
Advantage of Agitated film evaporators:

✓ It is ability to give high rates of heat transfer with viscous liquids.
✓ As in other evaporators, the overall heat transfer coefficient falls as the viscosity rises, but
in this design the decrease is slow.
✓ The Agitated film evaporator is particularly effective with such viscous heat sensitive products as
gelatin, rubber latex, antibiotics and fruit juices.
Disadvantages:
✓ High cost
✓ The internal moving parts, which may need considerable maintenance
✓ The small capacity of single units
Multiple-Effect evaporation:
✓ When a single evaporator is put into service and the vapours leaving the evaporator are
condensed and discarded, the method is known as, single effect evaporation.
✓ The economy of single evaporator is always less than one. , for evaporation of one kg of
water of solution, 1 to 1.3 kg of steam is required.
✓ The method of increasing the evaporation per kg of steam by employing a series of
evaporators between the steam supply and the condenser is known as multiple-effect
evaporation (or the method of reusing of latent heat to increase the economy by using a
series of evaporators between the steam supply and the condenser is called multiple
evaporation).
✓ It is the only way to increase the economy of an evaporator system.
9
✓ If the vapour (as the heat source / as the heat supply) from one evaporator is fed to the
steam chest of the second evaporator then this system is called as double effect evaporator
system and so on.
Methods used of feeding multiple evaporation system
1. Forward feed :
✓ In this arrangement, the liquid feed flows in the same direction as the vapour flows.
Fresh feed enters the first effect and steam is also fed to the steam chest of this
effect.
✓ The vapours produced in the first effect are fed to the steam chest of the second
effect as the heating medium and the concentrated liquor from the first effect is fed
to the next effect in series.
✓ The pressure in the second effect is less than in the first effect and so on.
✓ For effectively utilizing temperature potentials, this arrangement is preferable.
✓ As feed flows in the direction of decreasing pressure, the heat transfer, the transfer
from effect to effect can be done without pumps.
2. Backward feed:
✓ In this arrangement, the feed solution and the vapour flow in the opposite direction
to each other.
✓ Fresh feed is admitted to the last effect and then pumped through other effects.
✓ The steam is admitted to the steam chest of the first effect and vapours produced in
the first effect are fed to the steam chest of the second effect and so on.
10
✓ The pressure in the first effect is highest and that in the last effect is lowest.
✓ If the liquid is very viscous then we have to adopt a backward feed arrangement as
the temperature of the first effect is highest and corresponding viscosity will be
less.
✓ This method of feeding requires a pump between each effect (since feed flows in
the direction of increasing pressure) in addition to the thick liquor pump.
3. Mixed feed :
✓ In this feed arrangement, steam is admitted to the steam chest of the first effect and
the vapours leaving the first effect evaporator are fed to the steam chest of the
second effect and so on.
✓ Feed solution is admitted to an intermediate effect and flows to the first effect from
where it is fed to the last effect for final concentration.
✓ This arrangement is a combination of the forward and backward feed adopted for
best overall performance.
11
Difference between Single and multiple-effect evaporator:
s.no. Single evaporator Multiple-effect evaporator
1. low capital cost High capital cost
2. High steam cost Low steam cost
3. Low overall heat transfer coefficient High to low heat transfer coefficients
Based on feed arrangements.
4. Only feed pump is required Several pumps are required-based on feed
arrangements.
5. Scaling problem is high since all conc. is Scaling problem is low – based on feed
carried out in a single unit. arrangements.
6. Simple piping complex piping
Comparison of forward feed and backward feed arrangements:
s.no. Forward feed Backward feed
1. The flow of the solution to be The flow of the solution to be concentrated
concentrated is parallel to the steam. is in the opposite direction to steam.
2. Does not need a pump for moving the Need pumps for moving the solution from
solution from effect to effect as vacuum effect to effect as transfer of solution is to be
is maintained in the last effect. done from the evaporator operating at low to
operating at high pressure.
3. All heating of cold is done in first effect, Heating is done in each effect ,resulting in
resulting in lower economy high economy
4. Maintenance and power cost is low Maintenance and power cost is high
5. Arrangement is less effective thermally. Arrangement is more effective thermally.
6. More economical in steam At low temperature high economy
Design calculation for single effect evaporator

✓ Heat and material balances for evaporators the basic equation for solving for the capacity
of a single effect evaporator
q = UAT
Where,
Q- Heat transfer rate
U- Overall heat transfer coefficient
A – Heat transfer area
T
– Difference in temperature between condensing steam and boiling liquids
Feed: F kg/hr
Solid content: XF mass fraction
Temperature: TF
Enthalpy:hF J/kg
12
Concentrated liquid: L kg/hr
Solid content: XL mass fraction
Temperature: TL
Enthalpy: hL
Vapour: (pure solvent having a solid content): V kg/hr
Temperature: Tv
Enthalpy: hV
Steam: Skg/hr
Temperature: TS
Enthalpy: hS (Steam gives off only its latent heat 
 = H s − hs -------------------- (1)
Material balance:
F = L + V -------------------- (2)
For a balance on the solute (solid) alone
FxF = LxL ---------------------- (3)
Heat Balance:
Total heat entering = Total heat leaving
Heat in feed + Heat in steam = Heat in concentrated liquid + heat in vapour + heat in condensed
steam -------------------- (4)
This assumes no heat loss by radiation or convection
FhF + SH S = LhL + VHV + ShS ------------------------ (5)
FhF + S ( H S − hs ) = LhL + VHV
Sub equation (1) in (5)
FhF + S = LhL + VHV ----------------------- (6)
Alternative method
Heat lost by condensing steam (Latent heat) = Heat gained by solution to increase its temperature
to boiling point + heat required to vaporise / evaporate water
Q = QS = S λS =FCpf (T-Tf) + V λv------------------ (7)
Heat transfer area:
Heat balance equation can be written as
Q = UAT = SS ------------------------- (8)
13
So the heat transfer area is
Q
A= ------------------------- (9)
UT
Design calculation for multiple effect evaporator
Assumptions:
i. Equal heat transfer rate in each of the effects
ii. Equal heat transfer surface in each of the effects
iii. Equal evaporation in each of the effects
 Q1 = Q2 = Q3
U1 A1T1 = U 2 A2 T2 = U 3 A3T3
A1 = A2 = A3
U1T1 = U 2 T2 = U 3T3
U1
T2 = T1
U2
U1
T3 = T1
U3
T = T1 = T2 = T3
T = TS − TL1 + TV 1 − TL 2 + TV 2 − TL 3
T = TS − TL 3 (TV 3 )
First effect Second effect Third effect
Steam TS TV1 TV2
Liquid TL1 TL2 TL3
Vapour TV1 TV2 TV3
T TS-TL1 TV1-TL2 TV2-TL3
BPR/BPE TL1-TV1 TL2-TV2 TL3-TV3
The heat transfer area of the individual effects is as follows
First effect:
Q = mS S = U1 A1T1
mS S
A1 =
U1T1
Second effect:
Q = mV 1V 1 = U 2 A2 T2
mV 1V 1
A2 =
U 2 T2
Third effect:
Q = mV 2V 2 = U 3 A3T3
mV 2V 2
A3 =
U 3T3
14
If A1  A2  A3 and the deviation is more than  10% and the new temperature drop is
calculated as
A1 A A
T1' = T1  ; T2' = T2  2 ; T3' = T3  3
Aavg Aavg Aavg
A1 + A2 + A3
 Aavg =
3
Forward feed arrangement
Material Balance
First effect
Overall balance: F = L1 + V1
Solute balance: FxF = L1 xL1 + 0 (no solute in vapour)
Second effect
Overall balance: L1 = L2 + V2
Solute balance: L1 xL1 = L2 xL 2 + 0
Third effect
Solute balance: L2 xL 2 = L3 xL 3 + 0
For the entire system
Overall balance: F = V + L3
Where, V = V1 + V2 + V3
Solute balance: FxF = L3 xL 3 + 0
Energy balance
15
First effect
FhF + SS = V1hV 1 + L1hL1
Second effect
L1hL1 + V1V 1 = V2 hV 2 + L2 hL 2
Third effect
L2 hL 2 + V2V 2 = V3hV 3 + L3hL 3
Backward feed arrangement
Material balance
First effect
Solute balance: L2 xL 2 = L1 xL1
Second effect
Solute balance: L3 xL 3 = L2 xL 2
Third effect
Overall balance: F = L3 + V3
Solute balance: FxF = L3 xL 3
For the entire system
Overall balance: F = L1 + V
Where, V = V1 + V2 + V3
Solute balance: FxF = L1 xL1
Energy balance
First effect
L2 hL 2 + SS = V1hV 1 + L1hL1
Second effect
16
L3hL 3 + V1V 1 = V2 hV 2 + L2 hL 2
Third effect
FxF + V2V 2 = V3hV 3 + L3hL 3
Hydrostatic head effect:
✓ The depth of the liquid (or liquid head) above the tube bundles adds to the pressure at the
heating surface and this rises the boiling temperature of the liquid.
✓ This is called hydrostatic head effect.
Part A Questions
1. Compare economy and capacity in evaporator.
2. Define steam Economy.
3. What is boiling point elevation in evaporation?
4. Explain dubring rule.
5. Mention four reasons for boiling point elevation.
6. Define flash evaporation.
7. Why the economy of a single-effect evaporator is less than one?
8. When is backward feed evaporator preferred over forward feed?
9. What is the advantage of effect of liquid head and boiling point elevation?
10. Why is multiple effect evaporation preferred over a single effect operation?
11. What are the advantages of multiple effect evaporator?
12. List out the different types of evaporation.
13. What is the principle of a thermo-compression evaporator?
Part B
1. Classify evaporators. Explain the working of a falling film evaporator with a neat sketch.
2. With a neat sketch, explain the construction and working of an evaporator. (short tube
calendria type standard vertical evaporator is preferred). What are its merits and
limitations?
3. Discuss the different feeding arrangements in multiple effect evaporator with neat sketches.
4. Discuss different types of multiple effect evaporator based on feeding.
5. Explain briefly the liquid characteristics which affect evaporation.
6. Explain the constructional details of short tube evaporator.
7. Derive and explain the design procedure for single and multiple effect evaporators.
PROBLEMS
1. A single - effect evaporator is to concentrate 20000kg/hr of a solution containing 5% salt
to a concentration of 20% salt by weight. Steam is fed to the evaporator at a pressure
corresponding to the saturation temperature of 399 K (126˚C). The evaporator is operating
at atmospheric pressure and boiling point rise is 7K. Calculate the heat load and the steam
economy.
Data
Feed temperature = 298 K (25 C)
Specific heat of feed = 4.0 kJ/kg.K
Latent heat of condensation of steam at 399 K = 2185kJ/kg
17
Latent heat of vaporization of water at 373K = 2257 kJ/kg
Step : 1 Material balance
F=L+V---------------------1
Material balance of the solute:
Solute in feed = solute in thick liquor
FxF = LxL----------------2
0.05 X 20,000= 0.20 (L)
L= 5000 Kg/hr
F=L+V
20,000 = 5000 + V
V = 15,000 kg/hr
Step 2 Heat balance (To find steam consumption S)
λS = Latent heat of condensation of steam at 399 K = 2185kJ/kg
λv = λ =Latent heat of vaporization of water at 373K = 2257 kJ/kg
T = temperature of thick liquor= boiling point of solution +B.P.R = 373+7 = 380 K
Tf = Temperature of feed = 298K
F = 20,000 kg/hr
Cpf = 4.187 kJ/kg.K
Q = QS = S λS =FCpf(T-Tf)+V λv
= S (2185) = 20,000 X 4 (380-298) +15,000 (2257) =
S = 18496.6 kg/hr
Steam consumption S = 18496.6 kg/hr
Step 3 To find Steam economy
Economy of evaporator = kg/hr water evaporated/kg/hr steam consumed
= V/ S = 15,000 / 18496.6 = 0.811
Step 4 To heat load Q
Rate of heat transfer = Q= S λS = 18496.6 (2185) = 4041507.1 kJ / hr
= 4041507.1 (1000) / 3600 = 1122641 J/s = 1122641 W
2. An evaporating is operating at atmospheric pressure. It is desired to concentrated the feed
from 5% solute to 20% solute(by weight) at a rate of 5000kg/hr. dry saturated steam at a
pressure corresponding to saturation temperature of 399 K (126˚C) is used. The feed is at
298K (25˚C) and boiling point rise (Elevation) i.e. B.P.E.(B.P.R) is 5 K. the overall heat
transfer coefficient is 2350W/(m2.K). Calculate the economy of the evaporator and the area
of heat transfer to be provided.
Data
Latent heat of condensation of steam at 399 K = 2185kJ/kg
Latent heat of vaporization of water at 373K = 2257 kJ/kg
Specific heat of feed = 4.187 kJ/kg.K
F=L+V---------------------1
18
FxF = LxL----------------2
0.05 X 5000= 0.20 (L)
L= 1250 Kg/hr
F=L+V
5000 = 1250 + V
V = 3750 kg/hr
Heat lost by Condensing steam (latent heat) = Heat gained by solution to increase its temperature
to boiling point + heat required to vaporize/evaporate water
T = temperature of thick liquor= boiling point of solution +B.P.R = 373+5 = 378 K
F = 5000 kg/hr
Cpf = 4.187 kJ/kg.K
Q = QS = S λS =FCpf(T-Tf)+V λv
S (2185) = 5000 X 4.187 (378-298)+3750 (2257) =
S = 4640.1 kg/hr
= V/S = 3750/4640.1 = 0.808
Step 4 To find area
Q = UAΔT
U = 2350W/(m2.K)
Temperature driving force =ΔT=TS-T = Saturation temperature – boiling (or) product
temperature
ΔT= 399-378=21K
Rate of heat transfer = Q= S λS =4640.1(2185) = 10138619 kJ / hr=2816283J/s=2816283W
Q = UAΔT
A = Q/ UΔT = 2816283/(2350 X 21)
A = 57.07 m2
Heat transfer area to be provided = 57.07 m2
3.1000 kg/hr of a dilute solution of sodium hydroxide containing 10% NaOH is to be
concentrated to 40% NaOH by weight in a single effect evaporator. The feed is available at
25˚C. Boiling point of the solution may be considered as 100˚C.
Specific heat of dilute solution = 4180J/kg.K
Latent heat of vaporization of water = 2239KJ/Kg
Latent heat of condensation of steam= 2212 KJ/Kg
Saturated steam corresponding to 1.8 bar pressure and 117˚C is available for
heating purpose. If the overall heat transfer coefficient for the system is 850 W/
m2.K. Calculate
19
(i) The quantity of water evaporated
(ii) Steam consumed and steam economy
(iii) Surface area of the evaporator.
F=L+V---------------------1
FxF = LxL----------------2
0.01 X 1000= 0.4 (L)
L= 250 Kg/hr
F=L+V
1000 = 250 + V
V = 750 kg/hr
Heat lost by Condensing steam (latent heat) = Heat gained by solution to increase its
temperature to boiling point + heat required to vaporize/evaporate water
T = temperature of thick liquor= boiling point of solution = 373
F = 1000 kg/hr
Cpf = 4.18 kJ/kg.K
Q = QS = S λS = FCpf(T-Tf) + V λv
S (2212) = 1000 X 4.187 (373-298) + 750 (2239) = S = 900 kg/hr
Steam consumption S = 900 kg/hr
= V/S = 750/ 900 = 0.83
Step 4 To find area
Q = UAΔT
U = 850W/(m2.K)
temperature
ΔT= 390 – 373 = 17 K
Rate of heat transfer = Q= S λS = 900 (2212) = 1990800 kJ/hr = 553000 J/s
Q = UAΔT
A = Q/ UΔT = 553000 /(850 X 17)
A = 38.26 m2
4. A single effect evaporator is fed with 5000 kg/hr of solution containing 1% solute by
weight. The feed temperature is 303K (30˚C). it is to be concentrated to solution containing
20
2% solute by weight. The evaporation is carried out at atmospheric pressure (101.325kPa)
and the area of the evaporator is 69 m2. Saturated steam is supplied at 143.3kPa as a
heating medium. Calculate the steam economy and the over all heat transfer coefficient.
Data
Enthalpy of feed at 303K = 125.79 kJ/kg
Enthalpy of vapour at 101.325kPa = 2676.1 kJ/kg
Enthalpy of saturated steam at 143.3kPa = 2691.5 kJ/kg
Saturation temperature of steam=383K (110C)
Boiling point of saturation = 373K
Enthalpy of product = 419.04 kJ/kg
Enthalpy of saturated water at 383K = 461.30 kJ/kg
F = L+V---------------------1
FxF = LxL----------------2
0.05 X 5000= 0.02 (L)
L= 2500 Kg/hr
F=L+V
5000 = 2500 + V
V = 2500 kg/hr
FhF + S λS= LhL+VhV-------------------3
F= 5000kg/hr, L=2500 kg/hr, V=2500 kg/hr
From data
hF = 125.79 kJ/kg, hL = 419.04 kJ/kg, hV = 2676.1 kJ/kg
λS= latent heat of condensing steam
= Enthalpy of saturated steam- Enthalpy of saturated water
= 2691.5-461.30 = 2230.2 kJ/kg
All values are substitute in equation 3
FhF + S λS= LhL+VhV
5000 (125.79) + S (2230.2) = 2500(419.04) + 2500(2676.1)
S = 3187.56 kg/hr
Steam consumption = 3187.56 kg/hr
= V/S = 2500/3187.56 = 0.784
Step 4 To over all heat transfer co efficient
Q = UAΔT
A = 69 m2
temperature
21
ΔT= 383-373 = 10K
Rate of heat transfer = Q= S λS = 3187.56 (2230.2) = 71088963 kJ/hr= 1974693 J/s = 1974693W
Q = UAΔT
U = Q/ AΔT = 1974693/(69 X 10) = 2862 W/(m2.K)
Over all heat transfer co efficient U = 2862 W/(m2.K)
5.A forced – circulation evaporator is to concentrate 20,000 kg/hr of 30% sodium
hydroxide solution to 50% solids. The gauge pressure of steam is 1.56 atm. The absolute
pressure in the vapour space is 100mm Hg. The temperature of the feed is 40˚C. If the
over all heat transfer coefficient is 2000 W/ m2.K, calculate
(i) The heat transfer area
(ii) The amount of steam consumed and
(iii) The steam economy
Data:
Enthalpy of feed at 40˚C = 40kcal/kg
Boiling point of solution at 100 mm Hg 100˚C
Enthalpy of Thick liquor at 100˚C =130 kcal/kg
Enthalpy of superheated vapour at100˚C 10mm Hg = 670 kcal/kg
Heat of vaporization of steam at 1.5 atm = 530 kcal/kg
Condensation temperature of steam = 130˚C
F = L+V---------------------1
FxF = LxL----------------2
20000 (0.3) = 0.5 (L)
L= 12000 Kg/hr
F=L+V
20000 = 12000 +V
V = 8000 kg/hr
FhF + S λS= LhL+VhV-------------------3
F= 20,000kg/hr, L=12,000 kg/hr, V=8,000 kg/hr
From data
hF = 40 Kcal/kg = 167.43 kJ/kg,
hL =130 Kcal/kg = 544.15 kJ/kg,
hV = 670 Kcal/kg = 2804.5 kJ/kg
λS= latent heat of condensing steam
= 530 Kcal/kg = 2218.4 kJ/kg
All values are substitute in equation 3
FhF + S λS= LhL+VhV
20000 (167.43) + S (2218.4) = 12000(544.15) + 8000 (2804.5)
S = 11547.16 kg/hr
22
Steam consumption = 11547.16 kg/hr
= V/S = 12,00/11547.16 = 0.692
Step 4 To heat transfer Area
Q = UAΔT
U = 69 m2
temperature
ΔT= 403-373 = 30K
Rate of heat transfer = Q= S λS = 11547.16 (2218.4) = 25616219.7 kJ/hr= 7115.6 x 103J/s =
7115.6 x 103 W
Q = UAΔT
A = Q/ U ΔT = 7115.6 x 103 /(2000 X 30) = 118.5 W/(m2.K)
Heat transfer area A = 118.5 m2
6. A solution containing 10% of solids is to be concentrated to a level of 50% solids. Steam
is available at a pressure of 0.2Mpa (Saturation temperature of 393K). Feed rate to the
evaporator is 30000 Kg/hr. The evaporating is operating at a reduced pressure such that
the boiling point is 323 K the over all heat Transfer coefficient is 2.9KW/ m2.K estimate
(i) The steam economy
(ii) The Heat transfer surface for (1) feed introduced at 293K (2) Feed
introduced at 308K.
DATA
Specific heat of feed = 3.98KJ/kg.K
Latent heat of condensation of steam at 0.2MPa = 2202 KJ/Kg
Latent heat of vaporization of water at 323K = 2383KJ/Kg
F = L+V---------------------1
FxF = LxL----------------2
0.10 X 30,000= 0.50 (L)
L= 6000 Kg/hr
F=L+V
30,000 = 6000 - V
V = 24,000 kg/hr
CASE (I) FEED AT 293K
Q = QS = S λS =FCpf (T-Tf) + V λv
F = 30,000 kg/hr, V = 24,000 kg/hr
Cpf = 3.98
λS = Latent heat of condensation of steam at 0.20 MPa = 2202 kJ/kg
23
Tf = feed temperature = 293K
T = Boiling point of solution = 323K
Q = S (2202) = 30,000 X 3.98 (323-293) + 24,000 (2383) =
S = 27,599.5 kg/hr
Steam consumption S = 27,599.5 kg/hr
= V/S = 24,000 / 27,599.5 = 0.87
Step 4 To find area
Q = UAΔT
U = 2.9 kW/(m2.K) = 2900 W/(m2.K)
temperature
ΔT= 393 – 323 = 70K
Rate of heat transfer = Q= S λS = 27,599.5 (2202) = 60774099 kJ / hr
= 16881694J/s = 16881694W
Q = UAΔT
A = Q/ UΔT = 16881694 / (2900 X 70)
A = 83.16 m2
CASE (II) FEED AT 308K
Q = QS = S λS =FCpf (T-Tf) + V λv
F = 30,000 kg/hr, V = 24,000 kg/hr
Cpf = 3.98
λS = Latent heat of condensation of steam at 0.20 MPa = 2202 kJ/kg
Tf = feed temperature = 308 K
T = Boiling point of solution = 323K
Q = S (2202) = 30,000 X 3.98 (323-308) + 24,000 (2383) =
S = 26,786 kg/hr
Steam consumption S = 26,786 kg/hr
= V/S = 24,000 / 26,786 = 0.896
Step 4 To find area
Q = UAΔT
U = 2.9 kW/(m2.K) = 2900 W/(m2.K)
temperature
ΔT= 393 – 323 = 70K
24
Rate of heat transfer = Q= S λS = 26,786 (2202) = 58982772 kJ / hr
= 16384103 J/s = 16384103 W
Q = UAΔT
A = Q/ UΔT = 16384103 / (2900 X 70)
A = 80.71 m2
Finally as the feed temperature goes down, economy decreases and as U and ΔT do not change
the area increases due to increase in the heat load.
Tf = 308 K = Economy = 0.896, area = 80.71 m2
Tf = 293 K = Economy = 0.87, area = 83.16 m2
USING STEAM TABLES
7. A feed of 8000 kg/hr of a 0.5% by weight salt solution at 311˚K enters continuously a single
effect evaporator and being concentrated to 38% by weight. The evaporation is at 0.7
atmospheric pressure and the area of the evaporator is 75 m2. Saturated steam at 390˚K is
supplied for heating. Assume the solution has no boiling point elevation. Cp of feed is 3.65
KJ/kg ˚K. Calculate the overall heat transfer coefficient.
Solution
λS = Latent heat of condensation of steam at 390˚K
= Enthalpy of saturated steam- Enthalpy of saturated water = 2532.9 – 71.3 = 2461.6 KJ/kg
λv = λ =Latent heat of vaporization of water at 0.7 atm = 2660.1-376.9 = 2284 KJ/kg
F=L+V---------------------1
FxF = LxL----------------2
0.05 X 8000= 0.38 (L)
L= 1052 Kg/hr
F=L+V
8000 = 1052 + V
V = 6948 kg/hr
λS = Latent heat of condensation of steam at 399 K = 2461.6 kJ/kg
T = temperature of thick liquor= boiling point of solution = 373
Tf = Temperature of feed = 311 K
F = 8000 kg/hr
Cpf = 3.65 kJ/kg.K
Q = QS = S λS = FCpf (T-Tf) + V λv
S (2461.6 ) = 8000 X 3.65 (373 - 311) + 6948 (2284) = S = 7182.2 kg/hr
25
= V/S = 6948 / 7182.2 = 0.967
Step 4 To over all heat transfer co efficient
Q = UAΔT
A = 69 m2
temperature
ΔT= 390 - 373 = 17K
Q= S λS = 7182.2 (2461.6) = 17679703.5 kJ/hr = 4911028.7 J/s = 4911028.7 W
Q = UAΔT
U = Q/ AΔT = 4911028.7/(17 X 75) = 3851.7 W/(m2.K)
TRIPLE EFFECT EVAPORATOR PROBLEMS
9. A triple effect evaporator is concentrating a solution that has no appreciable boiling point
elevation. The temperature of steam to the effect is 381.3K (108.30C) and boiling point of the
solution in the last effect is 327.4K (51.70C).The overall heat transfer coefficients in the first,
second and third effect are 2800, 2200 and 1100W/m2K respectively. At what temperature
will the solution boil in the first and second effects?
Solution:
Total temperature drop = T = 381.3 − 324.7 = 56.6 K
 U U 
T = T1 1 + 1 + 1 
 U2 U3 
 2800 2800 
56.6 = T1 1 + +
 2200 1100 
T1 = 11.75K
 U U 
T = T2 1 + 2 + 2 
 U1 U 3 
 2200 2200 
56.6 = T2 1 + +
 2800 1100 
T2 = 14.95K
and  T3 = 56.6 − (11.75 + 14.95) = 29.9 K
T1 = TS − T1'
T1' = 381.3 − 11.75 = 369.55K
T2 = T1' − T2'
T2' = 369.55 − 14.95 = 354.6 K
Boiling point of the solution in the first effect = 369.55K
Boiling point of the solution in the second effect = 354.6K
26
10. A triple effect evaporator system is used to concentrate 4500kg/hr of a weak solution
from 10% to 50% solids. Steam at 393K is used for the said purpose. Vacuum is maintained
in the last effect such that B.P.in the last effect is 325K. If the feed initially at 297 K is used
and the backward feed arrangement is used, what will the steam consumption, temperature
distribution in the system and heat transfer area of each effect (effects are identical in
dimension). For the calculation purpose, take Cp for the solution as 4.18 KJ/kg. K over the
given concentration range.
Data
U for I, II, and III effect is 2500,2000,1600 W/m2K respectively.
Solution
F = 4500 kg/hr = 1.25 kg/s
Material balance of solids:
F=L1+V1---------------------1
FxF = L1xL----------------2
0.10 X 1.25 = 0.50 (L1)
L1 = 0.25 Kg/s
F=L1+V1
1.25 = 0.25 – V1
V1 = 1.0 kg/ s
Step : 2
ΔT = ΔT1+ ΔT2 + ΔT3-----------------3
ΔT = TS – T3 = 393-325 = 68 K
Assume identical heat transfer surface in each effect

U1 ΔT1 = U2 ΔT2= U3 ΔT3
2500 ΔT1= 2000 ΔT2= 1600 ΔT3
2500
T2 = T1 = 1.25T1
2000
2500
T3 = T1 = 1.5625T1
1600
ΔT = ΔT1+ ΔT2 + ΔT3
68 = ΔT1+ 1.25 ΔT1 + 1.5625 ΔT1 = 3.812 ΔT1
ΔT1 = 68/3.812 = 17.84 K
ΔT2 = 1.25 ΔT1 = 1.25 (17.84) = 22.3K
ΔT3 = 1.5625 ΔT1 = 1.5625 (17.84) = 27.87K
ΔT1 = Ts - T1
17.84 = 393 - T1
T1 = 393-17.84 = 375.16 K
27
ΔT2 = T1 – T2
22.3 = 375.16 - T1
T1 = 375.16 -22.3 = 352.86 K
ΔT3 = T2 – T3
27.87 = 352.86 – T3
T1 = 352.86 -27.87 = 324.99 K
From steam table:

λv at 393 K = 2202kJ/kg λv at 375.16 K = 2251kJ/kg
λv at 352.86 K = 2308kJ/kg λv at 325 K = 2378 kJ/kg
Material balance over first effect:

L2 = V1 + L1---------------1
L2 = V1 + 0.25
Enthalpy balance over the first effect:
S λS = L2 Cp (T2 –T1) + V1 λv1
S λS = (V1 + 0.25) Cp (T2 –T1) + V1 λv1
S (2202) = (V1 + 0.25) 4.18 (375.16 –352.86) + V1 (2251)
S = 1.0646V1 + 0.0106
Material balance over second effect:
L3 = V2 + L2---------------2
Sub eqn 1 in eqn 2
L3 = V2 + (V1 + L1) = V2 + V1 + L1 = V2 + V1 + 0.25 ---------------3
Enthalpy balance over the second effect:
V1 λV1 = L3 Cp (T2 –T3) + V2 λv2
V1 λV1 = (V2 + V1 + 0.25) Cp (T2 –T3) + V2 λv2
V1 (2251) = (V2 + V1 + 0.25) X 4.18 X (352.86 –325) + V2 (2308)
V1 = 1.136 V2 + 0.01364
Enthalpy balance over the third effect:
V2 λV2 = FCp (T3 –TF) + V3 λv3
V2 (2308) = 1.25 X 4.18 (325 –297) + V3 (2378)
V2 (2308) = 146.3+ V3 (2378)
V3 = 0.9706 V2 – 0.0615
V = V1 + V2 + V 3
V = (1.136 V2 + 0.01364) + V2 + (0.9706 V2 – 0.0615)
1.0 = (1.136 V2 + 0.01364) + V2 + (0.9706 V2 – 0.0615)
V2 = 0.337 kg/s
V1 = 1.136 V2 + 0.01364
V1 = 1.136 (0.337) + 0.01364 = 0.3965 kg/s
V3 = 0.9706 V2 – 0.0615
V3 = 0.9706 (0.337) – 0.0615 = 0.2656 kg/s
28
S = 1.0646V1 + 0.0106
S = 1.0646(0.3965) + 0.0106 = 0.4327 kg/s
Steam consumption = 0.4327 kg/s = 1558 kg/hr
Heating surface required:
S S 0.4327 X10 3 (2202)
A1 = = = 21.36m 2
U 1 T1 2500(17.84 )
V1 V1 0.3965X10 3 (2251)

A2 = = = 20..01m 2
U 2 T2 2000(22.3)
V2  V 2 0.337 X10 3 (2308)
A3 = = = 17.44m 2
U 3 T3 1600(27.87 )
Average area of each effect = (21.36+20.01+17.44) / 3 = 19.60m2
13. A triple effect evaporator is concentrating a liquid that has no appreciable elevation in
boiling point. The temperature of the steam to the I effect is 108˚C,the boiling point of the
solution in the last effect is 52˚C.the overall heat transfer coefficient in kW/ m 2˚C are 2500
in I effect, 2000 in II effect and 1000 in III effect. At what temperature will the liquid boil in
the I and II effects.( H.W.)
29

HT Unit 4 .1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HT Unit 4 .1

Uploaded by

Copyright:

Available Formats

UNIT 4 EVAPORATION AND RADIATION

Advantage of Agitated film evaporators:

Design calculation for single effect evaporator

Assume identical heat transfer surface in each effect

From steam table:

Material balance over first effect:

V1 V1 0.3965X10 3 (2251)

You might also like