EVAPORATORS IN

INDUSTRIES

BY HAMZA MIR

PRESENTED BY
HANIA ALI
FAJAR SHAHID
HAMZA MIR
JAZAB CHOHAN
ABEER NAJAM CH
ZUNAIRA
 TABLE OF CONTENTS

 INTRODUCTION
 EVAPORATORS IN INDUSRIES
 CLASSIFICATION OF EVAPORATORS
 NATURAL CIRCULATION EVAPORATORS
 FORCED CIRCULATION EVAPORATORS
 FILM EVAPORATORS
EVAPORATOR

An evaporator is a device that absorbs

the heat surrounding it to cause the
liquid refrigerant inside it to boil until the
refrigerant leaves as a superheated
(saturated) gas. Each evaporator
operates according to the same basic
formula: it absorbs heat while boiling off
the liquid refrigerant.

Evaporator must be at a lower

temperature than its surroundings.
 EVAPORATORS IN INDUSTRIES
Single-effect
evaporator:
It consists of a container or surface and
a heating unit.

Multiple-effect
It uses the vapour produced in one unit
evaporator:
to heat a succeeding unit.
Double-, triple-, or quadruple-effect
evaporators may be required in
industrial and steam heating plants.
CLASSIFICATION
Evaporators are divided mainly into three groups.

1. Natural
circulation 3) Film evaporator
evaporator

I. Evaporating pans i) Wiped Film evaporator

II. Evaporating stills ii)Long Tube Evaporator
III. Short tube evaporator. a) Climbing film evaporator
b) Falling film evaporator

2) Forced
circulation
evaporator.
Natural circulation
evaporators
 Working principle:
Natural Natural circulation is the ability of a fluid in a
circulation system to circulate continuously, with the
difference in density being the only driving
evaporators force. In another way, natural circulation is
caused by convection currents which result
from the uneven heating of the water in a
boiler.
What is Convection current ?
Heat energy can transfer by convection when
there is a significant difference in temperature
between two parts of a fluid. When this
temperature difference exists, hot fluids rise
and cold fluids sink, and then currents or
movements are created in the fluid.
1) EVAPORATING
PANS
On a manufacturing scale, liquid extracts
containing water are evaporated in open
pans called evaporating pans.
The evaporating pan consists of :
 Hemispherical shallow made of Copper,
Stainless steel, Aluminum Enameled iron.
 Steam jacket
 The hemispherical shape gives the best
surface volume ratio for heating and the
largest area for the disengagement of
vapour.
WORKING

 The dilute solution is taken in the pan.

Steam is introduced through the steam
inlet into the jacket to heat the pan. In
these evaporators the movement of the
liquid results from convection currents set
up by the heating process. The
concentrated liquid is collected through the
outlet placed at the bottom of the pan.
 DISADVANTAGE
ADVANTAGES
S

 They are easy to use and clean.

• The whole of the liquid is

heated all the time which
Stirring of the evaporating liquids
can be done easily. may lead to decomposition
 of the components.
They are simple, easy and cheap
to construct. • They can not be used for
evaporating extracts
containing organic solvents
like alcohol etc.
2) Evaporating
still evaporator
Evaporating still is used to carry
out evaporation process
Construction:
 It consists of a jacketed-
evaporating pan with a cylindrical
cover that connects it to a
condenser.
 The overall assembly is called
still.
 The cover is clamped with the
evaporating pan.
Working
Working:
 The dilute liquid is fed into the still, the cover is clamped.
 Steam is introduced into the jacket.
 The liquid is evaporated and condensed in the condenser and
collected.
 The product (i.e., concentrated liquid) is collected through the
product outlet
 For thermolabile substances, we create a vacuum by decreasing
the pressure and the liquid is evaporated at lesser boiling point
 The evaporator leaves and is condensed in the condenser while
the concentrated product is not deteriorated.
Advantages:
1. Simple construction and easy to clean and maintain.
2. The vapor is removed by condensation which
 speeds evaporation
 reduces inconvenience and allows the equipment to be used for
solvents other than water e.g., ethanol.
3. A receiver and vacuum pump can be fitted to the condenser, permitting
operation under reduced pressure and, hence, at lower temperature.

Disadvantages:
 Natural convection only
 All the liquor is heated all the time
 The heating surface is limited.
 3) Short tube
evaporators
Short-tube vertical evaporators are the
oldest but still widely used in sugar
industry in evaporation of cane-sugar
juice. These are also known as calandria
evaporators.
Construction :
 Short-tube vertical evaporators consist
of a short tube bundle (about 4 to 10 ft
in length) enclosed in a cylindrical shell.
This is called calandria.
 The lower portion of the vessel consists
of a nest of tubes with the liquor inside
and steam outside
 The feed inlet is at the top of the calendria. The product outlet
is placed at the bottom of the evaporator.
 Steam inlet and outlet is placed from the side of the calendria.

Principle:
In standard vertical tube evaporators, the liquid is passed
through the vertical tube, when steam is supplied heat transfer
take place through the tubes and liquid inside gets heated, so
solvent evaporates and vapor escapes from the top , the
concentrated liquid is collected at the bottom.
Uses:
This evaporator is used in manufacturing of cascara extract, sugar, salt
and caustic soda
 Working:
The feed is introduced in the cylindrical body in such a
way that it remain above the tubes.

Steam is introduced outside the tubes

The liquid inside the tube is heated and starts to boil

As it boils it will come out of the tube and goes into the
dpwnward direction taking the central path

In such a way that it will set up a circular motion of hot

liquid. This enhances the rate of heat transfer, then the
vapor evaporated from the outlet and the final product (
concentrate) obtained is collected
 Advantages Disadvantages
• Use of tubular calendria increases • This evaporator has complicated
the heating area, possibly by a design, difficult for cleaning and
factor of 10 to 15 compared to that maintenance.
of an external jacket. • Since the evaporator is filled to a
• Increasing the rate of heat transfer. point above the level of the calendria,
a considerable amount of liquid is
• Condenser and receiver can be
heated for a long time. The effect of
attached to run the evaporation
this continual heating can be reduced
under vacuum with non aqueous to some extent by removing
solvents. concentrated liquor slowly from the
outlet at the bottom of the vessel.
Forced
circulation
evaporator
 In general, forced
circulation evaporators are
required when the fouling
characteristics of a liquid
will cause problems if the
liquid boils on a heating
surface.
 FCE operate with a
significantly high speed
velocity of 2-5m/s through
the tubes.
 PRINCIPLE
 Heat is transferred from steam to
liquor by forced convection.
 Forced circulation evaporator
working principle involves the liquor
being pumped through tubes at very
high velocity
 . The liquor goes from the bottom of
the vapour body, through the tubes
and then back into the vapour body.
 When the liquid comes out of the
tubes and enters the vapour body,
there is a sudden fall in pressure,
leading to the flashing of
superheated liquor. Hence,
evaporation takes place in the
vapour body. Forced circulation
evaporator working also creates a
WORKING

 Feed is introduced from the

bottom of the Calandria portion
by pump
 Velocity in the tubes is
maintained at 2 to 5m/s which is
very high.
 Because of pressure created by
pump boiling point is increased
and that's why boiling doesn't
occur in tubular portion
WORKING

 The liquid rises up in the tubes

and heated by steam circulated
outside tubes through its valve
 This super heated liquor when
exits from the end of tubes in
vapor head there is sudden flash
due to loss of pressure
WORKING

 Liquids strike deflector and vapor

are separated from droplets
 Vapors are removed and liquid
concentrate return to circulation
 Thick viscous liquid can be
collected from product. Out let at
bottom
ADVANTAGES
 They do not depend on a natural thermosyphon effect that limits the heat-
transfer coefficient.
 The chance of fouling and scaling is reduced due to high speed of
concentrate.
 Forced-circulation evaporators offer the highest operational flexibility, since
heat transfer, vapor-liquid separation and crystallization can take place in
separate components.
 These devices are ideal for crystallizing, and for concentrating thermally
degradable materials and viscous solutions.
DISADVANTAGES AND LIMITATIONS

 These evaporators are usually • Expensive

less economical than other • Very high power consumption
types, due to operating and • Require analytically skilled staff
maintenance costs for the
pumps.
• Machines are expensive to
maintain
 Corrosion-erosion can occur,
due to high circulation
velocities.
 Also, plugging of tubes where
liquor enters can be a problem
in salting services where the
salt deposits detach and
accumulate at the bottom.
Film
evaporators
1)Wiped Film
Evaporator:
 A type of film evaporator coming
into increased use is “Wiped Film
Evaporator”.

 Consists of a short tube(1-2m)

and a wider diameter.

 Figure on the right side shows a

basic diagram of WFE for the
understand of it.
The liquor is introduced at the top of the vessel
and spread as a film over the heated wall by the
action of the rotor.

Evaporation occurs as the liquor passes down the

wall, vapour is taken to a condenser and the
concentrated liquor withdrawn at the bottom of
the vessel

The evaporator is therefore a form of single tube,

falling film evaporator in which the film is formed
and agitated mechanically with the help of
2)Long tube
evaporators

Types :
 Climbing Film
Evaporator

 Falling Film
Evaporator
I. Climbing
film
evaporator
Construction:
 The heating system consists of steam-
jacketed tubes, having a length to
diameter ratio of about 140 to 1, so that
a large evaporator may have tubes
50mm in diameter and about 7m in
length.

 The liquor to be added is introduced into

the bottom of the tube, a film of liquid
forms on the walls and rises up the tubes,
hence it is called CLIMBING FILM
EVAPORATOR.
Working:
 At the upper end, the mixture of vapor and
concentrated liquor enters a separator, the vapor
passes to a condenser, and concentrated liquid to a
receiver.
 Cold or pre-heated liquor is introduced into the tube.
 Heat is transferred to the liquor from the walls and
boiling begins.
 Ultimately sufficient vapor are formed for smaller
bubbles to unite to a larger bubble, filling the width
of the tube and trapping a ‘Slug’ of liquid above the
bubble.
 As more vapor is formed, the slug of the liquid is
blown up the tube, the tube is filled with vapor, while
the liquid continues to vaporize rapidly, the vapor
escaping up the tube and, because of friction
between the vapor and the liquid, the film also is
dragged above the tube up to a distance of 5 to 6
meters.
 ADVANTAGES DISADVANTAGES

• Large area for heat transfer. • Expensive

• Enhanced heat transfer. • Construction is complicated.
• Suitable for heat sensitive • Cleaning and maintenance is
material. difficult.
• Used for foam forming liquids. • Large head space required.
• Instrument needs less space. • Not for viscous, salting & scaling
liquids.
II. Falling Film Evaporators

Need ?
• Rising Film needs Hydrostatic head which
leads problem with heat sensitive material.
• In falling film the contact time is reduce so
good for heat sensitive products
Composition

 Heaters,
 separators,
 condensers,
 preheaters,
 vacuum systems,
 heat pumps,
 electrical meters
Principle

 In this type of evaporators, the high velocity

feed enters from the top of the evaporator and
falls down the tube wall. As the temperature is
uneven within the tubes (due to steam), the
boiling of feed occurs when it has travelled half
way into the tubes. As the feed moves further
downwards, its temperature decreases due to
evaporation and it forms vapours. These
vapours form small bubbles which aggregate to
form large bubbles and travel downwards. This
mixture of liquid and vapour gets separated at
the bottom. The separated liquid gets
concentrated during falling and is collected as
product from the bottom.
Phenomenon

 The phenomenon involved in the whole processes are as follows

 Gravity
 Density
 Temperature gradient
Advantages

 It has higher heat-transfer coefficients satisfactory operation

at low temperature driving forces (10-1 25°F), and
concentration of heat-sensitive and viscous chemical
products.
 Hold up time of liquid is less.
 No obstruction in the flow of liquids.
 Maintenance is easy.
Disadvantages

 These are the same as for rising-film types, except that, in addition, feed
distribution is a major problem.
 Not suitable for solid feeds and suspensions due to plug formation.
 Recirculation may be required at times.
 Not suitable for salting or scaling liquids.
Applications

 In the fertilizer industry, these evaporators are used to

concentrate urea, phosphoric acid ammonium nitrate, etc.
 They are also employed for processing food and dairy
products, and for desalting seawater.
 Concentrates the extracts of tea, coffee and yeast.
 Used in the manufacture of Gelatin.
 Used to separate volatile and non-volatile components from
low viscosity feed.
References

 https://www.c65.co.in/2021/11/principle-construction-working-and
-application-of-falling-film-evaporator.html
 https://www.youtube.com/watch?v=9lm2ubpOoL4
 https://www.vobisllc.com/types-of-evaporators#:~:text=Advanta
ges%3A%20Forced%2Dcirculation%20evaporators%20are,is%20
kept%20to%20a%20minimum