Ice Condensation Vacuum Systems

Karl Tomas Eriksson

• German Technology meets ASAGA World Congress

on Oils and Fats and 31st Lecture series
• Rosario – Argentina - Oct. and Nov. 2015
 Traditional Multistage Ejector System with Cooling Tower

1 Booster (stage 1)
2 Booster (stage 2)
3 Main direct contact
condenser
4 Ejector (stage 3)
5 Inter condenser
6 Ejector (stage 4)
7 Seal tank
8 Cooling water pump I
9 Cooling tower
10 Cooling water pump II

Low cost system

but polluted cooling water
Maintenance free
11 Motive steam
(no risk of pollution in
12 Fresh water (cooling
the condensers) tower) 13 Bleed (cooling
Cooling tower must be tower)
cleaned time to time 14 Overflow of fatty water
15 Draining
Air pollution 16 Gas outlet
17 Stripping steam
from deodorizer

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 Alkaline Vacuum System (Chilled Water)
1 Booster (stage 1)
2 Main direct contact condenser
Low energy consumption 3 Ejector (stage 2)
4 Inter condenser
Low amount of waste water 5 Liquid ring vacuum pump
6 Fat separator (buffer tank)
7 Circulation pump
No air pollution 8 pH-control unit
9A Plate heat exchanger (in operation)
Save operation 9B Plate heat exchanger (stand by)
10 Brine pump
11 Compensation vessel
12 Coolant compressor (chiller)
13 Cooling tower pump
14 Cooling tower
15 Motive steam
16 Heating steam
17 Stripping steam
from deodorizer
18 Condensate
19 Circulation water
20 Chilled water
21 Total over flow
22 Caustic soda (NaOH)
23 Gas outlet
24 Fresh water (cooling tower)
25 Bleed (cooling tower)

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 Ice Condensations Vacuum System
Most efficient system for large capacities

Lowest energy consumption

Minimum amount of waste

1 Ice condenser I
2 Ice condenser II
3 Melting vessel
4 Condensate pump
5 Ejector stage1
6 Ejector stage 2
7 Air evacuation condenser
8 Liquid ring vacuum pump
9 Gas separator (Liquid ring vacuum pump)
10 Re-cooler (Liquid ring vacuum pump)
11 Refrigerant compressor
12 Expansion valve
13 Priority vessel
14 Refrigerant separator
15 Evaporative condenser
16 Cooling water
17 Motive steam
18 Stripping steam from deodorizer
19 Gas outlet (Liquid ring vacuum pump)
20 Over flow (liquid ring vacuum pump)
21 Overflow (melting vessel)
22 Heating steam
23 Condensate
24 Fresh water (soft water)
25 Bleed (evaporative condenser)
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 Operation Cycle and step sequence of the Ice Condensation
System
Ice Condenser I Ice Condenser I
on melting on pre-cooling
Ice Condenser II Ice Condenser II
on loading on loading

SWITCH OVER Ice Condenser I

on loading
Ice Condenser I Ice Condenser II
on loading on melting
Ice Condenser II
on loading

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 Example of Installation of an ICE Condensation Vacuum System

Ammonia
Separator

Air
Evacuation
Unit ICE Condenser Block

Liquid ring
Vacuum Unit Melting
Vessel

Refrigerant
Compressor

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 Main Advantages of an Ice Condensation Vacuum System

significant energy saving by

high efficiency

far less waste water will be produced

nearly no air pollution will

be produced

minimum space requirement

(skid mounted units)
R e frgi e ran t
S epa ra ot r
non barometric installation

newest technology with

Ice C onden se r
computer controlled operation

experience by various installation

world wide since 1988

S et am Je tE ej c ot r
V a cuum G roup P ro ce ss V e sse l

qi u di R ni g C onden sa et
V a cuum P um p M e ltni g V e sse l P um p

R e frgi e ran t
R e frgi e ran t C onden se r
C om p re sso r

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 ICE Condenser Vertical vs. Horizontal installation

Rising film Rising film

Falling film Rising film

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 Typical design of a Körting ICE Condenser
CROSS FLOW

Melting
Air Melting steam
evacuation steam

NH3 out

Process
NH3 in Process flow
flow

Condensate

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 Controlled and Uncontrolled Ice Building
View into a Körting ICE Condenser during loading

Controlled, constant and smooth ice

building due to the right condition,
cycle time and operation

View into an Condenser from our competitor during loading

Uncontrolled and
heavy ice building
due to over loading-

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 Ice Building – Loading Cycle Time
Chilling
Chilling capacity should be design capacity
Ice Condenser
for loading and peak conditions.
100 %
==> Avoid Vacuum fluctuation !
85 %
Safety margin
Insolalation losses
65 %

Koertig design for 60 minutes loading cycles Loading

(3.5 mm ice layer)
5 30 60
time (minutes)

Longer loading times (> 2 hours)

is not an advantage!
==> Pressure drop and electrical power
will dramatically increase !

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 Driving Forces for Koerting developing Ice Condensation vacuum
systems
Highest possible plant
availability and reliability
• 02 high quality valves at each suction
steam condenser inlet;
• 02 condenser inlets – Process and
Heating Steam;
• Horizontal condensers
• Natural flow, without pumps –
ammonia and heating steam cycles;
• Surface Area – 2 x 100%
• Condenser pipes;
– Configuration;
– Fixation (no welding on process side)
• Position of Air Evacuation Outlet
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Minimum Energy / Utilities
Consumption
• Optimal Heat Transfer - Ice Layer
and Cycle Time
• Lowest possible Pressure Drop;
– 02 Process and Heating Steam
Inlets;
– Cross Flow Condensers
– Natural flow - ammonia and
heating steam cycles;
• Optimal Melting - Fast and energy
efficient without necessity for
additional pumps
• Optimal Motive Steam
Consumption Less Cooling
Water  Less Waste Water
• Low electrical energy consumption
 Low pressure drop / thinner ice
layer / shorter cycles
12
 Comparison of the Various Systems

ICE ALKALINE
CONDENSATION CHILLED
WATER

Comparison of the Various Systems

∑ Motive Steam consumption = 235 kg/h ∑ Motive Steam consumption = 678 kg/h

(approximate daily production 600 t)

∑ Cooling Water consumption =
∑ Electrical Power consumption = 165 kW
42 m³/h ∑ Cooling Water consumption =
∑ Electrical Power consumption =
185 m³/h
210 kW
Design Data:= 0,489
250 kg/ stripping steam + 10 kg/ air + 4 kg/ FFA, 80°C
∑ Waste Water consumption m³/h h ∑ Waste Water
h consumption h= 0,935 m³/h

ALKALINE
1,5 mbar at inlet to the vacuum system; SURFACE
NORMAL WATER motive steam pressure 10 bar abs / saturatedCONDEN-
SATION
cooling water inlet temperature 30 °C;
wet bulb temperature 21 °C

∑ Motive Steam consumption = 2597 kg/h ∑ Motive Steam consumption = 3000 kg/h
∑ Cooling Water consumption = 425 m³/h ∑ Cooling Water consumption = 450 m³/h
∑ Electrical Power consumption = 40 kW ∑ Electrical Power consumption = 13 kW
∑ Waste Water consumption = 2,854 m³/h ∑ Waste Water consumption = 3,257 m³/h

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 Comparison of the Various Systems

ICE ALKALINE
CONDENSATION CHILLED
WATER

∑ Motive Steam consumption = 235 kg/h ∑ Motive Steam consumption = 678 kg/h
∑ Cooling Water consumption = 42 m³/h ∑ Cooling Water consumption = 185 m³/h
∑ Electrical Power consumption = 165 kW ∑ Electrical Power consumption = 210 kW
∑ Waste Water consumption = 0,489 m³/h ∑ Waste Water consumption = 0,935 m³/h

SURFACE
ALKALINE
CONDEN-
NORMAL WATER
SATION

∑ Motive Steam consumption = 2597 kg/h ∑ Motive Steam consumption = 3000 kg/h
∑ Cooling Water consumption = 425 m³/h ∑ Cooling Water consumption = 450 m³/h
∑ Electrical Power consumption = 40 kW ∑ Electrical Power consumption = 13 kW
∑ Waste Water consumption = 2,854 m³/h ∑ Waste Water consumption = 3,257 m³/h

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 Comparison of the Various Systems
Design Data : 250 kg/h stripping steam + 10 kg/h air + 4 kg/h FFA, 80 °C
1,5 mbar at inlet to the vacuum system
motive steam pressure 10 bar abs / saturated
cooling water inlet temperature 30 °C
wet bulb temperature 21 °C

Cost Comparison for 8.250 operation hours / year

ICE ACL (cold) ACL (warm) Surface

condensation

Steam costs (US $/t) / year 25 51.975 138.600 535.631 618.750

Re-cooling costs for the cooling water (Cent/m³) / year 10 33.000 174.900 350.625 378.675

Electrical power cost (Cent/kW) / year 10 134.475 181.500 33.000 8.250

Effluent costs (US $/m³) / year 4 16.698 30.657 94.182 107.481

Caustic soda costs 25% (Cent/kg) / year 8 0 1.980 1.980 1.980

Operation costs / year ( in US $ ) 236.148 527.637 1.015.418 1.115.136

Difference / year ( in US $ ) 878.988 587.499 99.718

Equipment price ( in US $ ) 1.000.000 410.000 360.000 325.000

Difference / year ( in US $ ) 675.000 85.000 35.000

Saving after 1 year 203.988 502.499 64.718

Saving after 2 years 1.082.976 1.089.998 164.436

Saving after 3 years 1.961.964 1.677.497 264.154

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Koerting do Brasil
Ejetores e Equipamentos de Vácuo Ltda.
Rua Adib Auada 35
Bloco B - Sala 110
06710-700 Cotia – SP

Tel.: +55 11 4321-2745

info@koerting.com.br

www.koerting.de