CASE STUDY

WORKING OF FORCED FEED

EVAPORATORS

Submitted by:

TEMEA18 - SONAR GITESH P

TEMEA19 - STEVE VINOD T

TEMEA13 - IMRAN SHAIKH

Subject Incharge:
Dr. Kavita Dhanawade

HVAC System Upgrade

Background:

Forced feed evaporators are vital components in numerous industrial processes,

particularly in sectors such as food and beverage, chemical processing, and
wastewater treatment. These evaporators are designed to concentrate solutions
by removing water through evaporation, thus increasing the concentration of
solids in the remaining liquid. The forced feed mechanism involves pumping
the solution into the evaporator at a controlled rate, ensuring continuous
operation and efficient concentration.

Objective:

The objective of this case study is to evaluate the performance of forced feed
evaporators in a chemical processing plant and identify opportunities for
optimization. Specifically, the study aims to assess the energy efficiency,
concentration effectiveness, and operational reliability of the evaporators within
the given production environment.

Methodology:

1. Data Collection: Gather operational data including flow rates,

temperatures, pressure levels, and energy consumption over a defined period.
2. Performance Analysis: Evaluate the efficiency of the forced feed
evaporators in terms of energy consumption per unit of product output and
concentration achieved.
3. Comparative Study: Compare the performance metrics with industry
standards and best practices to identify areas for improvement.
4. Operational Assessment: Assess the reliability of the evaporators by
analyzing downtime, maintenance requirements, and any operational challenges
encountered.
5. Stakeholder Interviews: Interview plant operators and maintenance
personnel to gather insights into operational issues and potential optimization
opportunities.
Types of Forced Feed Evaporators:
1. Falling Film Evaporators
2. Plate Evaporators
3. Forced Circulation Evaporators

1. Falling Film Evaporators

Falling film evaporators are a type of evaporator used in industries like

food, pharmaceuticals, and chemical processing to concentrate solutions. The
basic principle involves heating a liquid feed to its boiling point and then
passing it through tubes or plates as a thin film under vacuum conditions. This
design enhances heat transfer efficiency and minimizes residence time, reducing
the risk of thermal degradation of sensitive products.

Falling film evaporators are known for their high efficiency in

concentrating solutions due to their ability to provide a large heat transfer area,
short residence time, and low energy consumption compared to other types of
evaporators. However, achieving optimal efficiency requires careful
consideration of various factors and continuous monitoring and adjustment of
operating conditions.
 2. Plate Evaporators

Plate evaporators, also known as plate heat exchangers, are a type of

evaporator that uses a series of metal plates to facilitate heat transfer between
two fluids. They are widely used in industries such as food processing, chemical
processing, HVAC systems, and power generation.

Plate evaporators are favoured for their high efficiency, compact design,
and versatility in various industrial applications. They are capable of achieving
high rates of evaporation while consuming relatively low energy compared to
other types of evaporators. However, the efficiency of a plate evaporator can
vary depending on factors such as design, operating conditions, fluid properties,
and maintenance practices.

3. Forced Circulation Evaporators

Forced circulation evaporators, also known as forced feed evaporators,

are a type of evaporator used in industries for concentrating liquids. They
operate by continuously circulating the liquid feed through the evaporator
system using a pump, ensuring that the liquid is constantly in motion. This
circulation mechanism helps to prevent the formation of scale or deposits on the
heat transfer surfaces and promotes efficient heat transfer, resulting in higher
evaporation rates.
Comparing Evaporators:
Comparing three types of evaporators: Falling Film Evaporators, Plate
Evaporators (Plate Heat Exchangers), and Forced Circulation Evaporators,
across several key aspects:

1. Operating Principle :
- Falling Film Evaporators: Operate by allowing the liquid feed to form a thin
film along the evaporator surface, promoting efficient heat transfer and
evaporation under vacuum conditions.
- Plate Evaporators: Utilize a series of metal plates with alternating channels
for the liquid feed and heating medium, facilitating heat transfer through
turbulent flow to achieve evaporation.
- Forced Circulation Evaporators: Involve continuous circulation of the liquid
feed using a pump, ensuring constant motion and efficient heat transfer for
evaporation.

2. Heat Transfer Efficiency :

- Falling Film Evaporators: Known for efficient heat transfer due to the thin
film formation, maximizing the surface area for evaporation.
- Plate Evaporators: Offer high heat transfer efficiency with their large surface
area and turbulent flow within channels, promoting effective heat exchange.
- Forced Circulation Evaporators: Provide efficient heat transfer through
continuous circulation, preventing fouling and maintaining high heat transfer
rates.

3. Energy Consumption :
- Falling Film Evaporators: Typically energy-efficient due to the thin film
evaporation process and the use of vacuum conditions to reduce the boiling
point of the liquid.
- Plate Evaporators: Energy-efficient due to their compact design, large heat
transfer surface area, and precise temperature control.
- Forced Circulation Evaporators: Energy-efficient with continuous circulation
preventing fouling and allowing for precise temperature control, leading to
shorter processing times.

4. Scale and Fouling Prevention :

- Falling Film Evaporators: Can be prone to fouling if the liquid contains
suspended solids or high levels of impurities.
- Plate Evaporators: Less prone to fouling due to the turbulent flow within
channels and the ability to handle liquids with particulates.
- Forced Circulation Evaporators: Less susceptible to fouling due to
continuous circulation preventing the buildup of scale or deposits.
5. Flexibility :
- Falling Film Evaporators: Versatile in handling heat-sensitive liquids and
suitable for continuous processing applications.
- Plate Evaporators: Flexible in terms of capacity and can be easily scaled up
or down to accommodate different production requirements.
- Forced Circulation Evaporators: Versatile and can handle a wide range of
liquid feeds with varying viscosities, concentrations, and temperature
requirements.

6. Application Areas :
- Falling Film Evaporators: Widely used in industries like food processing,
dairy, pharmaceuticals, and chemicals for concentration and purification.
- Plate Evaporators: Commonly used in food processing, HVAC systems,
power generation, and chemical processing for heat exchange and evaporation.
- Forced Circulation Evaporators: Applied in industries requiring efficient
liquid concentration processes such as food processing, chemical
manufacturing, and wastewater treatment.

Results:

1. Energy Efficiency: The forced feed evaporators demonstrated moderate

energy efficiency, with energy consumption slightly above industry averages for
similar processes.
2. Concentration Effectiveness: Concentration levels achieved by the
evaporators met production requirements but showed room for improvement in
terms of throughput and speed.
3. Operational Reliability: The evaporators experienced frequent downtime
due to maintenance issues, primarily related to pump failures and heat
exchanger fouling.
4. Stakeholder Feedback: Interviews revealed concerns regarding the
complexity of the control system and the need for better training to optimize
operational parameters effectively.
Efficiency of the Evaporators :
According to the survey and the case study conducted, falling film evaporators
are often considered highly efficient, it's essential to note that the efficiency of
any evaporator depends on factors such as design, operating conditions, and
maintenance practices. Plate evaporators and forced circulation evaporators can
also be highly efficient depending on the specific requirements of the
application. Therefore, the choice of the most efficient evaporator ultimately
depends on a careful evaluation of these factors in the context of the intended
use.

Overall, each type of evaporator has its advantages and is suited to different
applications based on factors like heat transfer requirements, energy efficiency,
scalability, and the properties of the liquid feed. Understanding these differences
can help in selecting the most suitable evaporator for specific industrial
processes.

Recommendations:

1. Optimize Control Systems: Implement advanced control algorithms to

improve process stability and optimize energy consumption.
2. Enhance Maintenance Practices: Develop a proactive maintenance
schedule focusing on regular cleaning of heat exchangers and preventive
maintenance of pumps to minimize downtime.
3. Training Programs: Provide comprehensive training for operators and
maintenance staff to enhance their understanding of the equipment and optimize
operational parameters effectively.
4. Upgrade Equipment: Consider upgrading pumps and heat exchangers to
newer, more efficient models to improve reliability and performance.
Conclusion:

Forced feed evaporators play a critical role in industrial processes requiring

concentration of solutions. This case study highlighted opportunities for
optimization in energy efficiency, concentration effectiveness, and operational
reliability. By implementing recommended measures such as upgrading
equipment, optimizing control systems, and enhancing maintenance practices,
the chemical processing plant can improve overall performance, reduce
downtime, and achieve greater operational efficiency.