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Energetic and exergetic performance evaluation of the quadruple-effect

evaporator unit in tomato paste production


Z. Sogut
a
, N. Ilten
b,
*
, Z. Oktay
b
a
Technical Sciences Department, Army Academy, Ankara, Turkey
b
Mechanical Engineering Department, Faculty of Engineering, Balikesir University, 10110 Balikesir, Turkey
a r t i c l e i n f o
Article history:
Received 4 June 2009
Received in revised form
18 May 2010
Accepted 19 May 2010
Available online 3 July 2010
Keywords:
Energy
Exergy
Quadruple-effect evaporator
Tomato paste
Food production
a b s t r a c t
Quadruple-effect evaporator units are commonly used in food focus area in sector is evaporative unit. It
consumes about 60% of total energy input. The present study evaluates the performance of quadruple-
effect evaporator unit (QEEU) by using exergy analysis based on actual operational data. A tomato paste
factory is chosen for the analysis. The highest exergy destruction/loss occurs in the rst effect with
158.2 kW, 52.7% of exergy input in rst effect. Steam temperature should be decreased in order to
decrease exergy destruction in rst effect. Also, third effect achieves the highest exergy efciency with
93.3%. Exergetic improvement potential of each effect varies between 0.3 kW and 83.6 kW. The highest
and lowest exergetic improvement potential occurs in rst and third effect of QEEU system, respectively.
Exergetic improvement potential is equals to 52.80%, 11.10%, 6.73% and 69.8% of exergy loss/destruction
from the rst effect to the last effect, respectively. Total exergetic improvement potential is achieved as
128 kW (55% of total exergy loss/destruction) in QEEU system. It is expected that analyses result provide
important information for designer and/or resources of multiple effect evaporator unit.
2010 Elsevier Ltd. All rights reserved.
1. Introduction
Energy saving and efciency researches have started to gain
a vital importance in many industrial sectors. One of them is agri-
culture sector. It is a vital sector for Turkish economy. It is still
Turkeys largest employment provider and a signicant contrib-
uting sector to imports and exports. There has been increasing
interest in using energy analysis modeling techniques for energy
utilization assessments in order to attain energy saving and hence
nancial savings [1]. Turkey currently ranks fourth in the world
production of tomato paste. The tomato paste sector is a very
power-intensive sector during the short operating season, about
four months. Its consumption potential reaches 5% in Turkish
economy [2].
High energy inputs make it necessary to improve the energy and
exergy efciencies for decreasing the energy cost in this sector. As
known, energy input cost has very dominant effect on production
cost. Many studies have been made for both increasing the ef-
ciency and decreasing the losses. Main focus area in tomato sector
is the evaporator unit. It consumes about 60% of total energy input.
Many researchers have already performed analyses for Multiple
effect evaporators, based on mathematical modeling, simulation
and experimental data. Kaya and Sarac [3] have proposed the
mathematical modeling of multiple effect evaporators. They
applied the mathematic model to sugar factory by utilizing actual
data. Miranda and Simpson [4] describe a phenomenological,
stationary and dynamic model of a multiple effect evaporator for
simulation and control purposes. Also others [5e7] studied on
different areas about multiple effect evaporators. Yeh and Ho [5]
have investigated the closed-type multiple effect solar distillers.
They found that enthalpy losses from all effects increase when the
level of insulation increases, improvement in productivity in an
open-type distiller decreases as the strength of insulation increases.
Adel and Dayem [6] have studied experimentally and numerically
the performance of a simple solar distillation unit that is based on
the multiple condensationeevaporation cycle. Effect of multiple-
evaporator in the performance of a simple solar distillation unit is
investigated. Yeh and Chen [7] have investigated the energy
balances for upward-type, double-effect solar distillers, with air
ow through the second effect unit. The effects of various condi-
tions on modied factors are investigated experimentally.
First law energy analysis is commonly utilized in thermal
processes to increase efciency. Another method analyzing the
system is based on second law of thermodynamics. This is called
exergetic analysis. Exergy can be dened as the maximum work,
which can be produced by an energy source as it comes to equi-
librium with a reference environment [8e10]. Exergy analysis is
* Corresponding author. Tel.: 90 266 612 1194/5109; fax: 90 266 612 1257.
E-mail addresses: mzsogut@yahoo.com (Z. Sogut), nilten@balikesir.edu.tr (N.
Ilten), zuhal.oktay@gmail.com (Z. Oktay).
Contents lists available at ScienceDirect
Energy
j ournal homepage: www. el sevi er. com/ l ocat e/ energy
0360-5442/$ e see front matter 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.energy.2010.05.035
Energy 35 (2010) 3821e3826
a powerful concept for the analysis of industrial processes. The
main purpose of exergy analysis is to identify the causes and
quantitatively estimate the magnitude of the imperfection of
a thermal or chemical process. Exergy analysis leads to a better
understanding of the inuence of thermodynamic phenomena on
the process efciency, comparison of the importance of different
thermodynamic factors, and the determination of the most efcient
ways of improving the process under consideration [11]. A true
understanding of exergy and the insights it can provide to
comprehend the efciency, environmental impact and sustainable
energy systems, which are necessary parameters for the engineer
or scientist working in the area of energy systems and the envi-
ronment. Dincer [12] also reported the linkages between energy
and exergy, exergy and environment, energy and sustainable
development, and energy policy making and exergy in detail.
The energy utilization of industrial processes can be evaluated
using exergy analysis to gain insights into their efciency. Many
extensive works [11,13e17] have been published about the exergy
analysis in different industrial sectors. Szargut [11] introduced the
cumulative exergy consumption and cumulative degree of perfec-
tion for industrial processes and made the distinction between
second law efciency and cumulative degree of perfection for
industrial processes, rstly. Later, Kotas [16] has followed a similar
approach giving different industrial processes such as sulfuric acid,
gas turbine and refrigeration plants. Wall [17] presented the exergy
ows for a pulp, paper mill and a steel plant by establishing the
energy ows in processes and drawing up the exergy losses.
Several studies have been carried out on energy and exergy
analyses for the food sector [14,18,19]. However, no specic exergy
analysis for quadruple-effect evaporator unit in tomato paste
industry has been found in literature. So, in this study, an exergetic
analysis of a tomato paste factory is proposed by using actual data.
Energy and exergy analyses have been carried out for each effect
constituting the evaporator unit. Also our results are compared the
similar studies performed in different sectors in the literature.
Similar energetic characteristics are determined. This study will
also be benecial for studying energetic and exergetic investigation
of multiple effect evaporators in general.
2. Description of the tomato paste production
The tomato paste production is composed of the following
operations: washing, sorting, pre-heating, pulp-picking, ne
sieving, evaporating, pasteurizing, hot lling into sterile boxes,
cooling, drying, box packaging, storage and marketing (see Fig. 1).
In rst step of production, fresh tomatoes coming from farms are
taken down to pools in the factory. Then, they are washed with
pressurized water and undesirable objects are removed by using
sieves. Tomatoes are transported to breakers for pre-crushing with
chlorinated (5 ppm) water after pre-cleaning. They are heated in
pre-heating process between 1 and 3 min at about 80e100

C,
depending on tomatoes type. After pre-heating, they are chopped
with circular helical knives. Then, air and pulps are removed under
vacuum. Juice coming out of the sieves (0.6e1.5 mm) is transferred
to the juice tank. Then, the juice is heated up to 40e85

C in the
evaporator unit to achieve required brix ratio. It is stirred and
sterilized in the sterilization unit at about 40

C. In the nal process,


it is lled in Aseptic bags at the packaging unit.
It is known that both electrical and thermal energy are required
in industrial processes. Thermal energy is supplied from steam by
using natural gas-burned steam boiler in the investigated factory.
60% of total thermal energy consumption is used in the evaporator
unit. 25% and 15% of the remaining thermal energy consumption
are consumed in the pre-heater and sterilization unit, respectively.
System schematics and mass ow in the evaporator unit is given in
Fig. 2. Tomato paste enters the fourth effect with a temperature of
48

C and leaves the system at 82

C. Evaporation of water occurs
under vacuum (11e51 kPa) at relatively low temperatures.
3. Analyses
3.1. Determination of thermal properties of tomato paste
Specic heat capacities of each entering and exiting streamneed
to be known, in order to establish the energy balance in the
evaporator unit. Specic heat of food materials has been deter-
mined experimentally by several methods, including the method of
mixtures and using a differential scanning calorimeter [20]. Tonelli
et al. [21] have suggested the following model for the specic heat
for tomato paste:
C
p;ei
4:184 2:9337$X
ei
(1)
In here X
ei
indicates soluble solids concentration for tomato juice
for each effect. Brix ratio is expressed in
o
Brix. In analysis, reference
temperature and pressure values are taken as 0

C and 1 atm.
Enthalpy of the tomato paste is estimated through the specic heat
(C
p
), utilizing the following expression [21,22]:
h
ei
C
p;ei
$T
ei
4:184 2:9337$X
e
i$T
ei
(2)
The following thermodynamic relationships describing the
boiling point elevation have been determined experimentally for
multiple effects evaporator [23]. This property is signicant at high
soluble solids concentration. On a multiple effect equipment, the
effective temperature differences decrease for the combination of
boiling point. The following correlation reported by Miranda and
Simpson [4] is used.
Deb 0:175X
1:11
$e
3:86X
$P
0:43
(3)
Vapor is considered saturated within the evaporator. The
following correlations given by Perry and Chilton [24] allow for the
estimation of vapor properties with an error of less than 1%,
Fig. 1. Tomato paste production line.
Z. Sogut et al. / Energy 35 (2010) 3821e3826 3822
T
vi
32:5515$P
0:2898
i
17:7778 for 40

C < T
v
< 70

C
(4)
T
vi
39:0514$P
0:2382
i
17:7778 for 70

C < T
v
< 135

C
(5)
h
vi
2509:2888 1:6747$T
vi
(6)
h
cond;i
4:18,T
cond;i
(7)
here, T
vi
,P
i
andh
vi
demonstrate the vapor temperature (

C), vacuum
pressure (kPa) and vapor enthalpy (kJ/kg), respectively. i iden-
ties the effects.
3.2. Mass and energy balance equations
The mass balance equation can be expressed for steady state and
steady-ow process below as
Fig. 2. Shematic illustration of the quadruple-effect evaporation system.
Fig. 3. Sample calculation procedure for the rst effect.
Z. Sogut et al. / Energy 35 (2010) 3821e3826 3823
_ m
in
_ m
out
(8)
where, _ m is the mass ow rate. in and out express the inlet and
outlet, respectively. The general energy balance can be expressed as,
_
E
in

_
E
out
(9)
_
E
steam

_
E
pump

_
E
product;in

_
E
heat loss

_
E
product;out

_
E
condense water

_
E
flash vopour
(10)
where,
_
E
in
and
_
E
out
are the amount of input and output energy,
respectively. Output energy contains heat loss (
_
E
heat loss
),
condensed water energy (
_
E
condense water
) ash vapor (
_
E
flashvopour
)
and product energy (
_
E
product;out
). Thermodynamic properties of
steam and water are determined by using Energy Equation Solver
program(EES). This programis commonly used for thermodynamic
systemanalysis in the literature. Energy efciency can be dened as
the ratio of total useful energy to input energy as
h
_
E
useful
_
E
in
1
_
E
loss
_
E
in
(11)
3.3. Exergy analysis
Exergy analysis clearly indicates the locations of energy degra-
dation in a process and can therefore lead to improved operation or
technology. A main of exergy analysis is to identify meaningful
(exergy) efciencies and the causes and true magnitudes of exergy
losses [25].
Exergy balance equation can be expressed for the system as
follows:
_
Ex
steam

_
Ex
pump

_
Ex
product;in

_
Ex
loss

_
Ex
dest:

_
Ex
product;out

_
Ex
condense water

_
Ex
flash vopour
(12)
The ow exergy can be expressed as:
j h h
0
T
0
s s
0
(13)
where jand s are the owexergy and specic entropy, respectively.
Specic entropy of tomato paste is calculated by using the following
equation:
j C
p
$
_
T T
0
T
0
$ln
_
T
T
0
__
(14)
Exergy amount can be found as,
_
Ex j$ _ m (15)
Exergy efciency can be dened as the ratio of total output
exergy to input exergy and given as,
3
_
Ex
useful
_
Ex
in
1
_
_
E
loss

_
E
dest:
_
_
E
in
(16)
3.4. Improvement potential
Van Gool has proposed the new exergy parameter as improve-
ment potential, IP. This parameter shows how much improvement
potential exists for the system [26]:
I
_
P 1 3
_
_
Ex
in

_
Ex
out

(17)
Exergetic improvement potential can be calculated for each
effect in evaporator unit in the system using this relation.
3.5. Steam economy
The steam economy, SE, gives the total amount of vapour
generated per unit energy input or steam equivalent and may be
determined for a multiple effect evaporator as follows [8]:
SE
Vapor kg=s
Steam kg=s

_ m
v
i
_ m
s
(18)
where, i 1,2,3,.,n identify effects. _ m
vi
and _ m
s
indicate the mass
ow rate of vapor and steam, respectively.
3.6. Assumptions for calculations
Following assumptions are considered in the calculation
procedure:
System was assumed to be at steady state in a steady-ow
process.
Pump work input was neglected.
The change in the ambient temperature was neglected.
The reference state temperature and pressure are taken as 0

C
and 101.3 kPa, respectively for exergy analysis.
Table 1
Properties, energy and exergy rates at various locations of evaporator unit.
m (kg/s) T (

C) P (kPa) Brix E (kW) Ex (kW)


1 0.328 153 395 e 905.3 282.68
2 0.563 71 104 0.14 157.7 16.75
3 0.282 82 51 0.29 77.1 19.65
4 0.328 87 e e 119.6 15.74
5 0.281 82 51 e 743.5 115.78
6 0.092 82 51 e 253.9 37.70
7 0.189 82 51 e 521.6 78.00
8 0.675 59 104 0.11 153.8 14.55
9 0.563 71 40 0.14 157.7 16.75
10 0.189 82 e - 64.8 8.13
11 0.112 71 32 e 294.3 57.42
12 0.092 82 51 e 253.9 37.70
13 0.058 77 40 e 153 22.18
14 0.146 77 40 e 365.1 55.77
15 0.77 48 104 0.09 144.9 11.41
16 0.675 59 19 0.11 153.8 14.55
17 0.146 77 e e 47 5.59
18 0.096 59 19 e 250.3 42.58
19 0.154 66 26 e 406.2 78.68
20 0.80 45 101 0.086 141.5 10.52
21 0.77 48 11 0.09 144.9 11.41
22 0.154 66 e e 42.5 4.43
23 0.03 48 11 e 77.6 11.16
Fig. 4. Energy and exergy efciency values for each effect.
Z. Sogut et al. / Energy 35 (2010) 3821e3826 3824
4. Results and discussion
Energy and exergy analyses of quadruple-effect evaporator are
determined by utilizing actual data. Each effect in the evaporator
unit is analyzed according to the rst and second laws of thermo-
dynamics. A sample calculation is given in Fig. 3. Energetic and
exergetic efciency values of each effect were estimated by using
mass and thermodynamic data given in Table 1. Estimation of brix
ratio is one of the most important parameter for the determining
the thermodynamic properties of tomato paste. Brix ratios were
obtained from all samples for each effect. Then, brix ratios,
temperature and pressure data were used to estimate the enthalpy
and specic exergy of tomato paste. It was then noticed that the
brix ratio increases in each effect as a result of evaporation of water,
from 8.6% to 29%. The results are given below in detail for each
effect.
4.1. First effect
After the energetic and exergetic calculations, it is determined
that highest energy and exergy loss take place in the rst effect.
Exergy loss/destruction amount reaches to 158.2 kW. This exergy
represents 36% of total exergy loss and destruction in QEEU. The
highest exergetic improvement potential (83.6 kW) occurs in this
section. Exergetic efciency of rst effect was found to be 47.15%.
This amount is very low compared to the energy efciency. Energy
efciency reaches the highest point (88.4%) in rst effect for QEEU.
Thermal energy loss occurs as a result of no insulation. 11.6% of
thermal energy (123 kW) is released to the surroundings in the rst
effect. Although energy efciency shows that the rst effect is very
effective calculated exergy efciency values indicate that the
highest exergetic improvement potential occurs in this effect.
Exergetic efciency in the rst effect can be increased by decreasing
boiler steam temperature entering the rst effect. Both energy and
exergy efciencies could be further increased by applying
insulation to this effect. Exergetic improvement potential is equals
to 52.8% of exergy loss/destruction for rst effect. Exergy loss due to
energy release to the environment (caused by bad insulation) is
calculated from multiplying with energy loss and energy efciency
values as 108 kW.
4.2. Second effect
Energy and exergy efciencies calculated for the second effect of
the evaporator unit are found as 79.7 and 88.9%, respectively. 20.3%
of total thermal energy (132.9 kW) is released to surrounding in the
second effect. Improvement potential for the second effect is found
as 1.14 kW. Exergetic improvement potential is equals to 11.1% of
exergy loss/destruction for second effect. Exergy loss due to energy
release to the environment is found as 127 kW.
4.3. Third effect
The third effect evaporator unit uses the vapor mixture coming
from rst (0.112 kg/s) and second (0.092 kg/s) effects. Two vapor
mass ows enter into the vapor mixing chamber. Energy and exergy
efciencies for the third effect of evaporator unit are found as 86.3%
and 93.3%, respectively. The lowest improvement factor which
occurs in the third effect is found to be 0.3 kW. Also, 93.3%, the
highest exergy efciency occurs in the third effect for the system.
Exergetic improvement potential is equals to 6.73% of exergy loss/
destruction for third effect. Exergy loss due to energy release to the
environment is found as 50.8 kW.
4.4. Fourth effect
The lowest energy and exergy efciencies are found in this
effect. Energy and exergy efciency for the fourth effect of the
evaporator unit are found as 39.2% and 30.3%, respectively.
Improvement potential is determined to be 43.4 kW and exergy
destruction as 62.2 kW. Exergetic improvement potential is equals
to 69.8% of exergy loss/destruction for fourth effect. Exergy loss due
to energy release to the environment is found as 111 kW.
Energy and exergy efciencies for each effect are presented in
Fig. 4. Improvement factors and exergy destruction are given in
Figs. 5 and 6. Average improvement potential value for evaporator
unit is determined to be 32.1 kW. Average exergy destruction/loss is
found as 58.8 kW for the evaporator unit. Steam economy (SE) is
found as 1.58. Based on calculation, it was found that steam
economy decrease with increase in the inlet steam temperature.
Therefore, high steam temperatures are not required in the evap-
orator inlet to increase the exergy efciency and steam economy.
5. Conclusions and suggestion
In the present study, energetic and exergetic performance
evaluation of quadruple-effect evaporator unit (QEEU) are deter-
mined by actual operational data. The main conclusions that may
be drawn from the present study are listed as:
a) Exergy efciency values of QEEUwere found to vary from30.3%
to 93.3%. Balkan et al. have reported the exergetic efciency
values ranging between 75% and 90% for triple effect evapo-
rator. The main reason to get relatively lower exergy efciency
in our study arises from no insulation. Insulation of the pipes
and the heat exchangers is very crucial to improve energy and
exergy efciency for such industrial systems
b) The highest exergy destruction occurs in the rst effect because
of high temperature differences between steam and tomato
paste inlet.
Fig. 5. Improvement potential for each effect in evaporator unit.
Fig. 6. Total exergy destruction and loss for each effect in evaporator unit.
Z. Sogut et al. / Energy 35 (2010) 3821e3826 3825
c) Exergy efciency in the third effect reaches the highest value of
93.3%. Also, the lowest improvement potential is observed in
this effect.
d) In fourth effect, both energy and exergy efciency values are
obtained.
e) Steam economy (SE) is found as 1.58, which is lower than the
reported value of 2.14 by Balkan et al.
f) Collection of steam into a large tank before entering the
evaporator unit results in pressure loss. This pressure loss can
be eliminated by using automatic control system.
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Nomenclature
E: energy (kJ)
eb: boiling point elevation (

C)
_
Ex: exergy (kW)
h: specic enthalpy (kJ/kg)
m: mass (kg)
_ m: mass ow rate (kg/s)
s: specic entropy (kJ/kg K)
T: temperature (

C or K)
C
p
: specic heat capacity (kJ/kg K)
P: pressure (kPa)
X: concentration of soluble solids (kg/kg)
Greek letters
j: ow exergy (kJ/kg)
h: energy (rst law) efciency (%)
3: exergy (second law) efciency (%)
Indices
c: component
cond: condensate
in: input
dest: destroyed
ei: evaporator effect, i
fg: evaporation
gen: generation
out: output
s: steam
0: dead state or reference environment
v: vapor
Z. Sogut et al. / Energy 35 (2010) 3821e3826 3826

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