EVAPORATION

Separation Process II
Dr Nurul Ekmi Bt Rabat
Chapter 8 in Geankoplis 4th Edition
TOPIC 1)
2)
explain evaporation theory.
perform mass & energy balances of single
OUTCOMES 3)
effect evaporators for diluted feed
determine the boiling point rise of Single
effect evaporators for high concentrated
feed
4) Understand the temperature effects on
At the end of this multiple effect evaporators
topic, students
should be able to:
THINK PAIR Suggest any daily
SHARE activities that are
using EVAPORATION
process.
Definition
– process where vapor (solvent) from a boiling liquid solution is
removed and a more concentrated solution (solute) remains
– Solvent generally refers to the removal of water from aqueous
solution
– For example: Evaporation used in water desalination :

•4
Other Applications
■ Widely used in food and • Produce ■ In pharmaceutical
beverages industry to concentrated industry, evaporation
concentrate liquid food aqueous solution is used in
such as salt, sugar, soup, in such as manufacturing.
syrup, glycerol, milk.
sodium chloride,
sodium hydroxide

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PROCESSING FACTORS
❑ Types of evaporators are selected based on the physical and chemical
properties of the solution being concentrated and the vapor removed
Properties affecting processing methods :
1. Concentration in liquid
2. Solubility
3. Temperature sensitivity of materials
4. Foaming or frothing
5. Pressure and Temperature
6. Scale deposition / Materials construction

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 Concentration in the liquid

❑ liquid feed is relatively dilute

 low viscosity, high heat transfer coefficient
❑ solution may become very viscous due to evaporation
 heat transfer coefficient drops
 adequate circulation and/or turbulence must be present to keep the coefficient
moderate. •7
 Solubility curves of typical salts

Solubility
❑ Heat is provided, Evaporation takes
place
 concentration of solute increases
 exceed solubility limit of material
 form crystals thereby limit maximum
concentration in solution

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Temperature sensitivity of materials
Temperature-sensitive materials degrade at
higher temperature or prolonged heating
food & biological materials e.g. milk, vegetable
extracts
pharmaceutical products
fine organic chemicals
Degradation is a function of temperature & time

•9
 Foaming or frothing
Some solutions form a foam or froth during boiling
food solutions - skim milk
fatty acid solutions
foam + vapor = entrainment losses occur

•10
Pressure & Temperature
❑ High operating pressure cause rise in boiling point
❑ Heat sensitive materials are required to keep at low
temperature
❑ Recommended operating pressure under 1 atm
(vacuum) to keep temperature low in heat-sensitive
material

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Scale deposition
❑ Some solution deposit solid materials
(scale) on heating surfaces.
Possible cause:
products decomposition
decrease in solubility
Consequences: overall heat transfer
coefficient decreases, corroded evaporator
❑ Materials for evaporator should be chosen
to minimize corrosion

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Material of Construction
• Evaporators are made of steel (carbon steel)
• many solutions attack ferrous metal and/or contaminated by them
• use special material (nickel, stainless steel, aluminium), however it’s
expensive
▪ minimize corrosion
▪ avoid contamination

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QUESTION?

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SINGLE EFFECT EVAPORATOR
Vapor Typical evaporator is made up of three functional
sections:
Feed P
1. heat exchanger
2. evaporating section: liquid boils & evaporates
T 3. separator: vapor leaves liquid and passes off to
Condensate
condenser/other equipment

Steam •Tboil =Tvap , vapor is in equilibrium with boiling

solution.
•Used for small capacity operation and low cost
steam
Concentrated
•Energy wasted as latent heat of vapor
liquid discarded

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MASS AND ENERGY BALANCE

Vapor, V
T1, yV, HV
P1
Feed, F
TF, xF, hF T1
Steam, S Condensate, S
TS, HS TS, hS
Steam at saturation T → latent heat
Concentrated liquid, L
T1, xL, hL
P1: liquid saturation vapor P at boiling point T1
 SINGLE EFFECT EVAPORATOR: MASS
BALANCE

Overall Balance Vapor, V

F = L +V 1
Feed, F
Solute Balance xi.F

F  xi.F = L  xi.L 2 xw.F

Concentrated liquid, L
xi.L
xw.L
Total heat entering = Total heat leaving
F hF + S Hs = L hL + V HV + S hs 3

hF = enthalpy of feed [J/kg]

HS = enthalpy of saturated steam Vapor, V
[J/kg]
T1, yV, HV
hL = enthalpy of liquid [J/kg] Feed, F

HV = enthalpy of vapour [J/kg] hF

hs = enthalpy of condensed Steam, S Condensate, S
steam [J/kg] TS, HS TS, hS

Concentrated liquid, L
hL
 Latent Heat

 = Hs – hs = Latent heat of steam/condensation

Assumption: Condensed steam leaves at Ts
➔ steam gives off latent heat
Hv = Hv – hv = Latent heat of water/evaporation
➔ water gives off latent heat

From eq. 3:

F hF + Ss  = L hL + V HV
4
19
SINGLE EFFECT EVAPORATOR: HEAT BALANCE

Q = U AT
= UA(TS − T1 )
= S  5
Q = heat transferred per unit time [Watt] = capacity of evaporator
U = overall coefficient of heat transfer [W/m2 K]
A = heat transfer surface [m2]
T = temperature difference between condensing steam and boiling liquid [K]
S = mass rate of steam [kg/s]
 = latent heat of steam condensation at Ts [J/kg]

20 20
 F hF + Ss  = L hL + V HV

?
Latent heat of ? Latent heat of
condensation
evaporation at
at Ts
T1

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 hF & hL

for dilute inorganic & organic for concentrated inorganic

solution e.g. sugar, milk,
biological solids, juice
Hsol = 0
hf = CpF (TF – TBP)
hL = CpL(T1– TBP)
Often CpF & CpL = Cp of
water
solution e.g. NaOH, H2SO4,
CaCl2
Hsol  0
Refer hf & hL from
Enthalpy-Concentration Charts.
(available only for few substances)
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 EXAMPLE 1
A continuous single-effect evaporator concentrates 9072
kg/hr of a 1.0 wt% salt solution entering at 311.0 K (37.80C)
to a final concentration of 1.5 wt%. The vapor space of the
evaporator is at 101.325 kPa (1.0 atm abs) and the steam
supplied is saturated at 143.3 kPa. The overall heat
transfer coefficient, U and heat capacity of water, Cp are
1704 W/m2 K and 4.14 kJ/kg K, respectively.
Calculate:
a) The amount of vapor & liquid product
b) The heating surface area, A required.

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 V, yV,
TBP, HV

F = 9072 kg/h, PBP = 1 atm

xF = 0.01
TBP
TF = 311K
S, TS, hS
S,
P = 143.3 kPa
TS, HS

L, xL = 0.015,
TL, hL

U = 1704 W/m2 K
datum
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Perform Mass Balance
Solve for L &V, L = 6048 kg/hr & V = 3024 kg/hr
Perform heat balance

F hF + S s = L hL + V HV

steam dilutewater Assume CpF = Cp of

water = 4.14 kJ/kg K
T1 = (from steam table at P1)

hf = CpF (TF – TBP)

hf = ???
hL = CpL(TL– TBP)= 0 Assume TL is the same with TBP

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 h H

T1 = (from steam table at P1)

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 = latent heat of steam at 143.3 kPa
 = HS@TS – hS@TS
 (Ts= 1100C) = 2230.2 kJ/kg

HV = latent heat of water at 101.3 kPa

HV = Hv@T1 – hv@T1
HV (T1 = 1000C) = 2256.98 kJ/kg

27
28
 F hF + S s = L hL + V HV
Using heat balance, solve for S value,
S = 4108 kg steam/hr

Q = S = UAT = UA (Ts-TBP)
Using Q, solve for A
A = 149.3 m2

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QUESTIONS?

30
Recap – Single Effect Evaporator

31
 Discuss with your partner
EFFECTS OF PROCESSING VARIABLES
q= S = UAT = UA (Ts-TBP)
1) FEED
TEMPERATURE 2) PRESSURE

• 311 K < TBP • P = TBP

=1/4 steam used to heat • ↑ operating pressure,
TF ↑ temperature at boiling.
=3/4 vaporization • T increases, A & cost
• preheating reduces of evaporator decrease.
heat transfer area • A condenser and
vacuum pump can be
used
3) STEAM PRESSURE

• higher pressure, saturated steam ↑  T

 ↓ size and cost of evaporator
 But high pressure steam is costly The steam economy= V/S
• economic trade off needed to determine = kg vaporized/kg steam used
• optimum steam pressure 32
 Concentrated SOLUTIONS

Example 1- solution is dilute and assumed to have same

TBP as water
➢ If solutions are not dilute
❑ Thermal properties differ considerably from those of
water
 heat capacity, Cp
 boiling point, TBP

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BOILING POINT RISE & DUHRING
DIAGRAM
❑ The increase in boiling point over that of water is known as the boiling point rise
(BPR)
❑ For strong solutions of dissolved solutes, the TBP rise due to the solutes in the
solution cannot be predicted.
❑ Apply an empirical law – Duhring’s Rule:
BPR (at the same Pressure) = Boiling point of solution– Boiling point of water (refer
Duhring Diagram)

34
DUHRING CHART LINES FOR AQUEOUS SOLUTION OF NaCl
straight line

at the
same
pressure

Lines = Different given

concentrations

TBP solution
VS TBP of
pure water
35
EXAMPLE 2
The pressure in an evaporator is given at 25.6 kPa and a solution of 30%
NaOH is being boiled.
Determine:
The boiling temperature of the NaOH solution.
The boiling point rise of the solution.

36
BOILING POINT RISE & DUHRING DIAGRAM

NaOH-Water System

79.5C

65.6C
Boiling point of water (C)

TBR= TBP NaOH- TBP H2O =13.9 C

37
ENTHALPY-CONCENTRATION CHARTS OF SOLUTIONS

❖ Enthalpy of solution,
temperature and
concentration in wt% are
parts of enthalpy-
concentration chart.
❖ Used for solution with
non-negligible heat of
solution
❖ Only available for few
solutions

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EXAMPLE 3
An evaporator is used to concentrate 4536 kg/hr of a 20% solution of
NaOH in water entering at 60ºC (140ºF) to a product of 50% solids.
The pressure of the saturated steam used is 172.4 kPa and the pressure
in the vapor space of the evaporator is 11.7 kPa. The overall heat
transfer coefficient is 1560 W/m2 K (275 btu/h ft2 oF). Cp of water is
1.884J/kg. K
Calculate :
a) The steam used
b) The steam economy, kg vaporized/kg steam used
c) The heating surface area in m2

39
 V, yV,
T1, HV
F = 4536 kg/h,
P1 = 11.7 kPa
xF = 0.2,
TF = 60ºC T1

S,
P = 172.4 kPa S, TS, hS
TS, HS

L, xL = 0.5,
T1, hL
40
a) L = 1814 kg/h, V = 2722 kg/hr
❑ Heat balance: F hf + S  = L hL + V Hv

 hf = for NaOH at 20% (dilute) at

60ºC (140ºF) = 214 kJ/kg
 from enthalpy-concn. Chart

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 concentrated → boiling point rise
 At 11.7 kPa, Tbp of water = 48.8ºC from steam tables
 Boiling point of solution = 90.5ºC from Duhring = T1

BPR = TBP of solution – TBP of water = 41.6 ºC

Hv = enthalpy for superheated steam

= enthalpy of satd. Vap. @TBP of water+ Cpv(BPR)
= 2590 + 1.88 (41.6)
= 2669 kJ/kg

42
 hL = for NaOH at 50% (concentrated)
at 11.7 kPa
 hL = for NaOH at 50% at 90.5ºC =
520 kJ/kg (enthalpy-concn chart)

 S (steam used) = 3268.53 kg/h

43
b) Steam economy = V/S = 0.83
c) Heat transfer rate, q = S  = U A (Ts-T1)

❑ heating surface area, A = 51.54m2

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MULTIPLE EFFECT EVAPORATORS

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OPERATION METHODS :
MULTIPLE EFFECT EVAPORATORS
▪ Forward-feed
▪ Evaporated water from the 1st effect used as steam for the 2nd effect
▪ Feed flows to the direction of the vapor flow
▪ Used for hot feed

46

46
OPERATION METHODS : MULTIPLE EFFECT
EVAPORATORS

▪ Backward-feed
▪ Feed flows opposite to the direction of the vapor flow and pump required
▪ Used for cold feed, highly viscous product

47
 Heat Transfer rate and Boiling point of
Multiple Effect Evaporators

❑ Ts is the heating medium for 1st effect

❑ Allows boiling liquid at T1, P1 in the 1st effect
❑ In the 2nd effect "steam" is the vapor from first evaporator , i.e. Ts2
= T1
❑ Ts > T1 > T2 > T3 or P1>P2>P3 48
1) Amount of heat transferred per hour in first evaporator:

q1 = U1 A1 (Ts - T1) = U1 A1 T1

2) Amount of heat transferred per hour for 2nd evaporator:

q2 = U2 A2 (T1 - T2) = U2 A2 ∆T2

Under the assumption of:

• no boiling point rise, no heat of solution
• feed is supplied at its boiling point

49
 q1 = q2= q3
U1 A1 ∆T1 = U2 A2 ∆T2 = U3 A3 ∆T3

❑ Assuming equal A & U in each effect

Total heat transfer rate of a three effect evaporator

q = q1 + q2+ q3 = UA(Ts – T3)
Derive this!

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❑ if the evaporators are so constructed that A1 = A2
(Commercial practice)
U1 A (Ts - T1) = U2 A(T1 - T2)
U 2 T1
 = Derive this!
U1 T2
temperature differences are inversely proportional to overall heat transfer
coefficients in the two effects
❑ if T = T1 + T2 = Ts – T2
1
U1
T1 = T
1 + 1
U1 U2

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EXAMPLE 4
A solution with a negligible boiling point rise is
being evaporated in a triple effect evaporator
using saturated steam at 121.1 OC. The pressure
in the vapor of the last effect is 25.6 kPa. Heat
transfer coefficient are U1= 2840; U2= 1988;
U3= 1420 w/m2.K. If areas are equal, estimate
the boiling point at each effect.

52
T = T1 + T2 +T3 = Ts – T3 =121.1-65.6 = 55.5ºC
U1= 2840; U2= 1988; U3= 1420 w/m2.K

1
U1
T1 = T = 12.53
1 + 1 + 1
U1 U2 U3

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T2 =17.29, T3 = 12.07

T1 = Ts- T1 = 108.6 ºC

T2 = T1- T2 = 90.7 ºC
T3 = T2- T3 = 65.6 ºC

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