CHEM3012

Separation Process (II)

Learning Materials-Topic 1-Week 3
Multiple effect evaporators

Course Learning Outcomes

• Evaluate the basic fluid properties such as density, specific weight and viscosity and
their dimensions and units

• Demonstrate the dimensional analysis for planning experiments and the techniques
involved.

Lecturer Name: Dr Mostafa Ghasemi Baboli

Academic Year: 2022-2023
Course Coordinator Name: Dr Mostafa Ghasemi Baboli

References:
Felder, R.M. & Rousseau, R.W., Elementary Principles of Chemical Processes, 3th edition, J. Wiley &
Sons, New York, 2005.
Himmelblau, D, M, and Riggs, J, B. Basic Principles and Calculations in Chemical Engineering, 7th
Edition, Prentice Hall, 2004.
Calculation Methods for Multiple-
effect Evaporators
• Objective to calculate;
- temperature drops and the heat capacity of
evaporator.
- the area of heating surface and amount of vapor
leaving the last effect.

• Assumption made in operation;

- no boiling point rise.
- no heat of solution.
- neglecting the sensible heat necessary to heat
the feed to the boiling point.
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Calculation Methods for Multiple-
effect Evaporators
• Heat balances for multiple/triple-effect evaporator.
 the amount of heat transferred in the first effect is approximately same with
amount of heat in the second effect,
q = U1 A1 T1 = U2 A2 T2 = U3 A3 T3

 usually in commercial practice the areas in all effects are equal,

q/A = U1 T1 = U2 T2 = U3 T3

 to calculate the temperature drops in evaporator,

Equation 8.5-5
 T = T1 + T2 + T3 = TS – T3

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 Calculation Methods for Multiple-
effect Evaporators
hence we know that  T are approximately inversely proportional to
the values of U,
1 U1
T1  T Equation 8.5-6
1 U1  1 U 2  1 U 3

similar eq. can be written for T2 & T3

if we assumed that the value of U is the same in each effect, the
capacity equation,

q = U A (T1 + T2 + T3 ) = UA  T

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 Simplified diagram of backward-feed
triple-effect evaporator

vapor T1 vapor T2 vapor T3

to vacuum
condenser
(1) (2) (3)

feed, TF
steam, TS T1 T2 T3

condensate

concentrated
product

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 Backward-feed multiple/triple-effect evaporators

 fresh feed enters the last and coldest effect and continues
on until the concentrated product leaves the first effect.
 advantageous when the fresh feed is cold or when
concentrated product is highly viscous.
 working a liquid pump since the flow is from low to high
pressure.
 the high temperature in the first effect reduce the viscosity
and give reasonable heat-transfer coefficient.

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Step-by-Step Calculation Methods for Triple-Effect
Evaporators
1. From the known outlet concentration and pressure in the last effect, determine the boiling point in
the last effect. (If a boiling-point rise is present, this can be determined from a Dühring-line plot.)
2. Determine the total amount of vapor evaporated by performing an overall material balance. For
this first trial, apportion the total amount of vapor among the three effects. (Usually, equal amounts
of vapor are produced in each effect, so that V1 = V2 = V3 is assumed for the first trial.) Make a
total material balance on effects 1, 2, and 3 to obtain L1, L2, and L3. Then calculate the solids
concentration in each effect by a solids balance on each effect.
3. Using Eq. (8.5-6), estimate the temperature drops ΔT1, ΔT2, and ΔT3 in the three effects. Any effect
that has an extra heating load, such as a cold feed, requires a proportionately larger ΔT. Then
calculate the boiling point in each effect.
If a boiling-point rise (BPR) in °C is present, estimate the pressure in effects 1 and 2 and
determine the BPR in each of the three effects. Only a crude pressure estimate is needed, since
BPR is almost independent of pressure. Then the ΔT available for heat transfer without the
superheat is obtained by subtracting the sum of all three BPRs from the overall ΔT of TS – T3
(saturation). Using Eq. (8.5-6), estimate ΔT1, ΔT2, and ΔT3. Then calculate the boiling point in each
effect.]

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Step-by-Step Calculation Methods for Triple-Effect
Evaporators
4. Using heat and material balances in each effect, calculate the amount
vaporized and the flows of liquid in each effect. If the amounts
vaporized differ appreciably from those assumed in step 2, then steps
2, 3, and 4 can be repeated using the amounts of evaporation just
calculated. (In step 2 only the solids balance is repeated.)
5. Calculate the value of q transferred in each effect. Using the rate
equation q = UA ΔT for each effect, calculate the areas A1, A2, and
A3. Then calculate the average value Am by Equation 8.5-10

If these areas are reasonably close to each other, the calculations are
complete and a second trial is not needed. If these areas are not
almost equal, a second trial should be performed as follows.
6. To start trial 2, use the new values of L1, L2, L3, V1, V2, and V3
calculated by the heat balances in step 4 and calculate the new solids
concentration in each effect by a solids balance on each effect.
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Step-by-Step Calculation Methods for Triple-Effect
Evaporators
7. Obtain new values , , and from Equation 8.5-11

The sum + + must equal the original ΔT. If not,

proportionately readjust all ΔT' values so that this is so. Then
calculate the boiling point in each effect.
If a boiling-point rise is present, determine the new BPRs in the three
effects using the new concentrations from step 6. To get a new value
of ΔT available for heat transfer, subtract the sum of all three BPRs
from the overall ΔT. Calculate the new values of ΔT' by Eq. (8.5-11).
The sum of the ΔT' values just calculated must be readjusted to the
new ΔT value. Then calculate the boiling point in each effect.] Step 7
is essentially a repeat of step 3 but using Eq. (8.5-11) to obtain a
better estimate of the ΔT' values.
8. Using the new ΔT' values from step 7, repeat the calculations starting
with step 4. Two trials are usually sufficient so that the areas are
reasonably close to being equal.
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EXAMPLE. 3:
Evaporation of Sugar Solution in a Triple- Effect Evaporator

A triple-effect forward-feed evaporator is being used to evaporate a

sugar solution containing 10 wt% solids to a concentrated solution of
50 %. The boiling-point rise of the solutions (independent of pressure)
can be estimated from (BPR ºC = 1.78x + 6.22 x2 ), where x is wt
fraction of sugar in solution. Saturated steam at 205.5 kPa and 121.1ºC
saturation temperature is being used. The pressure in the vapor space of
the third effect is 13.4 kPa. The feed rate is 22 680 kg/h at 26.7 ºC. the
heat capacity of the liquid solutions is cP = 4.19 – 2.35x kJ/kg.K.
The heat of solution is considered to be negligible. The coefficients of
heat transfer have been estimated as U1 = 3123, U2 = 1987, and
U3 = 1136 W/m2.K. If each effect has the same surface area, calculate
the area, the steam rate used, and the steam economy.

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 Solution:
V1 = 22,680 – L1 V2 = L1 – L2 T3
F = 22680 V3 = L2 - 4536
T1 T2
xF = 0.1
TF = 26.7 ºC P3 = 13.7 kPa
(1) (3)
(2)
S =?
TS1 = 121.1 ºC
TS1 TS2 TS3
PS1 = 205.5 kPa

T3
T1 , L1 , x1 T2 , L2 , x2 L3 = 4536
x3 = 0.5

Fig. 8.5-1: Flow diagram for example 8.5-1

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Solution:
Solution,
The process flow diagram is given in Fig. 8.5-1..
Step 1,
From steam table, at P3 = 13.4 kPa, get Tsat = 51.67 ºC. Using the BPR equation for
third effect with xL = 0.5,
BPR3 = 1.78 (0.5) + 6.22 (0.52) =2.45 ºC.
T3 = 51.67 + 2.45 = 54.12 ºC. (BPR = T – Ts)
Step 2,
Making an overall and a solids balance.
F = 22 680 = L3 + (V1 + V2 + V3)
FxF = 22 680 (0.1) = L3 (0.5) + (V1 + V2 + V3) (0)
L3 = 4536 kg/h
Total vaporized = (V1 + V2 + V3) = 18 144 kg/h
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Solution:
Assuming equal amount vaporized in each effect,
V1 = V2 = V3 = 18 144 / 3 = 6048 kg/h

Making a total material balance on effects 1, 2, and 3, solving

F = 22 680 = V1 + L1 = 6048 + L1, L1 = 16 632 kg/h.
L1 = 16 632 = V2 + L2 = 6048 + L2, L2 = 10 584 kg/h.
L2 = 10 584 = V3 + L3 = 6048 + L3, L3 = 4536 kg/h.

Making a solids balance on each effect, and solving for x,

22 680 (0.1) = L1 x1 = 16 632 (x1), x1 = 0.136
16 632 (0.136) = L2 x2 = 10 584 (x2), x2 = 0.214
10 584 (0.214) = L3 x3 = 4536 (x3), x3 = 0.5 (check)

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Solution:

Step 3, The BPR in each effect is calculated as follows:

BPR1 = 1.78x1 + 6.22x12 = 1.78(0.136) + 6.22(0.136)2 = 0.36ºC.
BPR2 = 1.78(0.214) + 6.22(0.214)2 =0.65ºC.
BPR3 = 1.78(0.5) + 6.22(0.5)2 =2.45ºC. then,
T available = TS1 – T3 (sat) – (BPR1 + BPR2 + BPR3 )
= 121.1 – 51.67 – (0.36+0.65+2.45) = 65.97ºC.

Using Eq.(8.5-6) for T1 , T2 , and T3

1 U1 
65.97 (1 3123)
T1  T
1 U1  1 U 2  1 U 3 (1 3123)  (1 1987)  (1 1136)

T1 = 12.40 ºC T2 = 19.50 ºC T3 = 34.07 ºC

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 Solution:

However, since a cold feed enters effect number 1, this effect requires more heat.
Increasing T1 and lowering T2 and T3 proportionately as a first estimate, so
T1 = 15.56ºC T2 = 18.34 ºC T3 = 32.07 ºC

The above data T1, T2 and T3 are getting from iteration-s

To calculate the actual boiling point of the solution in each effect,

T1 = TS1 - T1 = 121.1 – 15.56 = 105.54 ºC.
T2 = T1 - BPR1 - T2 = 105.54 – 0.36 – 18.34 = 86.84 ºC.
TS2 = T1 –BPR1 = 105.54 – 0.36 = 105.18 ºC.
T3 = T2 - BPR2 - T3= 86.84 – 0.65 – 32.07 = 54.12 ºC.
TS3 = T2 –BPR2 = 86.84 – 0.65 = 86.19 ºC.
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Solution:
The temperatures in the three effects are as follows:
Effect 1 Effect 2 Effect 3 Condenser
TS1 = 121.1ºC TS2 = 105.18 TS3 = 86.19 TS4 = 51.67
T1 = 105.54 T2 = 86.84 T3 = 54.12

Step 4,
The heat capacity of the liquid in each effect is calculated from the equation
cP = 4.19 – 2.35x.

F: cPF = 4.19 – 2.35 (0.1) = 3.955 kJ/kg.K

L1: cP1 = 4.19 – 2.35 (0.136) = 3.869 kJ/kg.K
L2: cP2 = 4.19 – 2.35 (0.214) = 3.684 kJ/kg.K
L3: cP3 = 4.19 – 2.35 (0.5) = 3.015 kJ/kg.K

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 Solution:
The values of the enthalpy H of the various vapor streams relative to water at 0 ºC as a
datum are obtained from the steam table as follows:

Effect 1:
H1 = HS2 + 1.884 BPR1 = 2684 + 1.884(0.36) 2685 kJ/kg.
S1 = HS1 – hS1 = 2708 – 508 = 2200 kJ/kg.

Effect 2:
H2 = HS3 + 1.884 BPR2= 2654 + 1.884(0.65) = 2655 kJ/kg.
S2 = H1 – hS2 = 2685 – 441 = 2244 kJ/kg.

Effect 3:
H3 = HS4 + 1.884 BPR3 = 2595 + 1.884(2.45) = 2600 kJ/kg.
S3 = H2 – hS3 = 2655– 361 = 2294 kJ/kg.
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 Solution:
Write the heat balance on each effect. Use 0ºC as a datum.
FcPF (TF –0) + SS1 = L1cP1 (T1 –0) + V1H1 ,, ………(1)
22680(3.955)(26.7-0)+2200S = 3.869L1(105.54-0)+(22680-L1)2685

L1cP1 (T1 –0) + V1S2 = L2cP2 (T2 –0) + V2H2 ………(2)

3.869L1(105.54-0)+(22680-L1)2244=3.684L2(86.84-0)+(L1-L2)2655

L2cP2 (T2 –0) + V2S3 = L3cP3 (T3 –0) + V3H3 ………(3)

3.68L2(86.84-0)+(L1-L2)2294=4536(3.015)(54.1-0)+(L2-4536)2600

Solving (2) and (3) simultaneously for L1&L2 and substituting into(1)
L1 = 17078 kg/h L2 = 11068 kg/h L3 = 4536 kg/h
S = 8936kg/h V1 = 5602kg/h V2 = 6010kg/h
V3 = 6532kg/h
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Solution:
Step 5, Solving for the values of q in each effect and area,
 8936 
q1  SS 1   2200 x1000  5.460 x10 W
6

 3600 
 5602 
q2  V1S 2   2244 x1000  3.492 x10 W
6

 3600 
 6010 
q3  V2 S 3   2294 x1000  3.830 x10 W
6

 3600 

q1 5.460 x106 q 3.492 x10 6

A1    112.4m 2 A2  2
  95.8m 2
U1T1 312315.65 U 2 T2 198718.34

A3 
q3

3.830 x106
 105.1m 2 ( A1  A2  A3 )
Am   104.4m 2
U 3 T3 113632.07  3
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Solution:

Am = 104.4 m2, the areas differ from the average value by less than 10 % and a
second trial is really not necessary. However, a second trial will be made starting
with step 6 to indicate the calculation methods used.

Step 6,
Making a new solids balance by using the new L1 = 17078, L2 = 11068, and
L3 = 4536, and solving for x,

22 680 (0.1) = L1 x1 = 17 078 (x1), x1 = 0.133

17 078 (0.130) = L2 x2 = 11 068 (x2), x2 = 0.205
11 068 (0.205) = L3 x3 = 4536 (x3), x3 = 0.5 (check)

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Solution:

Step 7. The new BPR in each effect is then,

BPR1 = 1.78(0.133) + 6.22(0.13)2 =0.35ºC.
BPR2 = 1.78(0.205) + 6.22(0.205)2 =0.63ºC.
BPR3 = 1.78(0.5) + 6.22(0.5)2 =2.45ºC. then,
T available = 121.1 – 51.67 – (0.35+0.63+2.45) = 66.0 ºC.

The new T are obtained using Eq.(8.5-11),

T A 15.56112.4  T2 A2 18.3495.8
T  1 1 
'
 16.77C T 
2
'
  16.86C
1
Am 104.4 Am 104.4

T3 A3 32.07105.1
T 
3
'
  32.34C T  16.77  16.86  32.34  65.97C
Am 104.4
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Solution:
These T’ values are readjusted so that T 1`= 16.77,

T 2`= 16.87, T 3` = 32.36, and T = 66.0 ºC.

To calculate the actual boiling point of the solution in each effect,

(1) T1 = TS1 + T 1` = 121.1 – 16.77 = 104.33ºC

(2) T2 = T1 – BPR1 - T 2` = 104.33 – 0.35 – 16.87 = 87.11 ºC
TS2 = T1 – BPR1 = 104.33 – 0.35 = 103.98ºC
(3) T3 = T2 – BPR2 - T 3` = 87.11 – 0.63 – 32.36 = 54.12 ºC
TS3 = T2 – BPR2 = 87.11 – 0.63 = 86.48 ºC.

Step 8;
Following step 4 to get cP = 4.19 – 2.35x,
F: cPF = 4.19 – 2.35 (0.1) = 3.955 kJ/kg.K
L1: cP1 = 4.19 – 2.35 (0.133) = 3.877 kJ/kg.K
L2: cP2 = 4.19 – 2.35 (0.205) = 3.705 kJ/kg.K
L3: cP3 = 4.19 – 2.35 (0.5) = 3.015 kJ/kg.K
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 Solution:
Then the new values of the enthalpy are,
(1) H1 = HS2 + 1.884 BPR1 = 2682 + 1.884(0.35) = 2683 kJ/kg.
S1 = HS1 – hS1 = 2708 – 508 = 2200 kJ/kg.
(2) H2 = HS3 + 1.884 BPR2 = 2654 + 1.884(0.63) = 2655 kJ/kg.
S2 = H1 – hS2 = 2683 – 440 = 2243 kJ/kg.
(3) H3 = HS4 + 1.884 BPR3 = 2595 + 1.884(2.45) = 2600 kJ/kg.
S3 = H2 – hS3 = 2655– 362 = 2293 kJ/kg.

Writing a heat balance on each effect,and solving,

(1) 22680(3.955)(26.7-0)+2200S = 3.877L1(104.33-0)+(22680-L1)2683

(2) 3.877L1(104.33-0)+(22680-L1)2243=3.708L2(87.11-0)+(L1-L2)2655
(3) 3.708L2(87.11-0)+(L1-L2)2293=4536(3.015)(54.1-0)+(L2-4536)2600
L1 = 17005 kg/h L2 = 10952 L3 = 4536 S = 8960
V1 = 5675 V2 = 6053 V3 = 6416
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Solution:
Solving for q and A in each effect,
 8960 
q1  SS 1   2200 x1000  5.476 x10 W
6

 3600 
 5675 
q2  V1S 2   2243x1000  3.539 x10 W
6

 3600 
 6053 
q3  V2 S 3   2293x1000  3.855 x10 W
6

 3600 
q1 5.476 x106
A1    104.6 m 2

U1T1' 312316.77 
q2 3.539 x106
A2    105.6 m 2

U 2 T2' 198716.87 
q3 3.855x106
A3    104.9 m 2

U 3 T3' 113632.36
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Solution:

The average area Am = 105.0 m2 to use in each effect.

steam economy =

V1  V2  V3 5675  6053  6416

  2.025
S 8960

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