1)

Evaporation Economy with and without Vapour Compressor:

( Steam Require for running vacuum ejector is to be added)
STEAM CONSUMPTION AND RUNNING COSTS OF EVAPORATORS
(WITH OUT HEAT LOSSES)

Number of
effects

One
Two
Three
2)

Steam consumption Normal

Steam consumption with TVR

with out Vacuum Ejector

(kg steam/kg water

evaporated)

(kg steam/kg water

evaporated)

1.1
0.58
0.39

0.7
0.44
0.32

The size of Heat Exchanger for other than NaCl Application

If properties for Cacl2 and NaoH is not available for approximation first size it assuming NaCl
operating it with NaOH solution HE is 1.32 times than it for NaCl
operating it with Cacl2 solution HE is 1.017 times than it for NaCl

3)
1

B.T.U./ h r. ft^2 .F
B.T.U./ h r. ft^2 .F
W/m K
Kcal /hr.m.C

Heat Trsf. Coeff.

5.6785
4.8824
0.1761
1.1622

For the Design of Evaporator for Effluent water :

Forced Convection ( Design Book)
Heat Transfer for Boiling Aqueous Solution(Natural)
Coulson & Richrdson
Evaporation Under Vacuum, where Heated fluid is Boiling
liquid (steam to water) & Condensing Vapour of steam
Thermo Convection- hi =

The following correlation is valid with tube side velocity of circulating m

Heat Transfer Coefficient for Boiling in tube side :

Max value for natural or forced circulation vaporizing aqueous solution of low conce
(Use Maximum if it exceeds by calculation )
Max value for organic Liquid

Cal. Tube side coeff by

hi =

or the Forced Circulation

hi =

hn Tube Bundle =

(0.023*Nre^0.25 *Pr^0.5*KL )/ ((L^2/L/(L -

some correlation is with constant 0.028 instead of 0.02

Correction for Tube Bundle
hn Tube Bundle =

hcod*(0.6+0.42*N^-0.25)

Kern [2] recommends that t he maximum allowable vaporizing film coefficients:

300 Btu/h.ft2 F for natural or forced circulation vaporizing organics.

1000 Btu/h.ft2 F for natural or forced circulation vaporizing aqueous solution of low concentration.
The maximum allowable heat flux:
20000 Btu/(h)ft2) for forced circulation reboilers and 12000 Btu/(h)ft 2) for natural circulat
30000 Btu/(h)ft2) for both forced or natural circulation reboilers vaporizing aqueous solu

4)

Pipe do
do

25.40
0.0254

( 16 BWG = 1.65 mm & 18 BWG = 2.11 mm)

th
2.11
di
0.0233
k for SS at 125 C
17.50
xw/kw =
0.00006

5)

Thermal resistances of scale deposits from various fluids ( Fouling Factor)

0.0003
0.00045
0.004
0.001
0.002
0.002

Aqueous Salt Solution :

Steam -Oil free
Condensatewater
River water
Cooling Water
Brakish water (Hard)
6)

Over All Heat Transfer Coefficient - U

(1/u) = (1/ho) + (xw/kw) + Ri + Ro + (I/hi)
Ri and Ro are thermal resistance for treated water, from Table
xw/kw is the thermal resistance for tube material from Table
Please do the Correction for HT coeff For Pipe ID to OD :

7)

Average Wall Temperature

Assume that h(assm) = 8500 W/m2.K for steam or 5500 W/m2.K for water. With this assum

Where,
( di tube ID and do tube OD)

Th(avg)= Average temperature of the hot fluid ( Vapour )

Thc=Calorific temperature of the hot fluid steam

8)

Avergae T for each Stage of evaporation is calculated as under:

Assumed that Heat transfer Area is almost same for all the HE
Let first stage HT coeff :
U1
second stage HT coeff :
U2
Third stage HT coeff :
U2
Temperature drop between steam temperature (Ts) and last stage vapor temperature TEff
then approximate value of
T1 = (Ts-TEff3)*(1/U1)/(1/U1 + 1/U2 + 1/U3) -BP Elevation of Liq. In first effect
T2 = (Ts-TEff3)*(1/U2)/(1/U1 + 1/U2 + 1/U3) -BP Elevation of Liq in second stage

T3 =
9)

(Ts-TEff3)*(1/U3)/(1/U1 + 1/U2 + 1/U3) - BP Elevation of Liq in third stage

Check for allowable vapor velocity (uv)

The maximum vapor velocity uv(m/s) at the liquid surface should be less than that given by the expressio

where, l = liquid density and , v = vapor density

10)

Tube velocity and pump flow selection For forced circulation :

Use tube side velocity min 3 m/s and maximum 4 m/s with flow Nre > 10^4 , preferably b
This would give tube side heat transfer coeff, the optimumvalue
Appx Pump Circulation Rate:
APV recommanded 100 to 150 times circulation flow for each kg of water evapor
HPFL Design
400
Times water quantity evaporated in 1st Effect Evaporator
600
Times water quantity evaporated in 2nd & 3rd Effect Evaporator
11)

Heat Transfer coefficient for Evaporation/condensation Out side tube : (Refeer In

(for Laminar Flow )
Horizontal Tube
hcond =

0.725 *[ (k^3 *^2* g *)/(D**t)]^0.25

(BTU.hr.f.F((W/m.C)
Veriticle Tube
hcond =

0.943 *[ (k^3 *^2* g *)/(L**t)]^0.25

(BTU.hr.f.F((W/m.C)

Alternatively for heating media other than steam use

Outside Transfer Factor (Shell side with segment baffle 25% cut), jh =
Heat Transfer coefficient for Evaporation Out side tube :
( Butterworth (1983) recommanded Labuntsov correlation/expression
(Verticle Tube, Turbulent Flow )
Heat Transfer Coefficient for Steam on Shell side :
(Maximum Value o be Taken)

12)

Baffle cut :

Select 25% Baffle cut that is used widely

13)

Baffle Spacing :

between 0.2 * Ds to Ds ( Ds is shell diameter )

minimum = 0.2 * Ds
Normal selection =

14)

Shellside cross flow area "As" = DCB /Pt

where
D=
C=
B=
Pt =

shell ID
Clearance Between the tubes
Baffle spacing
tupe pitch

15)

Clearance between Baffle and shell = 11 mm to 13 mm Max

16)

Mean Temperature Difference :

"TM"
whre
Q =U*A*TM

17)

B. Use Single Effect Evaporator with TVR upto 1350 kgs water vapour evaporati
C. If Boiling point Elevation is > 3 degree Centigrade, Do not use MVR
D. Forced circulation tube velocities are generally in the 15-20 ft/s (4.5-6 m/s) range. Min 2.0 m/s

E . Select Pump Circulation Rate : to get velocity in tube as recommanded abov

E. Boiling Point Elevation (BPE) as a result of having dissolved solids must be accounted for in the differences b

F. BPE's greater than 7 F (3.9 C) usually result in 4-6 effects in series (feed-forward) as an economical solution

G. Reverse feed results in the more concentrated solution being heated with the hottest steam to minimi

F. Interstage steam pressures can be increased with ejectors (20-30% efficient) or mechanical compress

I. Temperature rise across the tube bundle should be 2 to 3 degree centigrade o

18)

In Design of Condensor for Vapour

Select out let temperature of cooling water 5 C lower than vapour temperature
If vapor temp is say 50 C

CW out temp = 45 C
CW inlet temp Appx with T = 12C ( Max) is 33 C
In India in summer cooling tower temperature may be as high as 33 to 35 C so keep marg
Boiling Point Elevation : (BPE) in C is given by

Calculation of the overall heat transfer coefficients of evaporat

D.Fabri Journal of engineering physics
Volume 11, Issue 6 , pp 432-435
Search Boling Heat Transfer Coefficient

Boiling Heat transfer correlations

Rohsenow has developed the first and most widely used correlation for nucleate boiling,[3

Nucleate boiling occurs when the surface temperature is higher than the saturation tempe
q/ A = L* hfg [ g* (Lv )/ ]^0.5 * [CpL*(TsTsat)/ (Csf* hfg

Where cpL is the specific heat of the liquid

L is the liquid viscosity.
TsTsat is the excess temperature,(Liquid Temp for Boiling liquid - Vapour Temp
PrL is the Prandtl number of the liquid
Csf is the surface fluid combination and vary for various combinations of fluid a

The variable n depends on the surface fluid combination and typically has a value of 1.0 o
of 0.006 and n of 1.0.
Values of Csf for various surface fluid combinations
Surface fluid combinations
Water/copper
Water/nickel
Water/platinum
Water/brass
Water/Stainless steel, mechanically polished
Water/Stainless steel, Chemically etched

Water/Stainless steel, Ground and polished

C C l 4 /copper
Benzene/Chromium
n-Pentane/Chromium
Ethyl alcohol/Chromium
Isopropyl alcohol/copper
n-Butyl alcohol/copper

mpressor:
be added)
VAPORATORS
S)

STEAM CONSUMPTION AND RUNNING COSTS OF EVAPORATO

(WITH 6% HEAT LOSSES)

Total running cost

Number of
effects
(relative to a singleeffect evaporator)
1
0.52
0.37

One
Two
Three

Steam consumption Normal

Steam consumption
with TVR with out
Vacuum Ejector

(kg steam/kg water

evaporated)

(kg steam/kg water

evaporated)

1.2
0.62
0.41

0.8
0.42
0.34

mation first size it assuming NaCl solution than

t for NaCl

eff.
W/m K
Kcal/ h r. m^2 .C
B.T.U./ h r. ft^2 .F
KW /m C
900
Min
Average
2000
Max
3000
1900 to 2750

1400
to
1750

W/m K
W/m K

W/m.C

de velocity of circulating mass V = 3 to 3.5 m/s and above

1200
to
1500

aqueous solution of low concentration.

1000
5500
300
1700

B.T.U./ h r. ft^2 .F
W/m K
B.T.U./ h r. ft^2 .F
W/m K

D
D
D
D

Q
Q
Q
Q

Kern
Kern
Kern
Kern

Book
Book
Book
Book

0.0225 *(k/D)*(Nre)^0.8 * (Pr)^0.4

W/m K

(Badger banchero)

0.028 *(k/D)*(Nre)^0.8 * (Pr)^0.4

W/m K

(Evaporation, Mccabe & Smith)

*Pr^0.5*KL )/ ((L^2/L/(L -g)/g))^0.33

with constant 0.028 instead of 0.023 0r 0.025

.6+0.42*N^-0.25)

zing film coefficients:

zing organics.
solution of low concentration.

2000 Btu/(h)ft2) for natural circulation reboilers vaporizing organics.

reboilers vaporizing aqueous solution.

Tabl
Gauge
(BWG)
.18
16
14
12
NOTE:
mm
m

mm
m
m.k/W

us fluids ( Fouling Factor)

fthF/Btu
fthF/Btu
fthF/Btu
fthF/Btu
fthF/Btu
fthF/Btu

0.00005
0.00008
0.00067
0.0002
0.0004
0.0004

mK/W
mK/W
mK/W
mK/W
mK/W
mK/W

hco = hc *(ID/OD)

W/m2.K for water. With this assumed value, calculate the tube wall temperature ( T w):

ated as under:

last stage vapor temperature TEff3

evation of Liq. In first effect

evation of Liq in second stage

evation of Liq in third stage

e less than that given by the expression below to avoid too much entrainment.

For forced circulation :

ith flow Nre > 10^4 , preferably between 10^4 to 20^4

w for each kg of water evaporated

t Evaporator
d Effect Evaporator

ation Out side tube : (Refeer Int.Chem. Engg. By Badger & Banchero Page 142)
Condensate properties are atFilm
where

---------A

or hfg =

Heat of Vaporisation for Vapor (BT

f =

density of condensate (lb/f) ( Kg/

v =

density of vapor or steam (lb/f)

k or kf=

thermal cond of condensate BTU

Acceleration of gravity ( 4.18*10

g=
or f =
--------B

Dor do =
L=
t =
tf =

Viscosity of condensate film (lb/ft

out side pipe dia in (ft) (m)

Pipe length in (ft)(m)
Temp diff between vapor and met
temp of Saturated Vapor - 0.75*

Refer graph Shell side jH (CR Book vol -6)

n/expression

1500
8500

B.T.U./ h r. ft^2 .F
W/m K

D Q Kern Book
D Q Kern Book

t that is used widely

Ds ( Ds is shell diameter )

1 mm to 13 mm Max
In Evaporation of aqueous solution by steam, use TM ( mean temperature difference between
steam saturation temperature Ts and Vapour temp of aquous solution that is boiling Tv

50 kgs water vapour evaporation per hour

de, Do not use MVR

(4.5-6 m/s) range. Min 2.0 m/s

n tube as recommanded above (min Use 100 to 150 Kgs Liquid per Kg of vapor evaporated)

must be accounted for in the differences between the solution temperature and the temperature of the saturated vapor.

s (feed-forward) as an economical solution. With smaller BPE's, more effects in series are typically more economical, depending on the cos

heated with the hottest steam to minimize surface area. However, the solution must be pumped from one stage to the next.

30% efficient) or mechanical compressors (70-75% efficient).

be 2 to 3 degree centigrade only

an vapour temperature

high as 33 to 35 C so keep margine

where
Xb =
Tb =

coefficients of evaporating equipment with steam heating

correlation for nucleate boiling,[3]

higher than the saturation temperature (TS) by between 10C (18F) to 30C (54F).
Ref:

James R. Welty; Charles E. Wicks; Robert E. Wilson; Gregory L. Rorrer., "Fundam

r Boiling liquid - Vapour Temp leaving )

arious combinations of fluid and surface. See table below

and typically has a value of 1.0 or 1.7. For example, water and nickel have a Csf

Csf
0.013
0.006
0.013
0.006
0.0132
0.0133

0.008
0.013
0.0101
0.015
0.0027
0.0025
0.003

TS OF EVAPORATORS
LOSSES)
Total running cost

(relative to a singleeffect evaporator)

1
0.52
0.37

1150
2550
3950

Kcal/hr.m.C

B.T.U./ h r. ft^2 .F

D Q Kern

176
308
264

B.T.U./ h r. ft^2 .F

Mccabe & Smith)

xw/kw =

(do/2)*LN(do/di)*(1/k)
0R Appx =
thickness/k

do & di in mts

Table: Thermal resistance of heat exchanger tubes

Thickness
Values of th/k or xw/kw (m K/kW)
(mm)
Copper
Steel
Stainless Admiralty
steel
metal
1.24
0.0031
0.019
0.083
0.011
1.65
0.0042
0.025
0.109
0.0.15
2.10
0.0055
0.032
0.141
0.019
2.77
0.0072
0.042
0.176
0.046
Divide Table Value by 1000 to get value in m k/W

Alumm.
0.0054
0.0074
0.0093
0.01.23

Conversion
fthF/Btu

0.18

mK/W

roperties are atFilm Temp. tf

isation for Vapor (BTU/lb) ( KJ/Kg)

densate (lb/f) ( Kg/m)

por or steam (lb/f) ( Kg/m)

of condensate BTU.ft/f.hr.F (w/m.K)

of gravity ( 4.18*10^8ft/h)( 9.8 m/s)

ondensate film (lb/ft.hr ) (Pa.s)

dia in (ft) (m)

ween vapor and metal (F)(C)

ated Vapor - 0.75*t (F)(C)

ce between

vaporated)

por.

al, depending on the cost of steam.

age to the next.

Brine concentration in ppm

Boiling Temperature C

y L. Rorrer., "Fundamentals of Momentum, Heat and Mass transfer" 5th edition, John Wiley and Sons

Cadcame NaCl
Evapn.

1000
750
1500

W/m K

Gauge
(BWG)
18
16
14
12

Table: Thermal resistance of heat exchanger tubes

Thickness
Values of th/k or xw/kw (fthF/Btu)
(inch)
Copper
Steel
Stainless Admiralty
steel
metal
0.049
0.000018
0.00011
0.00047 0.000065
0.065
0.000024
0.00014
0.00062 0.000086
0.083
0.000031
0.00018
0.0008
0.00011
0.109
0.000041
0.00024
0.001
0.00026

ey and Sons

ubes
fthF/Btu)

BWG/Tube Wall Thicknesses

Alumm.
0.000031
0.000042
0.000053
0.000070

8
9
10
11
12
13
14
15
16

Inch
0.165
0.148
0.134
0.120
0.109
0.095
0.083
0.072
0.065

mm
4.19
3.76
3.40
3.05
2.77
2.41
2.11
1.83
1.65