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GEA Evaporation Technology
GEA Evaporation Technology
GmbH
GEA Evaporation Technologies
Evaporation
Technology
Evaporation Technology
Evaporation plants are used as a thermal separation technology, for the concentration or separation of liquid solutions,
preserved.
Certain pilot plants are available as mobile units and can therefore be installed at a customers site. Data is captured and
puter programs.
Contents
Research and Development
Evaporator Types
19
19
11
22
14
15
23
Caustic solutions
Organic acids
rence lists.
Inorganic acids
Saline solutions
Amines
Alcohol
Organic products
Pharmaceutical
solutions
Suspensions
Waste water
Protein solution
Fruit juices
Vegetable juices
Starch products
Sugar
Extracts
Hydrolisate
Beer
Emulsions
Miscella
Extracts
Tanning extract
Stillage
Steep water
Stick water
Blood
Evaporator Types
FALLING FILM EVAPORATORS
Product
Design
Vertical shell-and-tube heat exchanger, with laterally or concentrically arranged centrifugal separator.
Operation
The liquid to be concentrated is supplied to the top of the heating
Head
Heating
steam
Calandria
Vapour
Separator
Condensate
Separator duct
Calandria base
Concentrate
Particular features
Best product quality due to gentle evaporation, mostly
under vacuum, and extremely short residence times in the
evaporator.
High energy efficiency due to multiple-effect arrangement
or heating by thermal or mechanical vapour recompressor,
based upon the lowest theoretical temperature difference.
Simple process control and automation due to their small
liquid content falling film evaporators react quickly to changes
in energy supply, vacuum, feed quantities, concentrations,
etc. This is an important prerequisite for a uniform final concentrate.
Flexible operation quick start-up and easy switchover
from operation to cleaning, uncomplicated changes of product.
Fields of application
Capacity ranges of up to 150 t/hr, relatively small floor space
requirement.
Particularly suited for temperature-sensitive products.
For liquids which contain small quantities of solids and have
Heating steam
1 Falling film evaporator
2 Preheater
3 Condenser
CD
F
E
Cooling water
Deaeration
Product
CC
B
Vapour condensate
Concentrate
Evaporator Types
FORCED CIRCULATION EVAPORATORS
Design
Horizontal or vertical shell-and-tube heat exchanger or plate
heat exchanger as the calandria, with flash vessel/separator
Vapour
Flash vessel/separator
Calandria
Heating steam
Concentrate
Condensate
Product
Operation
The liquid is circulated through the calandria by means of a
circulation pump, where it is superheated at an elevated pressure, higher than its normal boiling pressure. Upon entering
the separator, the pressure in the liquid is rapidly reduced
resulting in some of the liquid being flashed, or rapidly boiled
off. Since liquid circulation is maintained, the flow velocity in
the tubes and the liquid temperature can be controlled to suit
the product requirements independently of the pre-selected
temperature difference.
Particular features
Long operating periods boiling/evaporation does not take
place on the heating surfaces, but in the separator. Fouling due
to incrustation and precipitation in the calandria is therefore
minimised.
Optimised heat exchange surface flow velocity in the tubes
determined by the circulation pump.
Fields of application
Liquids with a high tendency for fouling, highly viscous
liquids, as the high concentration step in multiple-effect eva-
poration plants.
Forced circulation evaporators are optimally suited as
crystallising evaporators for saline solutions.
1a
1b
1c
2
3
Heating steam
F
1b
1a
1c
CC
CD
CD
CD
B
A
Cooling water
Deaeration
Vapour condensate
Heat. steam cond.
Concentrate
Product
Evaporator Types
PLATE EVAPORATORS
Design
Plate heat exchanger, separator.
A plate-and-frame configuration employs special plates, with
alternate product and heating channels. The plates are sealed
by gaskets located within specially designed slots that do not
require adhesives. These gaskets can be inserted and removed
without special tools.
Vapour
Main separator
Pre-separator
Plate calandria
Heating steam
Concentrate
Concentrate
Condensate
Product
Operation
Particular features
the system can be heated with both hot water as well as with
steam.
the vapour duct of the plate package. Residual liquid and va-
The wide inlet duct and the upward movement ensure op-
changer.
Fields of application
For low to medium evaporation rates.
For liquids containing only small amounts of undissolved
solids and with no tendency to fouling.
For temperature-sensitive products, for highly viscous
products or extreme evaporation conditions, a product circulation design is chosen.
Heating steam
2
1
1 Plate calandria
2 Separator
3 Condenser
Cooling water
CC
CD
B
A
Deaeration
Vapour condensate
Heating steam condensate
Concentrate
Product
Evaporator Types
CIRCULATION EVAPORATORS
Particular features
Design
Fields of application
For the evaporation of products insensitive to high temperatures, where large evaporation ratios are required.
For products which have a high tendency to foul and for
Operation
heating of the tubes the liquid film on the inside walls of the
tubes starts to boil releasing vapour. The liquid is carried to the
top of the tubes as a result of the upward movement of the
vapours.
The liquid is separated from the vapours in the downstream
separator and flows through a circulation pipe back into the
evaporator, ensuring stable and uniform circulation. The larger
the temperature difference between the heating chamber and
the boiling chamber, the greater the intensity of evaporation
and, consequently, the liquid circulation and heat transfer
rates.
Where the boiling chamber of the circulation evaporator is
divided into several separate chambers, each one equipped
with its own liquid circulation system, the heating surface
required for high final concentrations can be considerably
reduced compared to an undivided system.
The final concentration is only reached in the last chamber. In
other chambers, the heat transfer is considerably higher due to
the lower viscosities and boiling point elevations.
1 Calandria
2 Separator
3 Condenser
2
Heating steam
D
1
CD
Product
Vapour condensate
Concentrate
10
Deaeration
Cooling water
Heating steam condensate
CC
B
Design
Vertical fluidised bed heat exchanger (on
Design
pump.
of the unit.
Operation
Operation
the inside walls. The external heating of the tubes causes the
Particular features
Particularly gentle product treatment due to very low
Particular features
Fields of application
pressure loss.
Fields of application
1 Fluidised bed calandria
2 Separator
3 Condenser
D
E
CD
Heating steam
Deaeration
Heating steam
condensate
Cooling water
Concentrate
CC
A
Vapour condensate
Product
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COUNTERFLOW-TRICKLE
EVAPORATORS
Design
Vertical shell-and-tube heat exchanger
Design
Operation
The liquid to be concentrated is supplied to the bottom and
rises to the top in accordance with to the mammoth pump
principle, or rising film principle.
Due to external heating, the liquid film starts to boil on the inside walls of the tubes and is partially evaporated during this
process. As a result of the upward movement of the steam
bubbles, the liquid is transferred to the top. During the ascent
more and more vapours form. The film starts to move along
the wall, i.e. the liquid rises. The vapours and liquid are then
separated in the top-mounted separator.
Particular features
High temperature difference between heating chamber
and boiling chamber in order to ensure a sufficient liquid
Operation
are also suited for products of high viscosity and those with
Particular features
Fields of application
For large evaporation ratios, for high viscosities and products having a tendency to foul.
Can be used as a high concentrator in single pass operation
Partial distillation amounts of volatile constituents contained in the product to be concentrated can be stripped. This
process can be enhanced by the supply of an entraining stream,
such as steam or inert gas, to the lower part of the calandria.
Fields of application
This type of evaporator, designed for special cases, is used to
enhance the mass transfer between liquid and vapour. If a gas
stream is passed in counterflow to the liquid, chemical reactions can be triggered.
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STIRRER EVAPORATORS
Design
Design
with stirrer.
Operation
The liquid to be evaporated flows as a boiling film from the
top to the bottom in parallel flow to the vapour. The expanding
vapours produce a shear, or pushing effect on the liquid film.
The curvature of the path of flow induces a secondary flow,
which interferes with the movement along the tube axis. This
additional turbulence considerably improves the heat transfer,
especially in the case of high viscosities.
Particular features
Small apparatus dimensions due to the spiral shape,
longer tube lengths and consequently larger heating surfaces
relative to the overall height of the unit can be obtained.
Large evaporation ratios due to large temperature differences and single pass operation.
Operation
The liquid is supplied to the vessel in batches, is caused to boil
while being continuously stirred and is evaporated to the re-
Fields of application
For high concentrations and viscosities, e.g. for the concentration of gelatine.
Particular features
Low evaporation rate due to small heat exchange surface.
For this reason, large temperature differences between the
heating jacket and the boiling chamber are required. The product properties permitting, the heating surface can be enlarged
by means of additional immersion heating coils.
Fields of application
For highly viscous, pasty or pulpy products, whose properties are not negatively influenced by a residence time of several
hours, or if particular product properties are required by long
residence times.
It can also be used as a high concentrator downstream from
a continuously operating pre-evaporator.
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A=B+C
cA
C=AB
Vapour flow C [kg/hr]: Evaporated water,
solvent
Initial concentration cA
of the product flow A kg/hr
B
cB
e = A
B
cB
cA
Final concentration cB
of concentrate flow B kg/hr
the solution. The lower the initial concentration cA, the steeper the
Given
Quantity A to be
Required
Formula
C = A
e1
e
B = A
1
e
evaporated
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Multiple-effect evaporation
Multiple-effect evaporation
Vapour
1-effect-plant
1 kg/h
1 kg/h
100 %
3-effect-plant
1 kg/h
3 kg/h
33 %
5-effect falling film evaporation plant for apple juice concentrate, directly
heated, with aroma recovery. Evaporation rate: 12,000 kg/hr
Decrease of the specific steam consumption in % and increase of the approximate total heating surface F in relation to the number of effects
15
Heating steam
1, 2
3, 4
5
6, 7
8
9
10
11
7
1
Cooling water
Deaeration
E
10
9
11
CC
CC
A
B
16
Service water
Vapour condensate
Product
Concentrate
1-effect falling film evaporation plant heated by mechanical vapour recompression for wheat starch effluent. Evaporation rate: 17,000 kg/hr
Heating steam
1
2
3
4
5
6
7
1
6
Cooling water
Product
Deaeration
A
E
7
G
CC
B
CC
Service water
Vapour condensate
Concentrate
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Directly heated
C
C
CD
CC
CC
2-effect design
D
C
CD
CC
A
B
C
CC
CD
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Product
Concentrate
Condensate
Vapour condensate
Heating steam
condensate
D Heating steam
E Electrical energy
platforms.
quired.
The most important of these are condensers, preheaters,
pumps, fittings, vents, vacuum systems and cleaning systems.
To guarantee trouble-free operation of the plant, state-of-theart measuring, control and computer monitoring systems are
used.
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Cleaning systems
this duty.
the evaporation plant is equipped with the necessary components, cleaning agent tanks, additional pumps and fittings.
Evaporators
perties.
Separators
Vapour scrubbers
with live steam but with discharge stream such as dryer ex-
Condensers
Where possible, the heat content of the vapours produced
the heating medium. The residual vapours from the last effect
system.
Deaeration/vacuum systems
Materials
Pumps
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4b
3a
2a
1a
3b
2b
5
1b
4a
8
8
4c
8
8
7
1a, b
2a, b
3a, b
4a, b, c
5
6
7
8
Surface condenser
Vapour scrubber
Vacuum pump
Product and condensate pumps
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1. Manual control
The plant is operated by means of manually operated valves.
Concentrate samples must be checked at certain intervals. This
type of control is suitable for simple plants and for products
where slight variations in quality are acceptable.
parameters are entered into the fields shown on a graphic display. The plant is self-monitored and is automatically switched
lers, motors and valves are manually operated from the PC.
ble. All key measured values are recorded and displayed on the
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assigned to this task, who are also available to train the custo-
transport.
mers personnel.
their size.
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Distillation/rectification plants
rectification etc.
from the treatment of raw material, fermentation and distillation to stillage concentration and drying of spent products.
Membrane filtration
GEA Wiegand GmbH Einsteinstrasse 915 D-76275 Ettlingen Germany Phone: +49 (0) 72 43/7 05-0
Fax: +49 (0) 72 43/7 05-3 30 E-Mail: info@gea-wiegand.de Internet: www.gea-wiegand.com