Chapter 5

Single Batch Evaporators

Numerical Problems

1
Single Effect Evaporator
1) A given solution boils at a temperature of 380 K (107o C) and boiling point
of water at a pressure in the vapor space is 373 K (100o C). Temperature of
condensing steam is 399 K (126o C).C) What is the boiling point elevation of the
solution and driving force for heat transfer?
Solution:
B ili point
Boiling i off solution
l i = T = 380 K
Boiling point of water = T’ = 373 K
Boiling point of elevation = T – T’ = 380 – 373 K = 7 K (or oC)

Saturation temperature of condensing steam = Ts = 399 K q=uadt

Driving force for heat transfer = Ts – T = 399 – 380 = 19 K

Note:
Whenever pressure at which the steam is available and pressure prevailing in the
vapor space of the evaporator are given, then steam table should be referred to
find out temperature of steam, latent heat of condensation of steam based on
steam pressure and latent heat of evaporation of water i.e. latent heat of vapor
based on pressure prevailing in the vapor space of the evaporator. 2
Single Effect Evaporator
2) An evaporator operating at atmospheric pressure (101.325 kPa) is fed at the
rate of 10000 kg/h of weak liquor containing 4% caustic soda. Thick liquor
leaving the evaporator contains 25% caustic soda.
soda Find the capacity of the
evaporator.

Solution:
Basis: 10000 kg/h of weak liquor entering the evaporator.
Let m’ be the kg/h of thick liquor leaving the evaporator.
Material balance of caustic soda:
Caustic soda in feed = Caustic soda in thick liquor
0.04*10000 = 0.25*m’
m' = 1600 kg/h.
g

Overall material balance:

kg/h of feed = kg/h water evaporated + kg/h of thick liquor
10000 = kg/h water evaporated + 1600
Water evaporated = 10000 – 1600 = 8400 kg/h
Capacity of evaporator = 8400 kg/h
3
Single Effect Evaporator
3) An evaporator is operating at atmospheric pressure. It is desired to concentrate
the feed from 5% solute to 20% solute (by weight) at a feed rate of 5000 kg/h.
Dry saturated steam at a pressure corresponding to saturation temperature of 399
K (126o C) is used. The feed is at 298 K (25o C) and boiling point rise (elevation)
i.e. B.P.E. (B.P.R) is 5 K. Overall heat transfer coefficient is 2350 W/(m2K).
Calculate economy of evaporator and area of heat transfer to be provided.
Data:
Latent heat of condensation of steam at 399 K = 2185 kJ/kg.

Treating solution as pure water and neglecting B.P.R., Latent heat of vaporization
of water at 101.325 kPa and 373 K = 2257 kJ/kg

Specific heat of feed = 4.187 kJ/ (kg K)

Solution:
B i 5000 kg/h
Basis: k /h off feed
f d to evaporator.
Let mf, m’ and mv be the kg/h of feed, thick liquor and water vapor / water
evaporated. 4
Single Effect Evaporator
Material balance of solute:
Solute in feed = Solute in thick liquor
0.05*5000 = 0.20 * m’
m' = 1250 kg/h

Overall material balance:

kg/h of feed = kg/h water evaporated + kg/h of thick liquor
Water evaporated = mv = 5000 – 1250 = 3750 kg/h

Enthalpy balance:
Let ms be kg/h of steam required (Steam consumption)
λS = latent heat of condensation of steam at 399 K = 2185 kJ/kg
λV = λ = latent heat of vaporization of water at 373 K = 2257 kJ/kg
p
T = temperature of thick liquor
q
= T’ + B.P.E = 373 + 5 = 378 K

5
Single Effect Evaporator
(λV is taken as equal to λ for calculation purpose, effect of B.P.E is eliminated)
Tf = temperature of feed = 298 K
mf = 5000 kg/h
CPf = 4.187 kJ/ (kg.K)

Heat balance over evaporator:

Heat lost by condensing steam (latent heat) = Heat gained by solution to increase
its temperature
p to boilingg ppoint + Heat required
q to vaporize
p /evaporate
p water
ms λs = mf Cpf ( T – Tf) + mv λ
ms * 2185 =5000 * 4.187(378 – 298) + 3750*2257
ms = 4640.1 kg/h
Steam consumption = 4640.1 kg/h

Economy
y of evaporator
p = kg/h
g water evaporated
p / kg/h
g steam consumed
= 3750 / 4640.1 = 0.808

6
Single Effect Evaporator
Ts = saturation temperature of steam = 399 K

Temperature driving force = ∆T = Ts – T = 399 – 378 = 21 K (21 o C)

U = 2350 W/(m2K)
Rate of heat transfer = Q = ms λs = 4640.1*2185 = 10138619 kJ/hr
= 10138619 * 1000 / 3600
= 2816283 J/s = 2816283 W

Q = UA ∆T
A = Q / U ∆T = 2816283 / (2350 * 21) = 57.07 m2
Heat transfer area to be provided = 57.07 m2

7
 EVAPORATOR WORKING AT A TEMP MEANNS BP OF SOLN IF
BPE =0
Single Effect Evaporator
4) A solution containing 10% solids is to be concentrated to a level of 50% solids.
Steam is available at a pressure of 0.20 MPa [saturation temperature of 393 K
(120o C)].
C)] Feed rate to the evaporator is 30000 kg/h.
kg/h The evaporator is working at
reduced pressure such that boiling point is 323 K (50o C). The overall heat
transfer coefficient is 2.9 kW/ (m2K). Estimate steam economy and heat transfer
surface area for:
Feed introduced at 293 K (20o C)
Feed introduced at 308 K (35o C)

Data:
Specific heat of feed = 3.98 kJ/(kg K)

Latent heat of condensation of steam at 0.20 MPa = 2202 kJ/kg

Latent heat of vaporization of water at 323 K

(i.e. at pressure in the vapor space) = 2383 kJ/kg.

8
Single Effect Evaporator
Solution: Basis: 30000 kg/h of feed to the evaporator.
Let mf, m’ and mv be the mass flow rate of feed, thick liquor and water vapor
respectively.
ti l

Material balance of solids:

Solids in feed = Solids in thick liquor
0.10*30000 = 0.5 m’
m' = 6000 kg/h
g

Overall material balance:

F d = water
Feed t evaporator
t + thick
thi k liquor
li
Water evaporated = mv = 30000 – 6000 = 24000 kg/h

9
Single Effect Evaporator
Feed at 293 K (Tf):
ms = mass flow rate of steam in kg/h
mf = 30000 kg/h, mv = 24000 kg/h
CPf = 3.98 kJ/ (kgK)
Ts = saturation temperature of steam = 393 K
T = boiling point of solution = 323 K
λs = latent heat of condensation of steam at 0.20 MPa = 2202 kJ/kg
λ = latent heat of vaporization of water at 323 K = 2383 kJ/kg

Enthalpy balance over evaporator assuming no heat loss:

Q = ms λs = mf CPf (T – Tf) + mv λ
ms * 2202 = 30000 * 3.98 * (323 – 293) + 24000 * 2383
ms = 27599.5 kg/h
Steam consumption = 27599.5 kg/h

Steam economy = water evaporated /steam consumed = 24000 / 27599.5 = 0.87

10
Single Effect Evaporator
∆T = Ts – T = 393 – 323 = 70 K
U = 2.9 kW/(m2K) = 2900 W/(m2K)
Heat load = Rate of heat transfer = Q = msλs = 27599.5*2202 = 60774099 kJ/h
= 60774099 * 1000 / 3600
= 16881694 J/s
= 16881694 W

Q = U A ∆T
A = Q / U ∆T = 16881694 / (2900*70) = 83.16 m2

Heat transfer area required = 83.16 m2

11
Single Effect Evaporator
Feed at 308 K:
Heat balance gives
ms * 2202 = 30000 * 3.98 * (323 – 308) + 24000 * 2383
ms = 26786 kg/h
Steam consumption = 26786 kg/h

Economy of evaporator =24000/26786 = 0.896

Heat load = Rate of heat transfer = Q = ms λs = 267866 * 2202 = 58982772 kJ/h

= 58982772 *1000 / 3600 = 16384103 J/s
= 16384103 W

Q = UA ∆T
80 71 m2
A = Q / U ∆T = 16384103 / (2900*70) = 80.71
Heat transfer area required = 80.71 m2
12
Single Effect Evaporator
5) A single effect evaporator is fed with 5000 kg/h of solution containing 1%
solute by weight. Feed temperature is 303 K (30o C) and is to be concentrated to a
solution of 2% solute by weight.
weight The evaporation is at atmospheric pressure
(101.325 kPa) and area of evaporator is 69 m2. Saturated steam is supplied at
143.3 kPa as a heating medium. Calculate steam economy and overall heat
transfer coefficient.

Data:
Enthalpy of feed at 303 K = 125.79 kJ/kg
Enthalpy of vapor at 101.325 kPa = 2676.1kJ/kg
Enthalpy of saturated steam at 143.3 kPa = 2691.5 kJ/kg
Saturation temperature of steam = 383 K (110o C)
B ili point
Boiling i t off saturation
t ti = 373 K
Enthalpy of product = 419.04 kJ/kg
Enthalpy of saturated water at 383 K = 461.30 kJ/kg

13
Single Effect Evaporator
Solution: Basis: 5000 kg/h of feed to evaporator.
Let m’, mv be the flow rate of product and water vapor.

Material balance of solute:

0.01 * 5000 = 0.02 * m’
m' = 2500 kg/

Overall material balance:

Feed = Water evaporated + Thick liquor
Water evaporated = 5000 – 2500 = 2500 kg/h

Energy Balance:
Assuming no heat loss, the heat balance is:
mf Hf + msλs = m’ H’+ mv Hv

14
Single Effect Evaporator
Energy Balance:
Assuming no heat loss, the heat balance is:
mf Hf + msλs = m’ H’+ mv Hv

Hf = 125.79 kJ/kg; H’ = 419.04 kJ/kg,; Hv = 2676.1 kJ/kg;

λs = latent heat of condensing steam = enthalpy of saturated steam – enthalpy of
saturated water = 2691.5 – 461.30 = 2230.2 kJ/kg

5000 * 125.79 + ms (2230.2) = 2500 * 419.04 + 2500 * 2676.1

ms = 3187.56 kg/h

Steam consumption = steam flow rate = 3187.56 kg/h

Steam economy = 2500 / 3187.56 = 0.784

15
Single Effect Evaporator
Rate of heat transfer = ms λs = 3187.56 * 2230.2 = 71088963 kJ/h
= 71088963 *1000 / 3600 = 1974693.4 J/s (i.e. W)

∆T = Ts – T = 383 – 373 = 10 K
Q = U A ∆T
U = Q / A ∆T = 1974693.4 / (69*10) = 2862 W / (m2K)
Overall heat transfer coefficient = 2862 W / (m2K)

16
Single Effect Evaporator
6) If the evaporator pressure is reduced to 38.58 kPa, what would be the change
in heat transfer area? Use the same steam pressure and overall heat transfer
coefficient as in Problem 5.
5

Data:
Boiling point of water / solution at 38.58
38 58 kPa = 348 K
Enthalpy of water vapor = 2635.3 kJ/kg
Enthalpy of product = 313.93 kJ/kg

Solution:
Heat balance is
mf Hf + msλs = m
m’ H
H’+ mv Hv
5000 * 125.79 + ms * 2230.2 = 2500 * 313.93 + 2500 * 2635.3
ms = 2320.18 kg/h
Q = ms λs = 2320.8 * 2230.2 = 5174465.4 kJ/h
= 5174465.4 * 1000 / 3600
= 1437351.5 J/s = 1437351.5 W
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Single Effect Evaporator
Q = U A ∆T
Where, U = 2862 W/ (m2K)
∆T = 383 – 348 = 35 K
A = Q / U ∆T = 1437351.5 / (2862*35) = 14.35 m2

Heat transfer area in this case is 14.35 m2.

Heat transfer area decreases from 69 m2 to 14.35 m2. In this case a condenser
and vacuum pump should be used

18
Single Effect Evaporator
7) A single effect evaporator is to concentrate 20000 kg/h of a solution having a
concentration of 5% salt to a concentration of 20% salt by weight. Steam is fed
to the evaporator at a pressure corresponding to the saturation temperature of
399 K (126o C). The evaporator is operating at atmospheric pressure and boiling
point rise is 7 K. Calculate the heat load and steam economy.

Data:
Feed temperature = 298 K (25o C)
Specific heat of feed = 4.0
4 0 kJ/kg K
Latent heat of condensation of steam at 399 K = 2185 kJ/kg
Latent heat of vaporization of water at 373 K = 2257 kJ/kg

19
Single Effect Evaporator
Solution: Basis: 20000 kg/h of solution to the evaporator.
Evaporator is operating at atmospheric pressure i.e. at 101.325 kPa. Boiling
point
i t off pure water
t att 101.325
101 325 kPa i 373 K (100o C).
kP is C)
Let mf, m’ and mv be the flow rate of feed, thick liquor and water vapor.

Material balance of salt:

0.05 * 20000 = 0.20 * m’
m' = 5000 kg/h
m

Overall material balance over evaporator:

Feed = Water evaporated + Thick liquor
Water evaporated = 20000 – 5000
mv = 15000 kg/h

20
Single Effect Evaporator
Energy Balance:
λs = 2185 kJ/kg
λv = λ = 2257 kJ/kgg
CPf = 4.0 kJ/ (kg.K)
Tf = 298 K
Boiling point of solution = T= T’ + B.P.R = 373 + 7 = 380 K
Temperature of condensing steam = Saturation temperature of steam = 399 K

Heat balance over evaporator:

Heat load
l d=Q
Q = ms λs = mf CPf (T – Tf) +mv λ
ms * 2185 = 20000 * 4.0 (380 – 298) + 15000 * 2257
ms = 18496.6 kg/h
Steam consumption = 18496.6 kg/h

Economy of evaporator = 15000 / 18496.6 = 0.811

21
Single Effect Evaporator
Energy Balance:
Heat load = Q = ms λs = 18496.6 * 2185 = 4041507.1 kJ/h
= 4041507.1 * 1000 / 3600
Heat load = Q = 1122641 J/s = 1122641 W

22
Practice Problems:
P1) A single effect evaporator concentrates 10000 kg/hr of a chemical solution
from 10 % to 20 % solids by weight. Feed enters at 30 oC. Saturated steam at 110
oC (latent heat of 540 kcal/kg) is available.
available Condensate leaves at saturation
temperature. The solution boils at 45 oC (latent heat = 570 kcal/kg). Specific
heats of all solutions may be taken as 1 kcal/kg oC. Overall heat transfer
coefficient is taken as 1800 kcal/hr m2 oC. Calculate the (i) Steam consumption
rate in kg/hr; (ii) Heat transfer area.

Answer:
s e
(i) Steam flow rate = 5555.6 kg/hr
(ii) Area (A) = 25.64 m2.

23
Practice Problems:
P2) A single effect evaporator is to be designed to concentrate 9000 kg/hr of a
solution from 12% to 20% solids. Feed enters at 25 oC. Saturated steam at 110
oC (latent
(l t t heat
h t = 540 kcal/kg)
k l/k ) is i available
il bl andd the
th condensate
d t leaves
l att the
th
condensing temperature. Saturation temperature of vapor is 40 oC (latent heat =
580 kcal/kg). Specific heats of all solutions may be taken as 1 kcal/kg oC.
Overall heat transfer coefficient is taken as 1900 kcal/hr m2 oC.
C Calculate the (i)
Steam consumption rate in kg/hr; (ii) Heat transfer area.

Answer:
s e
(i) Steam flow rate = 4117 kg/hr
(ii) Area (A) = 16.71 m2.

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