TYPES OF

EVAPORATO
RS
Industrial Operations

Submitted to: Sir. Kamran Khalid

Submitted by: Ms. Pakeeza
Bukhari
Roll no 17
B.Sc Industrial
engg
Institute of Quality & Technology
Management, University of
Punjab
 EVAPORATION:

Evaporation is the process by which the moisture content of a dilute

liquid product is reduced to obtain a more concentrated product.
Evaporators are classified according to the mechanism they dry the
product. The following evaporators are being discussed:
1. Horizontal tube evaporator
2. Short tube vertical evaporator
3. Long tube vertical evaporator
4. Forced-circulation evaporator

1. HORIZONTAL TUBE EVAPORATORS:

The first evaporator that got recognized was a design utilizing
horizontal tubes.

1.1 CONSTRUCTION & WORKING:

The simplest evaporator design is a shell and horizontal tube
arrangement with heating medium in the submerged tubes and
evaporation on the shell side.

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Tubes are usually 7/8 inch to 1-1/2 inches in diameter and 4 to 16 feet
long. The maximum area in a feasible design is about 5,000 sq. ft. The
tube bundle is not removable. Above the heating section there is a
cylindrical section in which separation of liquid from vapour takes
place. The vapour leaves through some de-entraining device in the
separator so the vapour leaving the tube doesnot carries liquid
droplets. The thick liquor is obtained from the bottom. With the
passage of time, Modifications were made in its design. One of them is
the use of U-bend tubes to facilitate bundle removal for inspection and
cleaning. Another modification is the kettle-type re-boiler. This design
permits the use of longer tubes which means more heat transfer
surface can be provided. The tube bundle can also be removed for
inspection and cleaning in this re-boiler modification. Another
alternative is the use of bent-tubes.

1.2 ADVANTAGES:
The advantages of horizontal tube evaporators include:
• relatively low cost in small-capacity applications
• easy mechanical cleaning of the outside tube surface and
possibility of tube bundle dismounting (for limited heat
exchange surface)
• the space within the tube bundle allows the evaporated vapors
to flow around the tubes at low velocity and enables a very low
evaporation temperature
• large vapor-liquid separation area
• relatively good heat transfer with proper design
• the potential for easy semiautomatic de-scaling

1.3 DISADVANTAGES:
Disadvantages include:
• Limitations for use in salting or scaling applications, generally
• Bent-tube designs are relatively expensive
• Liquid circulation is poor so it is unsuitable for viscous liquors

1.4 APPLICATIONS:
• They are well adapted for non-scaling, low viscosity liquids
• The short tube variety is seldom used today except for
preparation of boiler feed water
• The kettle-type re-boiler is frequently used in chemical plant
applications for clean fluids

2. SHORT TUBE VERTICAL EVAPORATORS:

Although the vertical tube evaporator was not the first to be built, it
was the first type to receive wide popularity. The first was built by

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Robert and the vertical tube evaporator is often called the Robert type.
It became so common that this evaporator is sometimes known as the
standard evaporator. It is also called a calandria.

2.1 CONSTRUCTION & WORKING:

It is similar in construction & working to horizontal tube evaporator
except that vertical tubes are used i-e tubes 4 to 10 feet long, often 2
to 3 inches in diameter, are located vertically inside a steam chest
enclosed by a cylindrical shell. The first vertical tube evaporators were
built without a downcomer. These were never satisfactory, and the
central downcomer appeared very early. There are many alternatives
to the center downcomer; different cross sections, eccentrically located
downcomers, a number of downcomers scattered over the tube layout,
downcomers external to the evaporator body. Circulation of liquid past
the heating surface is induced by boiling (natural circulation). The
circulation rate through the evaporator is many times the feed rate.
The downcomers are therefore required to permit liquid flow from the
top tubesheet to the bottom tubesheet. The downcomer flow area is
generally approximately equal to the tubular flow area. Downcomers
should be sized to minimize liquid holdup above the tubesheet in order
to improve heat transfer, fluid dynamics and minimize foaming. For
these reasons, several smaller downcomers scattered about the tube
nest are often the better design.

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2.2 Basket Type Evaporators:
In the basket type evaporator construction and operation is much the
same as a standard evaporator except that the downcomer is annular.
This construction often is more economical and permits the evaporator
to be removed for cleaning and repair. Also that crystal formed in the
downcomer donot breakup. As the circulation of the liquors in the tube
is better, it is widely used in the sugar and salt industries where
throughput is large.

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2.3 APPLICATIONS:
Short tube vertical evaporators are best applied:
• when evaporating clear liquids, mild scaling liquids requiring
mechanical cleaning
• crystalline product when propellers are used
• and for some foaming products when inclined calandrias are
used

2.4 ADVANTAGES:

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The short tube evaporator offers several advantages:
• Low headroom
• High heat transfer rates at high temperature differences
• ease of cleaning
• low initial investment

2.5 DISADVANTAGES:
• Disadvantages include:
• High floor space and weight
• Relatively high liquid holdup
• Poor heat transfer at low temperature differences or high
viscosity.
• Natural circulation systems are not well suited for operation at
high vacuum

3. LONG TUBE VERTICAL EVAPORATORS

More evaporator systems employ this type than any other because it is
versatile and often the cheapest per unit capacity.

3.1 CONSTRUCTION & WORKING:

The essential parts are (1) a tubular exchanger with steam in shell and
liquid to be concentrated in the tubes, (2) a separator or vapor space
for removing entrained liquid from the vapor, (3) when operated as
circulation unit, a return leg are provided for the liquid from the
separator to the bottom of the exchanger. Inlets are provided for feed
liquid and steam, and outlets are provided for vapor, thick liquor,
steam condensate, and noncondensable gases from the steam.
Long tube evaporators normally are designed with tubes 1 to 2 inches
in diameter and from 12 to 30 feet in length. Long tube units may be
operated as once-through or may be recirculating systems. If once
through, no liquid level is maintained in the vapor body, tubes a
deflector plate is often provided in the vapor body, and tubes are 12 to
20 feet long. Recirculated systems can be operated batchwise or
continuously. Circulation of fluid across the heat transfer surface
depends upon boiling. The temperature of the liquid in the tubes is far
from uniform and relatively difficult to predict. These evaporators are
less sensitive to changes in operating conditions at high temperature
differences than at lower temperature differences. The effects of
hydrostatic head upon the boiling point are quite pronounced for long
tube units.

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3.2 Rising or Climbing Film Evaporators
The long tube evaporator described above is often called a rising or
climbing film evaporator.

3.2.1 Theory:
The theory of the climbing film is that vapor traveling faster than the
liquid flows in the core of the tube causing the liquid to rise up the tube
in a film. This type of flow can occur only in a portion of the tube. When
it occurs, the liquid film is highly turbulent and high heat transfer rates
are realized. Residence time is also low permitting application for heat
sensitive materials.

3.3 Falling Film Evaporators

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The falling film version of the long tube evaporator eliminates the
problems associated with hydrostatic head.

3.3.1 Working:
Liquid is fed at the top of long tubes and allowed to fall down the walls
as a film. Evaporation occurs on the surface of the highly turbulent film
and not on the tube surface. This requires that temperature differences
be relatively low. Vapor and liquid are usually separated at the bottom
of the tubes. Sometimes vapor is allowed to flow up the tube counter
to the liquid. Pressure drop is low and boiling point rises are minimal.
Heat transfer rates are high even at low temperature differences.

3.3.2 Uses:
The falling film evaporator is widely used for concentrating heat
sensitive products because the residence time is low. Falling films are
also used in fouling services because boiling occurs on the surface of
the film and any salt resulting from vaporization is swept away and not
deposited on the tube surface. They are also suited for handling
viscous fluids.
Falling film units are also easily staged.

3.3.3 Problems:
The main problem associated with falling film units is the need to
distribute the liquid evenly to all tubes. All tubes must be wetted
uniformly and this may require recirculation of the liquid unless the
ratio of feed to evaporation is relatively high. Recirculation can only be
accomplished by pumping. Distribution can be achieved with
distributors for individual tubes, with orifice plates above the tubes and
tubesheet, or by spraying. Updraft operation complicates the liquid
distribution.

3.4 APPLICATIONS:
• They are best applied when handling clear fluids, foaming
liquids, corrosive fluids, large evaporation loads.
• Falling film units are well suited for heat sensitive materials or
for high vacuum application, for viscous materials, and for low
temperature difference.

3.5 ADVANTAGES:
The long tube vertical evaporator offers several advantages:
• Low cost, large units, low holdup, small floor space, good
heat transfer over a wide range of services.

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3.6 DISADVANTAGES:
Disadvantages include:
• High headroom
• Recirculation is frequently required, and
• They are generally unsuited for salting or severely scaling
fluids.
• They are best applied when handling clear fluids, foaming
liquids, corrosive fluids, large evaporation loads
• Falling film units are well suited for heat sensitive
materials or for high vacuum application, for viscous
materials, and for low temperature difference.

4. FORCED CIRCULATION EVAPORATORS:

The basic principle of forced circulation evaporator is that the liquid-
film transfer coefficient is increased by increasing the flow of liquor
through tubes.

4.1 CONSTRUCTION & WORKING:

In forced-circulation evaporator and pump is mounted outside the
evaporator body. The liquor is introduced at the bottom and pumped
straight through the calandria, or it is introduced in the separating
section. The liquid enters the bottom of the tubes and is heated as it
rises and at the same time pressure falls. This type of evaporator is
often called the submerged-tube type because the heating element is
placed below the liquid level and uses the resulting hydrostatic head to
prevent boiling.
The heating element may be installed vertically usually single pass.
Heating elements may also be installed horizontally often two pass
Sometimes the pumped fluid is allowed to vaporize in the tubes. This
often provides higher heat transfer rates but increases the possibility
of fouling. Consequently this type of evaporator is seldom used except
where headroom is limited or the liquids do not scale, salt, or foul the
surface.

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The forced circulation system is the easiest to analyze and permits the
functions of heat transfer, vapor-liquid separation, and crystallization
to be separated. Forced circulation systems are generally more
expensive than natural circulation systems and are therefore used only
when necessary. A choice of forced circulation can be made only after
balancing the pumping
energy cost, which is usually high, with the increase in heat transfer
rates or decrease in maintenance costs. Tube velocity is limited only by
pumping costs and by erosion at high velocities. These are therefore
suited for vacuum operation.

4.2 APPLICATION:
• Forced circulation evaporators are best applied:
• viscous products and corrosive products
• solutions with suspended solids
• solutions close to crystallization

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 • They are also well adapted for vacuum service and for services
requiring a high degree of concentration and close control of
product concentration

4.3 ADVANTAGES:
Forced circulation evaporators offer these advantages:
• high rate of heat transfer positive circulation
• relative freedom from salting, scaling, and fouling
• ease of cleaning; and a wide range of application

4.4 DISADVANTAGES:
Disadvantages include:
• High cost and relatively high residence time
• Necessary pumps with associated maintenance and operating
costs.

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