Double Effect Evaporator

Thermal design
Feed temperature is 86.85oC
Assume: specific heat of the concentrated liquor to be 0.87 kcal/kg oC
Pressure in effect I is 5.4 atm (547.2KPa)
Pressure in effect II = 547.2 303.975 = 243.23 KPa
Boiling point at this pressure = 126.5oC
(high molecular wt. solute, BPE is neglected)
Latent heat vapor (s2) generated in effect II at 243.23Kpa = 2183.73 KJ/kg
Heating steam is at 1519.88KPa gauge; temp (Ts) = 198.92oC
Latent heat (s) = 1943.87 KJ/kg
Feed rate = 7843.10 kg/h, solute content = 38%
Final concentration 80%
Solid in = 7843.10 x 0.38 = 2980.38 kg/h, water in = 7843.10 2980.38 = 4862.72 kg/h
Product out (80% solid) = 2980.38/0.80 = 3725.48 kg/h
Water out with the product = 3725.48 (1-0.80) = 745.10 kg/h
Total evaporation rate in two effects (ms1 + ms2) = 4862.72 745.10 = 4117.62 kg/h

eq.1

Allow equal areas to two effects, ie., UD1T1 = UD2T2

Ttotal = T1 + T2 = 198.92 126.50 = 72.42oC
The range for heat transfer coefficient for viscous solution like glucose is 300 900 W/m 2K
Assume: UD1 = 639.65 W/m2K ;

UD2 = 430 W/m2K

T1 = 40oC ; T2 = 32.42oC
Temperature of the vapor leaving effect I (T b1) = 198.92 57.94 = 140.98oC
Latent heat vapor generated in effect I at 140.98oC = 2141.30 KJ/kg (s1)

Energy Balance for Effect I

mfHf + ms(s) = (mf ms1)H1 + ms1Hs1
Enthalpy values: reference temperature = 140.98 oC (temp. of solution leaving effect I)
Hf = (86.85 140.98) (1kcal/kgoC) = -54.13 kcal/kg or -226.48KJ/kg

H1 = 0 (w.r.t. the reference temperature of 140.98oC)

s = 1943.87 KJ/kg ;

s1= 2141.30 KJ/kg

Therefore:
(7843.10 kg/h)( -226.48KJ/kg) + ms(1943.87 KJ/kg) = (7843.10 kg/h - ms1)(0) + ms1(2141.30
KJ/kg)
ms = 1.10ms1 + 913.80 eq.2

Energy Balance for Effect II

(mf ms1)H1 + ms1 s1 = (mf ms1 ms2)H2 + ms2Hs2
Enthalpy values: reference temperature = 126.5 oC
H1 = (140.92 126.5)(0.94 kcal/kgoC) = 13.55 kcal/kg or 55.72 KJ/kg
(specific heat of the solution leaving the 1st effect is taken as the mean value of the specific heat
of feed and the concentrated solution, i.e., (1 + 0.87)/2 = 0.94 kcal/kg oC)
H2 = o kcal/kg (w.r.t. the reference temperature of 126.5 oC
s1 = 2141.30 KJ/kg ;

ss2= 2183.73 KJ/kg

Therefore:
(7843.10 ms1)(55.72) + ms1(2141.30) = (7843.10 ms1 ms2)(0) + ms2(2183.73)
ms2 = 0.955ms1 + 200 eq. 3
Solving eqs. 1, 2, and 3 for ms, ms1, and ms2:
ms = 3118.09 kg/h , ms1 = 2003.89 kg/h , ms2 = 2113.72 kg/h

A 1=

m s s
(3118.09 ) (1943.87 )
=
=236.89 m2
U D 1 T 1
639.65 x 40

A 2=

m s 1 s 1
( 2003.89 )( 2141.30 )
=
=279.65 m 2
U D2 T2
430 x 32.38

The areas in the two effects are not equal. Revised calculation is required.
The revised temperature difference in the 1st effect,

T 1=35o C and T 2=37.42o C

Temperature of the saturated vapor from the first effect = 198.92 86.85 =112.07 oC
Corresponding evaporator drum pressure = 1.54 bar

Latent heat of the vapor leaving the 1st effect at 112.07oC = 2235.12 KJ/kg

( s 1)

Revised calculation: Energy balance for effect I (reference temp 112.07 oC)
Therefore:
(7843.10)( -226.48K) + ms(1943.87) = (7843.10 - ms1)(0) + ms1(2235.12)
ms = 1.15ms1 + 794.72

Revised calculation: Energy balance for effect II (reference temp 126.5 oC)
(7843.10 ms1)(55.72) + ms1(2235.12) = (7843.10 ms1 ms2)(0) + ms2(2183.73)
ms2 = 1.02ms1 + 200

Solving eqs. 1, 2, and 3:

ms1 = 1939.42 kg/h ; ms = 3025.05 kg/h ; ms2 = 3285.55 kg/h

A 1=

A 1=

m s s
(3025.05 )( 1943.87 )
=
=262 m2
U D 1 T 1
639.65 x 35

m s 1 s 1
( 1939.42) ( 2235.12 )
=
=270 m 2
U D2 T2
430 x 37.2

These areas are fairly close, A1 = A2 = 266 m2

Tube Details:
The proponent select 1 inch nominal diameter, 80 schedule, brass tubes of 12 ft length
Outer tube diameter (do) = 42.16 mm
Inner tube diameter (di) = 32.46 mm
Tube length (L) = 12 ft = 3.6576 m
Surface area of each tube (a) = pi x do x L = 0.4845 m2
Number of tubes required (Nt) A/a = (266/0.4845) = 549 tubes
Tube pitch (triangular), PT = 1.25 x do = 1.25 x 42.16 = 52.71 = 53 mm
Total area occupied by tubes = Nt x (1/2) x PT2 x sin (where =60o)
= 549 x 0.5 x (53e10-3)2 x 0.866 = 0.67 m2
This area is generally divided by a factor which varies from 0.8 to 1 to find out the actual area.

This allows for position adjustment of peripheral tubes as those cant be too close to tube sheet
edge.

Actual area required = 0.67/0.9 (0.9 is selected)

= 0.74 m2
The central downcomer area is generally taken as 40 to 70% of the total cross sectional area of
tubes. The proponents consider 50% of the total tube cross sectional area.
Therefore, downcomer area = 0.5(Nt x (pi/4) x do2
= 0.5 (549 x (pi/4) x (0.04216)2 = 0.38 m2
Downcomer diameter = sq.r((4x0.38)/pi)) = 0.696 m 2

Total area of tube sheet in evaporator = downcomer area + area occupied by tubes
= 0.696 + 0.74 = 1.44 m2
Tube sheet diameter = sq.r ((4 x 1.44)/pi) = 1.35 m

Mechanical design
Process design parameters and materials of construction:
Type of evaporator: Standard vertical short tube evaporator (Calandria type)
Evaporator drum operated at 1.54 bat
Amount of water to be evaporated = 4117.62 kg/h
Heating surface area = 266m2
Steam is available to first effect at 5.47 bar pressure
Density of 38% feed liquid 1 = 1050 kg/m3 (assumed)
Density of water vapor (v) = PM/RT at saturated vapor temperature in the first
effect (112.07oC)
= (1.54 x 18)/(8.314e10-5 x 385.22) = 0.866 kg/m3
Design pressure (P) = 38% more than the maximum working pressure
=1.05 x 5.47 = 5.74 bar
Volumetric flow rate of water vapor (V): 4117.62/(0.866 x 3600) = 1.32 m 3/s

Evaporator shell: low carbon steel (IS-2062)

Tube material: brass

Permissible stress for low carbon steel = 980 kg/cm 2
Modulus of elasticity for low carbon steel = 19e10 5 kg/cm2
Modulus of elasticity for brass = 9.5e105 kg/cm2
Conical head at bottom: cone angle = 120o
Conical head at top: cone angle = 120o

Check for Tube Thickness

The tube thickness is given by tt = Pdi/2f P
The permissible stress of brass (f) = 538 kg/cm 2; welding or joint efficiency, J
= 1 is used for seamless tube
Therefore, tt = (5.74 x 32.46)/(2(538 x 1) 5.74) = 0.174 mm

The specified thickness is 4.85 mm. Therefore, the selected tube is suitable
for this service.

Calendria Sheet Thickness Calculation

Thickness is given by: ts = PDo/2fJ + P
= (5.74 x 1350)/((2 x 980 x 0.85)+5.74) = 4.64mm
The corrosion allowance of 3mm is used for carbon steel.
It may be taken as ts = 10mm

Evaporator Drum Diameter Determination

Rd(=(V/A)/(0.0172 sq.r(( l v)/ v)
Where:
V = volumetric flow rate of vapor (m3/s)
A = cross sectional area of drum
For drums having wire mesh as entrainment separator device, R d may be taken as 1.3.

0.0172 (1050 0.866)(0.866)=1.95 m 2 m

1.3
V
1.32
A=
=

R x 0.0172

The drum diameter =

(4 x 2)/ =1.60 m

Drum height is usually taken as 2 t o5 times of tubes sheet diameter

Thus, the drum height = 4 x 0.866 = 3.464 m

Drum Thickness
Drum operating pressure 1.54 bar pressure
Design pressure = 5.74 bar
= 5.85 kgf/cm2
Drum thickness td = PDo/(2fJ + P)
=(5.85 x 866)/ (2(980x0.85) +5.85) = 3mm