Double effect evaporator

1 Aim
To understand the working of a double effect evaporator to effectively use heat energy for concentrating
salts like Sodium Carbonate.

2 Objective
• To concentrate the given sodium carbonate solution.
• To evaluate at steady state the following parameters:
– Material and heat balance on the double effect evaporator
– Economy and capacity of the evaporator
– The overall heat transfer coefficient

3 Introduction
With the increase in fuel oil costs and due to the alarming increase of concentration of greenhouse gases
in the atmosphere efficient use of energy is always encouraged. A double effect evaporator, a subset of
multiple effect evaporator, is a device for effective using heat energy available in steam generated during
the process of evaporation.

In double effect evaporator, water is boiled in two vessels connected in series where the second is main-
tained at a pressure lower than the first(See figure). Since the boiling temperature of water decreases
with the decrease in pressure it is possible to use the vapor generated in the first vessel to boil the water
in the second vessel. Thus heat source is only required for the first vessel leading to conservation of fuel
and efficient use of heat energy.

4 Theory
4.1 Material and Energy Balance around an Evaporator
Material Balance

Basis: Time units

Overall Material Balance:

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 Wf = W + Wv (1)
Solute Balance:

Wf Xf = W X (2)

Figure 1: Overall Material Balance

Heat Balance
We neglect the heat losses to the surroundings and the heat of dilution we have the following equation
for heat balance:

Ws λs + Wf hf = Wv H + W h (3)

Definitions:
Capacity: Evaporator capacity can be defined as kg. of water per hour of operation.
Economy: Steam Economy is defined as kg of water evaporated per kg of steam used.
Heat Transfer Coefficient: Heat transfer can be calculated from the overall steady state heat balance.

Qs = Ws λs = U A(Ts − T ) (4)

5 Description
The set-up consists of two evaporators fitted in series. Each is made up of stainless steel tubes surrounded
by a stainless steel jacket and fitted with accumulator. Dilute solution is feed to the first evaporator.
Steam from a steam generator is supplied to evaporator to concentrate the dilute feed solution to a
desired level. The jacket is fitted with a steam trap and the condensate is collected at the end of trap.
The vapors of volatile solvent produced in the first evaporator are supplied to the second evaporator. The
vapors of volatile solvent are condensed in a shell and tube type condenser and the balance non-volatile
solute collected in the accumulator is recycled through the evaporator.

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 Figure 2: Schematic of double effect evaporator

6 Utilities required
1. Electricity supply: single phase, 220 VAC, 50 Hz, 4kW. Combined with earth connection.
2. Water supply (initial fill)

3. Floor drain required.

4. Floor area required: 2.5 m ∗ 1 m.
5. 2 kg Sodium carbonate (N a2 CO3 ).

7 Experimental procedure
Starting Procedure:

1. Prepare calibration curve of concentration vs density for N a2 CO3 -Water solution at room tem-
perature.
2. Prepare 5% solution of sodium carbonate in water.

3. Close all the valves.

4. Fill cooling water tank with water.
5. Open funnel valve and air vent valve of steam generator and fill it 3/4th with water.
6. Close both the valves.

7. Ensure that switches given on the panel are at OFF position.

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 8. Connect electric supply to the set up.
9. Set the desired steam temperature (110 to 120 0 C) by operating the increment or decrement and
set button of DTC.
10. Switch ON the heater and wait till desired temperature achieves.

11. Open funnel valve and vent valve of feed tank, fill the solution in feed tank and close both valves
after it.
12. Connect compressed air supply to the set up and adjust the pressure of the feed tank in the range
0.5 to 1 kg/cm2 by pressure regulator and pressure gauge.

13. Open feed supply valve and allow feed to enter in the evaporator by control valve and Rotameter.
14. Open steam supply valve.
15. Open vent valve before steam trap of first evaporator to release air and then close the valve.
16. Stop feed supply through Rotameter after maintaining a level of solution in front glass of first
evaporator.
17. Open recirculation valve of first evaporator and wait till observing rise in temperature of vapor.
18. Open vent valve before steam trap of second evaporator to release air and then close the valve.
19. Partially open product outlet valve of first evaporator to allow feed to enter in second evaporator.

20. Open feed supply from rotameter and adjust the flow rate of feed so that the level of solution in
the side glass of first evaporator remains constant.
21. Stop feed supply through Rotameter after maintaining a level of solution in front glass of second
evaporator.

22. Open recirculation valve of second evaporator and wait till observing rise in temperature of vapor.
23. Switch ON the pump and set the flow rate of cooling water by Rotameter.
24. Partially open the product outlet valve of second evaporator.
25. Open feed supply from Rotameter and adjust the flow rate of feed so that the level of solution in
the side glass of both evaporator remains constant.
26. Record the flow rate of stem condensed by measuring cylindering and stop watch.
27. Record the evaporator vapor condensation rate by measuring cylinder and stop watch.
28. Record the temperature and flow rate of product.

29. Record the condensation of the product from calibration curve by measuring its density at room
temperature.

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Closing Procedure:
1. When experiment is over, switch OFF the heaters.
2. Partially open the vent valve of the steam generator to release pressure.
3. Switch OFF the pump.
4. Switch OFF power supply to the panel.
5. Stop compressed air supply to the set up and release air pressure using the regulator.
6. Drain the feed tank using the drain valve provided.
7. Drain the evaporator liquid by the product outlet valve.
8. Drain the condenser using the drain valve provided.
9. Drain water from steam generator.

8 Values for calculations

Data:

ρw = (kg/m3 ) (from data book)

Observations:

Vf = ml
Mf = gms
Calibration curve to understand the level of concentration achieved in the evaporator:

S.No. Concentration of Weight of N a2 CO3 (g) Volume of N a2 CO3 Density of solution

N a2 CO3 solution (%) (ml) (g/ml)

Observation table to estimate steady state:

Time(sec) T1 T2 T3 T4 T5 T6 T7 T8 1st Effect 2nd Effect Ff Fe Product

Steam Vapor
Vs ts Vv tv Vp tp Mp
10
20
30

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9 Calculation
Mf
ρf = Vf ∗ 1000, kg/m3 = , kg/m3
Mp
ρp = Vp ∗ 1000, kg/m3 = , kg/m3
Vp ∗10−6 ∗ρp
Wp = tp , kg/s = , kg/s
Ff ∗ρf
Wf = 3600 ∗ 10−3 , kg/s = , kg/s

Wf = W p + Wv = , kg/s

For first evaporator:

Vs ∗10−6 ∗ρw
Ws = ts , kg/s = , kg/s

For second evaporator:

Vv ∗10−6 ∗ρw
Wv = tv , kg/s = , kg/s
Wv
E= Ws =

C = (Ws + Wv ) ∗ 3600 =

10 Nomenclature
ρw = Density of water at the temperature of condensate from condenser, kg/m3

Vf = Volume of feed, ml

Mf = Weight of Vf ml of feed sample, gms

T1 = Steam Inlet Temperature, 0 C

T2 = Steam Outlet Temperature, 0 C(Trap)

T3 = Feed Inlet Temperature, 0 C

T4 = Temperature of Water Vapor coming from Ist Effect, 0 C

T5 = Temperature of Water Vapor at Outlet of Ist Effect after it has passed through heat exchanger
(Steam Temperature)

T6 = Temperature of Water Vapor coming from IInd Effect and entered into condenser, 0 C

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T7 = Cold water Inlet Temperature, 0 C

T8 = Cold water Outlet Temperature, 0 C

Fc = Flow rate of cold water, LPH

Ff = Flow rate of feed, LPH

Vp = Volume Product collected in time tp , ml

Vs = Volume of steam condensate collected in time ts , ml

Vv = Volume condensate collected from condenser in time tv , ml

Vf = Volume of feed, ml

ts = Time for S, sec

tp = Time for P, sec

tv = Time for V, sec

Mp = Weight of Vp volume of product, gms

ρf = Density of feed, kg/m3

ρp = Density of product, kg/m3

Ws = Rate of steam condensation, kg/s

Wv = Rate of condensation of vapor from condenser, kg/s

Wp = Flow rate of product, kg/s

Wp = Flow rate of feed, kg/s

E= Steam economy

C= Evaporator capacity, kg/hr

λs = Heat of condensation of steam, J/kg

H= Enthalpy of water vapor leaving the system, J/kg

hs = Enthalpy of Feed, J/kg

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h= Enthalpy of concentrated liquor, J/kg

11 Discussion
Answer the following questions in context of the experiment performed by you:

1. The double effect evaporator can be extended to accommodate even more vessels to make a multiple
effect evaporator. Show qualitatively what is the maximum number of vessels that can be connected
so that the evaporator is still economically feasible.
2. Is it possible to extend the evaporator (assuming ideal operation with no losses) infinitely ? Explain
your answer in detail.
3. Comment on the expected pressure in both the first and the second evaporating chamber .

4. Arrange the temperatures T1 to T8 in ascending order theoretically. Give reasons for your answer.
5. Now compare your answer from the previous question and compare it with your observation.
Explain any deviations from your theoretical deductions.
6. Identify the major losses that reduce the efficiency of the system and discuss on ways they can be
eliminated.

12 Precautions
• Never run the apparatus if power supply is less than 180 volts and above 230 volts.

• Never switch ON mains power supply before ensuring that all the ON/OFF switches given on the
panel are at OFF position.
• Always keep apparatus free from dust.
• Drain the apparatus completely after experimentation.

13 Troubleshooting
• If electric panel is not showing the input on the mains light, check the main supply.

14 Viva Questions
1. What is evaporation? How is it different from boiling?
2. Is a liquid always in equilibrium when it is evaporating?

3. Will Gibb’s phase rule apply to a evaporating liquid? Why?

4. What is the principle of a double effect evaporator?

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 5. Do the vapor from the first effect of a evaporator come in direct contact with the solution in the
second effect?
6. If the if the solution we wish to concentrate is of salt and water, what inlet steam pressure would
you recommend so that double effect evaporator works efficiently?

7. What are steam traps? Why are they used in this experiment?

15 References
1. Kern,D.Q.,”Process Heat Transfer”,16th ed., McGraw Hill, ND, 2007, page 408-412.

2. McCabe, W.L., Smith, J.C., Harriott, P.,”Unit Operation of Chemical Engineering”, 7th
ed., McGraw Hill, NY, 2005, Page 487-488, 505-510.
3. Earle,R.L.,”Unit Operations in Food Processing”, 7th ed., 2004, Chapter-8.