Part 2: Lecture 3

Santiago Faucher

Lecture 3 SF 1

Course Outline
1. Overview of Separation Processes (Course Notes
+ Chapter 1 Separation Processes by King)
2. Evaporation (Chapter 8 + PCEH 11-110)
3. Drying (Chapter 9)
4. Adsorption (Chapter 12)
5. Liquid-liquid extraction (Chapter 12)
6. Crystallization (Chapter 12)
7. Supercritical fluid extraction
8. Membrane processes (Chapter 13)
9. Filtration, Settling, Centrifugation (Chapter 14)

Lecture 3 SF 2
 Part 2: Evaporation
(Course Notes + Geankoplis Chapter 8 + Perry’s 11-110)
¾ Design Criteria and Processing Factors
¾ Evaporator Types and Applications
¾ Single Effect Evaporator Calculations
¾ Boiling Point Rise of Solutions
¾ Enthalpy-Concentration Diagrams for
Solutions
¾ Multiple Effect Evaporator Calculations

Lecture 3 SF 3

Evaporator Design Criteria and

Processing Factors
¾ Heat Transfer: Most important factor in evaporator design as it
affects heat transfer area which is the largest component of
evaporator cost.
¾ The best evaporator is the one that has the highest heat transfer cost
coefficient: J/s K per $ of installed cost.
¾ A circulation (pump) system is only attractive if the energy to run the
pump is offset by a higher heat transfer cost coefficient.

Do you know how to

calculate pumping cost?

Lecture 3 SF 4
 Evaporator Design Criteria and
Processing Factors
¾ Vapour-liquid Separation:
¾ Must prevent entrainment due to product loss
¾ Contamination of the vapour phase (polution)
¾ Condensation of vapour onto surfaces (corrosion and fouling)
¾ Overhead mist or spray may cause troublesome deposits
¾ Vortices increase pump head requirements and therefore equipment
configuration
¾ Short circuiting a big problem as it presents the problem of cavitation
(there must be a net positive suction head)

Lecture 3 SF 5

Why are the feeds, tubing, and pump located

where they are?

Have you learnt about

NPSHR and NPSHA?

Lecture 3 SF www.wintek-corp.com 6
 NPSHR and NPSHA
¾ NPSHR: Net Positive Suction Head Required
¾ From the pump curve.
¾ NPSHA: Net Positive Suction Head Available

Lecture 3 SF 7

NPSHR and NPSHA

NPSHA > NPSHR, otherwise we will flash.

Flash occurs when Pressure Inside the pump inlet side is less than the vapour
pressure.

Pressure inside the pump is:

Inlet Head (atm. + hydraulic head) – friction head loss – NPSHR

Therefore:

Inlet Head (atm. + hydraulic head) – friction head loss – NPSHR > Vapour pressure

Restating:

Inlet Head (atm. + hydraulic head) – friction head loss – Vapour Pressure > NPSHR

NPSHA
i.e. NPSHA > NPSHR

Lecture 3 SF 8
Example 3.1: An evaporator is operating at atmospheric pressure using a
forced circulation pump at a flowrate of 400 gpm. The feed to the recirculating
system is fed into the top of the evaporator at a rate of 40 gpm and at a
temperature of 140 F. The head losses in the return piping system are 9 ft
H2O. Calculate the height required between the pump and the top of the liquid
level in the evaporator.

NPSHA = Inlet Head (atm. + hydraulic head) – friction head loss – Vapour
Pressure

= 33.9 ft H2O + Height – 9 – 33.9 ft H2 = Height – 9

NPSHR from pump curve = 1 foot

Therefore: NPSHA = Height – 9 > 1 ft = NPSHR

So Height > 10 ft ! << You would want to add some fat to this so say 15 ft to be
sure.

Lecture 3 SF 9

Example 3.2: An evaporator is operating at atmospheric pressure using a

forced circulation pump at a flowrate of 400 gpm. The feed to the recirculating
system is fed before the pump at a rate of 40 gpm and at a temperature of 100
F. The head losses in the return piping system are 9 ft H2O. Calculate the
height required between the pump and the top of the liquid level in the
evaporator.
Note inlet temperature to pump has dropped from 212 F to approximately
(40*Cp*(100-32)+360*Cp*(212-32))/400*Cp + 32 = 200 F. At this temperature
from the steam tables the vapour pressure has been reduced from 14.7 psi to
11.52 psi or 33.9 ft to 26.6 ft H2O
NPSHA = Inlet Head (atm. + hydraulic head) – friction head loss – Vapour
Pressure = 33.9 ft H2O + Height – 9 – 26.6 ft H2 = Height – 9 + 7.6 = Height –
2.6
NPSHR from pump curve = 1 foot
Therefore: NPSHA = Height – 2.6 > 1 ft = NPSHR
So Height > 3.6 ft << You would want to add some fat to this so say 5 ft to be
sure.

Lecture 3 SF 10
 Other Design Criteria
¾ Liquid concentration -> relates to viscosity and heat transfer
¾ Temperature and Pressure
¾ Boiling temperature is inversely proportional to pressure.
¾ Boiling points may increase as solution get concentrated (boiling
point rise)
¾ Foaming -> will determine the height of your freeboard in the
design
¾ Solubility of materials -> May be the limit to the concentration
that you can achieve.
¾ Scale deposits -> decrease your heat transfer coefficient.

Lecture 3 SF 11

Lecture 3 SF 12
 Part 2: Evaporation
(Course Notes + Geankoplis Chapter 8 + Perry’s 11-110)
¾ Design Criteria and Processing Factors
¾ Evaporator Types and Applications
¾ Single Effect Evaporator Calculations
¾ Boiling Point Rise of Solutions
¾ Enthalpy-Concentration Diagrams for
Solutions
¾ Multiple Effect Evaporator Calculations

Lecture 3 SF 13

Evaporator Types
Horizontal Tube Short Tube Vertical Long Tube Vertical
Natural Convection Natural Convection

-Cheap -Cheapest per unit

-Cheap capacity
-Non-viscous mat’ls
-Non-viscous mat’ls -High velocities and long
-Best at high ΔT = high U
having high U tubes = one pass, short
-Large floor space
-Liquids that do not residence time
-Mild scaling
deposit scale -Not ideal for
crystallizations
Lecture 3 SF 14
 Evaporator Types
Falling Film Forced Convection

-Higher cost
-Compact -Suitable for viscous materials
-High heat transfer coeff. -Highest U
-Low hold up and short -Compact
residence time
-Suitable for scaling or crystallization
-Not ideal for scale forming
operations
Lecture 3 SF 15

Break time?
Planning a road trip? The Microjoule can make the journey between
New York and Los Angeles over three times on just one gallon of gas.

Amazingly the Microjoule doesn't have any fancy tricks — it's just an
aerodynamic, lightweight one-seater that runs off gasoline, but runs for
a long time.

The Microjoule isn't necessarily new. The projected started in 1985 as

an entry to the Shell Eco-Marathon, where cars compete to go the
farthest on the least amount of gas, and it has won the competition
every time since 1992 and broke the world record for the most miles-
per-gallon six times.

A team of students from St. Joseph La Joliverie, a technical school in

France, will take the MicroJoule to the Shell Eco-Marathon track at the
French Nogaro Motor Circuit this year.
Lecture 3 SF 16
 Part 2: Evaporation
(Course Notes + Geankoplis Chapter 8 + Perry’s 11-110)
¾ Design Criteria and Processing Factors
¾ Evaporator Types and Applications
¾ Single Effect Evaporator Calculations
¾ Boiling Point Rise of Solutions
¾ Enthalpy-Concentration Diagrams for
Solutions
¾ Multiple Effect Evaporator Calculations

Lecture 3 SF 17

Single Effect Evaporators

q = UAΔT = UA(Ts-T1)

Lecture 3 SF 18
 Approximations
¾ Most evaporation problems deal with solutions that are fairly
concentrated and as a result have differing:
¾ Boiling points (higher)
¾ Heat capacities
¾ Enthalpies
… than pure water.

¾ To resolve our heat balances we use the following approximations:

¾ The latent heat of evaporation of 1 kg mass of water from a solution can
be approximated as that of pure water at the boiling point temperature
of the solution (rather than use the latent heat at the equilibrium boiling
temperature expected for pure water at the operating pressure).
¾ If the heat capacities of the liquid and product stream are known we can
use these to calculate the enthalpies of these streams.

Lecture 3 SF 19

Example 3.3 Heat Transfer Area in a Single-Effect Evaporator

A continuous single-effect evaporator concentrates 9072 kg/hr of a 1.0 wt% salt

solution entering at 311K to a final concentration of 1.5 wt%. The vapour space of
the evaporator is at 1 atm and the steam supplied is saturated at 143.3 kPa. The
overall coefficient U = 1704 W/m2 K. Calculate the heat-transfer area required.
Assume that, since it is dilute, the solution has the same boiling point as water.

Lecture 3 SF 20
Space for calculation

Lecture 3 SF 21

Space for calculation

Lecture 3 SF 22
 Space for calculation

Lecture 3 SF 23

Effect of Process Variables

¾ Effect of feed temperature
¾ In Example 3.3 if we had operated at a feed temperature of 350K
(up from 311K), what reduction in evaporator size would have
been achieved? (Area decreases from 150 m2 to 126 m2)

¾ Effect of pressure
¾ At 1 atm the ΔT was 10K, if we reduce the pressure to 0.41 atm
what would the new surface area have been? (ΔT becomes 33K
and area decreases from 150 m2 to 42 m2, however now require
condenser and vacuum pump)

¾ Effect of steam pressure

¾ Using superheated steam will also reduce the size of the
evaporator but this is an expensive option.

Lecture 3 SF 24
Example 3.4 Heat Transfer Coefficient in a Single-Effect Evaporator

A continuous single-effect evaporator concentrates 4535 kg/hr of a 2.0 wt% salt

solution entering at 311K to a final concentration of 3.0 wt%. The vapour space of
the evaporator is at 1 atm and the steam supplied is saturated at 383.2K. The area
of the evaporator is 69.7m2. The heat capacity of the feed is Cp = 4.1 kJ/kg K.
Calculate the heat-transfer coefficient required. Assume the solution to be dilute,
since it is dilute, the solution has the same boiling point as water.

Lecture 3 SF 25

Space for calculation

Lecture 3 SF 26
Space for calculation

Lecture 3 SF 27

Space for calculation

Lecture 3 SF 28
 Break time?

There are 62,000 miles of blood

vessels in the human body – laid
end to end they would circle the
earth 2.5 times

Lecture 3 SF 29

Part 2: Evaporation
(Course Notes + Geankoplis Chapter 8 + Perry’s 11-110)
¾ Design Criteria and Processing Factors
¾ Evaporator Types and Applications
¾ Single Effect Evaporator Calculations
¾ Boiling Point Rise of Solutions
¾ Enthalpy-Concentration Diagrams for
Solutions
¾ Multiple Effect Evaporator Calculations

Lecture 3 SF 30
 Boiling Point Rise
¾ As mentioned previously most solutions being
evaporated differ significantly from the behaviour of pure
water in regard to:
¾ Their boiling point at a specific pressure
¾ Their heat capacities or enthalpies.

¾ Dühring’s rule is a useful approach to predict the boiling

point of solutions. Basically there is a linear relationship
between the boiling point of a solution and that of pure
water.
¾ All that is needed therefore is to know the boiling point
temperature of the solution at two pressures and one can then
estimate any intermediary boiling points.

Lecture 3 SF 31

Dühring’s rule

Lecture 3 SF 32
Example 3.5 Use of Dühring Chart for Boiling Point Rise

The pressure in an evaporator is given as 1 atm and a solution of 50

wt% NaOH is being boiled. Determine the boiling point temperature and
subsequently the boiling proint rise of this solution.

In this case the boiling point is

292°F and so the BPR is
292°F – 212°F = 80°F.

The latent heat of the vapour

would be estimated as 1177 Btu/lbm
from the saturated steam tables
at 292°F or alternatively from the
superheated steam tables at 292°F
And 14.7 psia as 1189 Btu/lbm.

Lecture 3 SF 33

Other Boiling Point Rise Plots (PCEH)

Lecture 3 SF 34
Other Boiling Point Rise Plots (PCEH)

When applied to example

3.5 where the BP was
292°F we quickly get a
BPR of 80°F.

Lecture 3 SF 35

Other Boiling Point Rise Plots (PCEH)

The real useful aspect of
this chart is determining
solids contents from
boiling point data.

As we know that at 1 atm

the BP of water is 212°F
and having measured a
BP of the solution of
292°F, we can determine
from this chart that the
solids content is: 50 wt%.

Lecture 3 SF 36
 Part 2: Evaporation
(Course Notes + Geankoplis Chapter 8 + Perry’s 11-110)
¾ Design Criteria and Processing Factors
¾ Evaporator Types and Applications
¾ Single Effect Evaporator Calculations
¾ Boiling Point Rise of Solutions
¾ Enthalpy-Concentration Diagrams for
Solutions
¾ Multiple Effect Evaporator Calculations

Lecture 3 SF 37

Dale Carnegie Principle No. 3

How do you make people want to do something?

“First, arouse in the other person an eager want. He who can do this
has the whole world with him. He who cannot walks a lonely way”

What does that mean?

Find a way/mechanism/logic to make the other person want to do the

task that you need them to accomplish. You cannot force someone
to do something; the result will be poor. But if the individual sees
value in it for themselves then they will eagerly take on the task.

Principle 3: Arouse in the other person an eager want.

Dale Carnegie, 1936

Lecture 3 SF 38
Dale Carnegie Summary of Fundamental
Techniques for Handling People
PRINCIPLE 1
Don’t criticize, condemn, or complain.

PRINCIPLE 2
Give honest and sincere appreciation.

PRINCIPLE 3
Arouse in the other person an eager want.

Dale Carnegie, 1936

Lecture 3 SF 39

End of Lecture 3 (Part 2)

Lecture 3 SF 40