Vacuum System

PLANT ENGINEER OLEOCHEMICAL

Introduction
• Vacuum can be practically defined as a space in which the pressure of
gases is low compared atmospheric pressure
Figure 1. Working Pressure
Range for Vacuum Pumps
Vacuum Equipments
• Jet Ejector

• Vacuum Pumps

Figure 2. Steam Jet Ejector Figure 3. Liquid Ring Vacuum Pump

Vacuum Equipments
Vacuum Advantages Disadvantages
Equipment
1. Low investment costs 1. Control is more
compared to liquid ring complicated
vacuum pumps 2. Need a steam supply
2. No moving parts, therefore
in order to operate
maintenance costs can be kept
low
Steam Jet 3. Compact construction and
easy installation
Ejector 4. Corrosion / erosion
resistant as ejectors can be
constructed from various
materials so as to handle even
corrosive fluids.
5. High vacuum capability at
high suction loads.
Vacuum Equipments
Vacuum Advantages
Equipment
1. Easy maintenance
2. One moving part, no metal-to-
metal contact in the
compression chamber, no
internal lubrication required
3. Work stable and reliable,
Vacuum simple operation, easy
maintenance
Pump
Disadvantages
1. These pump may be
injured by fluid slug
2. The fluid within the
pump & the process gass
should be well-suited to
avoid pollutions
3. The pump suction
pressure can be limited
wiith the vapor of the
fluid within the pump
4. Due to the sealant fluid
vapor pressure, the
obtainable vacuum can
be limited at the
operating temperature
Vacuum Positive
Oil Sealed Rotary Vane Pump
Diaphragm Pump

Pumps Displacement Scroll Pump

Roots Pump
Liquid Ring Vacuum Pump
Claw Pump
Screw Pump

Turbomolecular Pump
Kinetic
Vapor Diffusion Pump

Cryopump
Entrapment
Sputter Ion Pump
Oil Sealed Rotary Vane Pump
(Wet, Positive Displacement)
• In the rotary vane pump, the gas
enters the inlet port and is trapped by
an eccentrically mounted rotor which
compresses the gas and transfers it to
the exhaust valve. The valve is spring
loaded and allows the gas to discharge
when atmospheric pressure is
exceeded. Oil is used to seal and cool
the vanes. The pressure achievable
with a rotary pump is determined by
the number of stages used and their
tolerances. A two-stage design can
provide a pressure of 1×10-3 mbar. It
has a pumping speed of 0.7 to 275
m3/h (0.4 to 162 ft3/min).
Liquid Ring Pump (Wet, Positive
Displacement)
• The liquid ring pump compresses the gas by
rotating a vaned impeller located eccentrically
within the pump housing. Liquid is fed into the
pump and, by centrifugal acceleration, forms a
moving cylindrical ring against the inside of the
casing. This liquid ring creates a series of seals in
the space between the impeller vanes, which form
compression chambers. The eccentricity between
the impeller’s axis of rotation and the pump
housing results in a cyclic variation of the volume
enclosed by the vanes and the ring, which
compresses the gas and discharges it through a
port in the end of the housing.. It can provide a
pressure of 30 mbar using 15°C (59° F) water, and
lower pressures are possible with other liquids. It
has a pumping speed range of 25 to 30,000 m 3/h
(15 to 17,700 ft3/min).
Diaphragm Pump (Dry, Positive
Displacement)
• A diaphragm is rapidly flexed by a rod
riding on a cam rotated by a motor,
causing gas transfer in one valve and
out the other. It is compact, and low
maintenance. The lifetime of the
diaphragms and valves is typically over
10,000 operating hours. The diaphragm
pump is used for backing small
compound turbo-molecular pumps in
clean, high vacuum applications. It is a
small capacity pump widely used in R &
D labs for sample preparation. A typical
ultimate pressure of 5 x 10 -8 mbar can
be achieved when using the diaphragm
pump to back a compound turbo-
molecular pump. It has a pumping
speed range of 0.6 to 10 m3/h (0.35 to 5.9
ft3/min).
Scroll Pump (Dry, Positive
Displacement)
• The scroll pump uses two scrolls that
do not rotate, but where the inner one
orbits and traps a volume of gas and
compresses it in an ever decreasing
volume; compressing it until it
reaches a minimum volume and
maximum pressure at the spirals’
center, where the outlet is located. A
spiral polymer (PTFE) tip seal
provides axial sealing between the
two scrolls without the use of a
lubricant in the swept gas stream. A
typical ultimate pressure of 1 x 10-2
mbar can be achieved. It has a
pumping speed range of 5.0 to 46
m3/h (3.0 to 27 ft3/min).
Roots Pump (Dry, Positive
Displacement)
• The Roots pump is primarily used as a
vacuum booster and is designed to remove
large volumes of gas. Two lobes mesh without
touching and counter-rotate to continuously
transfer the gas in one direction through the
pump. It boosts performance of a
primary/backing pump, increasing the
pumping speed by approximately 7:1 and
improves ultimate pressure by approximately
10:1. Roots pumps can have two or more
lobes. A typical ultimate pressure of < 10 -3
Torr can be achieved (in combination with
primary pumps). It can achieve pumping
speeds in the order of 100,000 m 3/h (58,860
ft3/min).
Claw Pump (Dry, Positive
Displacement)
• The claw pump features two counter-
rotating claws and operates similarly
to the Roots pump, except that the gas
is transferred axially, rather than top-
to-bottom. It is frequently used in
combination with a Roots pump, that
is a Roots-claw primary pump
combination in which there are a
series of Roots and claw stages on a
common shaft. It is designed for harsh
industrial environments and provides
a high flow rate. A typical ultimate
pressure of 1 x 10-3 mbar can be
achieved. It has a pumping speed
range of 100 to 800 m3/h (59 to 472
ft3/min).
Screw Pump (Dry, Positive
Displacement)
• The screw pump utilizes two rotating
screws, one left- handed and one right-
handed, that mesh without touching. The
rotation transfers the gas from one end to
the other. The screws are designed so the
space between them becomes reduced as
the gas passes along, and it becomes
compressed, causing a reduced pressure
at the entrance end. This pump features
a high throughput capacity, good liquid
handling, and tolerates dust and harsh
environments. A typical ultimate
pressure of approximately 1 x 10-2 Torr
can be achieved. It has a pumping speed
range of up to 750 m3/h (440 ft3/min).
Turbomolecular Pumps (Dry,
Kinetic Transfer)
• Turbomolecular pumps work by transferring
kinetic energy to gas molecules using high speed
rotating, angled blades that propel the gas at
high speeds: the blade tip speed is typically 250 -
300 m/s (670 miles/hr.) By transferring
momentum from the rotating blades to the gas,
they provide a greater probability of molecules
moving towards the outlet. They provide low
pressures and have low transfer rates. A typical
ultimate pressure of less than 7.5 x 10 -11 Torr
can be achieved. It has a pumping speed range of
50 – 5000 l/s. The bladed pumping stages are
often combined with drag stages that enable
turbomolecular pumps to exhaust to higher
pressures (> 1 Torr).
Vapor Diffusion Pumps (Wet,
Kinetic Transfer)
• Vapor diffusion pumps transfer
kinetic energy to gas molecules using
a high velocity heated oil stream that
“drags” the gas from the inlet to the
outlet, providing a reduced pressure
at the inlet. These pumps feature an
older technology, largely superseded
by dry turbomolecular pumps. They
have no moving parts and provide
high reliability at a low cost. A typical
ultimate pressure of less than 7.5 x
10-11 Torr can be achieved. It has a
pumping speed range of 10 – 50,000
l/s.
Cryopump (Dry, Entrapment)
• The Cryopump operates by capturing
and storing gases and vapors, rather
than transferring them through the
pump. They use cryogenic technology to
freeze or trap the gas to a very cold
surface (cryocondensation or
cryosorption) at 10°K to 20°K (minus
260°C). These pumps are very effective
but have limited gas storage capacity.
Collected gases/vapours must
periodically be removed from the pump
by heating the surface and pumping it
away through another vacuum pump
(known as regeneration). Cryopumps
require a refrigeration compressor to
cool the surfaces. These pumps can
achieve a pressure of 7.5 x 10 -10 Torr
and have a pumping speed range of
1200 to 4200 l/s.
Sputter Ion Pumps (Dry,
Entrapment)
• The sputter ion pump traps gases using
the principles of gettering (whereby
chemically active materials combine with
gases to remove them) and ionisation (gas
molecules are made electrically conductive
and captured). A high magnetic field
combined with a high voltage (4 to 7kV),
creates a cloud of electrons-positive ions
(plasma) which are deposited onto a
titanium cathode and sometimes a
secondary additional cathode composed of
tantalum. The cathode captures the gases,
resulting in a getter film. This
phenomenon is referred to as sputtering.
The cathode must be periodically replaced.
These pumps have no moving parts, are
low maintenance, and can achieve a
pressure as low as 7.5 x 10-12 Torr. They
have a maximum pumping of 1000 l/s.
Liquid Ring Vacuum Pump
• The two important things in liquid ring vacuum pumps are used to create
vacuum are Liquid Sealant and Impeller.

• The vacuum is created in the vacuum pump by using a liquid seal ,the most
commonly used liquid sealant is water.

• Before starting the vacuum pump, as a minimum volume of ¼ of the

cylinder is filled with liquid sealant.

• The impeller is located eccentric to the casing center line of the vacuum
pump. Also the impeller is placed between two port plates. The port plates
are act as suction and discharge valve of vacuum pump.
Liquid Ring Vacuum Pump
Liquid Ring Vacuum Pump
• The portion between the impeller vane and the liquid is called “impeller
cell”. Let us consider an impeller cell at the top of the vacuum pump and the
impeller rotates in the clockwise direction (Refer above figure). At the top of an
impeller, the cell is filled with seal liquid. Due to the impeller rotation, the liquid
recedes from the impeller center will create a vacuum in the impeller cell. Due
to this air or gas/ vapor is drawn from the vessel (the system to be maintained in
vacuum) through the Inlet port of Vacuum pump. The inlet ports are located at
the side of the impeller.
• The impeller cell passes the inlet port and travels toward the discharge port, the
sealant liquid is forced back toward the center hub of the impeller, thereby the
trapped gasses are compressed.
• When the impeller cell near to the discharge port, the compression is at its
highest, and the gases, along with some of the liquid sealant are exhausted
through the discharge port to atmosphere. Although the diagrams show a very
smooth ring of liquid, but in actual, the liquid sealant is highly turbulent. Due to
turbulent the liquid sealants are discharged along with gas. This cycle will
repeat again.
Types of Vacuum Pump System
• Once-Through System

• Partial Recirculation System

• Total Recirculation System

Once-Through
System
The sealing liquid enters into the
vacuum pump is discharge from the
pump and sends to a separator
vessel. In the separator vessel due
to density difference the gas and the
liquid are separated. Usually the
gases are vented to atmosphere and
the liquid is drained. In this system
no recirculation or recovery takes
place.
This is a common arrangement
where conservation or
contamination of the seal liquid is
not a concern.
Partial
Recirculation
System
In this system, the seal liquid
enters and leaves the vacuum
pump in the same manner as
the once-through system
arrangement. But in this
system, a circulation line is
used to connect the separator
tank and the vacuum pump.
Partial
Recirculation
System
An additional makeup seal
liquid is added in to the
system, in order to add an
equal quantity of the liquid
(plus any condensate) is
discharged from the separator
tank via an overflow
connection. This is to maintain
an constant working level of
seal liquid in the system.
Partial
Recirculation
System
Fresh makeup sealing liquid is
also used to maintain the
proper temperature of sealing
liquid. It is essential for better
pump performance and avoid
cavitation.
Partial
Recirculation
System
This type of system is used
where seal-liquid conservation
is important (up to 50%
reduction in sealing liquid
consumption is possible, and if
other than water is utilized,
the consumption can be
reduced more than 50%,
depending upon the fluid vapor
pressure and temperature).
Total
Recirculation
System
In this system the sealing
liquid is totally re-circulated
within the system. The heat
generated in the vacuum
system is removed by a heat
exchanger and the seal liquid
will be reintroduced into the
vacuum pump.
Total
Recirculation
System
In this system, the sealing liquid
level in the recirculation tank
should be at, or slightly below,
the centerline of the pump shaft.
Provisions may also be made for
high-level overflow and low-level
makeup on total recovery
systems. These level controls
help prevent the starting of the
pump with the casing full of
water since this could overload
the motor and damage the pump.
If the pressure drop across the
system is very high then a
circulation pump is included in
the system.
Advantage and Disadvantage of
Vacuum Pump System Types
Vacuum Pump System
Types
Once-Through System
Partial Recirculation System
Total Recirculation System
Advantage Disadvantage
• This system is a simple • Sealing Liquid
and low initial cost consumption is very high
• Used for less critical
service
• This system is a simple
and low initial cost when
compared with a total
recirculation system
• Consumption of sealing
liquid is low.
• This system is used for • Initial cost and maintains
high critical gas/ vapor of the system is used high.
services.
• Consumption of sealing
liquid is very minimum.
Liquid Ring Vacuum Pump-
Cavitation and Prevention Methods
• How Cavitation will happen Vacuum Pump?

In liquid ring vacuum pump the cavitation is occurs as a result of vaporization

of the seal liquid. It is due to the vacuum pump operate at the vapor pressure
region of seal liquid

If the vacuum pump run at the vapor pressure

region, bubbles will form in the seal liquid. As
the bubble move from low pressure region to
high pressure region, the bubble is imploded
and create a void space. This will cause the
seal liquid to rush and fill the void space. As
a result of this an abnormal noise and
extensive erosion or pitting of the vacuum
pump internals is produced. This phenomena
is called as cavitation.
Reason for Cavitation occurs in
Vacuum Pump
• The operating pressure is equivalent to (or below) the vapor pressure of the
sealing liquid

• Sudden fluctuation or change of pump operating point from high vacuum to

low vacuum.

• Sealing liquid temperature rise.

Methods to eliminate cavitation in
Vacuum Pump
• Seal liquid Cooler
By using seal liquid cooler, the temperature of seal liquid is maintain below it
boiling points. There by the flashing of seal liquid is prevented and maintain below
its vapor pressure region. Refer below figure for the cooler arrangement .

• Low Vapor Pressure Seal Liquids

Based on the operating pressure of Vacuum pump, the seal liquid shall be selected
must having low vapor pressure property. This will prevent the seal liquid from
flashing and causing cavitation. The seal liquid should be compatible with process
gas mixture and the materials of construction of vacuum pump.

• Inlet Operating Pressure

Increase the inlet operating pressure (if this pressure will be tolerated by the
process) of vacuum pump beyond the vapor pressure region of seal liquid then
cavitation will be prevented. Usually this method is ot preferred, because changing
the inlet operating pressure, the downstream of vacuum pump will get affected.
Methods to eliminate cavitation in
Vacuum Pump
• Loading of Vacuum Pump
If the loaded less than 50% percent of the design capacity, the pump may be
operating at a lower absolute pressure. This may lead to increase in seal liquid
temperature and cause cavitation. A vacuum relief valve or air bleed valve can be
used to introduce an additional load so the pump will be able to operate closer to
the design capacity (also design pressure)

• Suction Pressure Booster arrangement

Normally the suction pressure of vacuum pump is boosted by installing a booster
pump or ejector arrangement in the upstream of the liquid ring vacuum pump.
The booster will compress and raise the absolute pressure of the vacuum pump
suction.
Calculating Evacuation Time (1)
• Evacuation time is time needed to reach vacuum level.

• T= V/SF

Where,
T= Evacuation time
V= Volume
S = Pumping speed
F = Down factor taken from graph shown in Fig below
Calculating Evacuation Time (2)
Calculates the pump downtime T, to reach a vacuum
level of 0.1 mbar if the chamber volume is 150 cubic
feet and the existing vacuum pump speed is 150 cfm.

Answer:
T = V / S F becomes T = 150 / 150 x 11 and T = 11
minutes (approximately)
Power Consumption Calculation (1)
• Liquid Ring Pump
BkW= 21.4x(SF)0.924
Where,

SF is defined as the “Size Factor” and can be calculated

SF = m/P; kg/h/torr

P = Operating pressure of system evacuated, torr (mmHga)

m = Air equivalent flow rate, kg/h

“m” can be calculated

m = G*sqroot((273.15+T)*28.96/(293.15*MW))

G = flow rate of the process gas being evacuated, kg/h

T = Temperatur of the process gas being evacuated, °C

MW= molecular weight of the process gas being evacuated

Power Consumption Calculation (2)
• Example

Dryer with T top 80 dC, moisture to be avacuated is 200kg/h with P dryer is

800 mbar. Calculate the power consumption needed by vacuum pump.
Ejector
• An ejector is a device used to suck the gas or vapor from the desired vessel
or system
Working of Ejector
• The suction line of the ejector is connected to the vessel which is to the kept
under low pressure. With reference to the below figure, a high pressure
motivating fluid enters at “A” and expands through the converging-diverging
nozzle to “B“. The motive fluid will create a vacuum in the mixing chamber
refer the pressure curve where the pressure is decreased and velocity is
increased. Due to this suction fluid “C” (air or gas) from the connected vessel
is moved toward the mixing chamber “D“. When the suction fluid starts mix
with the motive fluid in the mixing chamber. The velocity of the fluid at the
mixing chamber is approximately 600 to 900 metres per second.

• Then the mixture travels through the diffuser “E“, its velocity energy is
converted into pressure energy. Thereby the mixture gained higher pressure
send to the atmosphere or some closed system. Normally the discharge
pressure will be 10 to 15 times of the suction pressure.
Working of
Ejector
Capacity of Ejectors
• The capacity of an ejector is determined by its dimensions. By the required
capacity is very high then two or three ejectors are working in parallel. if
greater compression is required, two or more ejectors will be arranged in
series.

• At zero load, the ejector will evacuate to shut-off pressures of approximate

values shown below for various number of stages:
Single stage unit ------- 50 mmHgA (may be unstable)
Two stage unit---------- 4 to 10 mmHgA
Three stage unit -------- 0.8 to 1.5 mmHgA
Four stage unit --------- 0.1 to 0.2 mmHgA
Five stage unit---------- 0.01 to 0.02 mmHgA
Six stage unit ----------- 0.001 to 0.003 mmHgA
Ejector Installation
• Ejectors may be installed at any orientation. However, it is very important
to provide a provision to remove the condensate or solid particles from the
entrained gases of the ejector. Since any condensed or solid particles may
reduce throughput capacity of the ejectors.

• Hence it very important to provide a drain valve installed at low points can
be either manual or automatic float operated valves.

• Another important thing to check during ejector installation is external

loads(Piping load) act on the ejectors. Since any misalignment will adversely
affect the performance of ejector.
Benefits of Ejector
• Ejectors can be operated with many different motive fluids: steam, air,
organic vapor and other gases.

• No moving parts, no lubrication, no vibration. Hence low maintenance cost

when to compare with other peer equipment.

• Ejectors can be installed indoors or outdoors without restriction.

• Can be installed at any orientation. Hence space requirement will be very

low.

• Initial cost is very less and no spares required.

• Easy to handle corrosive and slugging liquids.

 • Liquid Jet Ejector
Types of The motive fluid is a non-
Ejector compressible liquid
(generally water) with no
heat energy hence with a
single stage centrifugal
pump we can not increase
its pressure much.
• Motive Fluid As a result motive fluid
• Number of Nozzles velocity at the nozzle tip is
very less and it affects its
non-condensable load
handling capacity
drastically.
 • Steam Jet Ejector
Types of The motive fluid is a jet of
Ejector high pressure and low
velocity compressible
steam which exists from
the nozzle at the designed
suction pressure and super
sonic velocity thus
• Motive Fluid entraining the vapour in to
• Number of Nozzles the suction chamber.
Due to the super
sonic velocity of the steam
at the tip of the nozzle, its
non-condensable load
handling capacity is much
higher than liquid jet
ejectors.
 • Gas/Air Jet Ejector
Types of Gas or compressed air is
Ejector used as the motive
medium. This is
particularly suitable where
no steam is available or
where compressed air or
gas as motive medium offer
• Motive Fluid advantages over steam.
• Number of Nozzles
 Single Nozzle Ejector :
Types of • Its compact size is the main advantage of the single

Ejector nozzle ejector.

• It is generally used where very large compression

ratios are required.

• Motive Fluid

• Number of Nozzles
 Single Nozzle Ejector :
Types of • A multiple nozzle ejector has one nozzle on centre

Ejector while remaining of the nozzles equally spaced

peripherally around it

• Multi nozzle ejectors designed for the same

conditions usually reduce steam consumption by 10%
to 15% as compared to Single Nozzle Ejector.
• Motive Fluid • The advantage of multiple nozzle ejectors is its much
higher efficiency compared to single nozzle ejectors.
• Number of Nozzles
• It is also considerably shorter in length than an
equally rated single nozzle ejector.
Example
• It is desired to evacuate air at 2.94 lbf/in2 with a steam ejector discharging
to 14.7 lbf/in2 with available steam pressure of 100 lbf/in2. Determine the
ratio between air and steam
𝑃03 14.7
• = =5
𝑃0𝑏 2.94

𝑃0𝑏 2.94
•
𝑃0𝑎
= 100
= 0.0294
Example
• It is required to extract M 0 = 50 kg/h
of air at 20 °C from a suction pressure
of p0 = 200 mbar. A motive steam
pressure of p1 = 10 bar g is available.
𝐾𝑔 𝑠𝑡𝑒𝑎𝑚
• 𝜇=3 𝐾𝑔 𝑎𝑖𝑟

• 𝑀1 = 𝜇 . 𝑀0 = 3. 50 = 150 𝐾𝑔 𝑠𝑡𝑒𝑎𝑚/ℎ
Example
• It is required to extract M 0 = 50 kg/h
of air at 20 °C from a suction pressure
of p0 = 200 mbar. A motive steam
pressure of p1 = 10 bar g is available.
𝐾𝑔 𝑠𝑡𝑒𝑎𝑚
• 𝜇=3 𝐾𝑔 𝑎𝑖𝑟

• 𝑀1 = 𝜇 . 𝑀0 = 3. 50 = 150 𝐾𝑔 𝑠𝑡𝑒𝑎𝑚/ℎ
Example