19CHE213

DESIGN OF HEAT TRANSFER EQUIPMENTS

Name: Sivagurunathan R
Roll no: CB.EN.U4CHE21049

Falling Film Evaporator

Principle:
The principle of operation for a falling film evaporator involves the concentration of a
liquid solution by evaporating its solvent. It functions by creating a thin liquid film that
descends along vertical tubes, while heat is transferred from the tube walls to the
liquid film, resulting in solvent evaporation.

To initiate the process, the liquid solution is introduced at the top of the evaporator
and distributed evenly across the upper section of vertical tubes using a distributor.
As the liquid flows downward through the tubes, gravity causes it to form a thin film,
and the tube walls facilitate the transfer of heat to the liquid film.

The application of heat prompts the solvent within

the liquid film to evaporate, leaving behind a more
concentrated solution. The resulting vapor ascends
through the central region of the tubes and is
collected in a vapor separator. The concentrated
liquid that remains at the bottom of the tubes is
then gathered for storage or subsequent
processing. The continuous replenishment of the
thin liquid film is maintained through the distributor
at the top of the tubes, enabling the process to
proceed until the desired concentration is achieved.

The benefits of falling film evaporators include:

High Efficiency: Falling film evaporators have a high heat transfer rate, allowing for
rapid evaporation of large quantities of solvent or water. This translates to improved
efficiency, saving time and energy in industrial processes.
Reduced Fouling: By creating a thin liquid film on the heat transfer surface, falling
film evaporators minimize the risk of fouling or scaling. This helps maintain a
consistent heat transfer rate and reduces downtime required for cleaning or
maintenance.
 Research work on Improving Heat Transfer in
Falling Film Evaporators in Food Industries

Falling film evaporators, due to their high heat transfer coefficients, low energy loss,
rather a low holdup time, and th ability to handle high capacities have broad
applications in food industries. Thus, this kind
of evaporator is being used in the production
of temperature sensitive compounds such as
syrups. In this study, through modelling of the
falling film evaporator with the use of
Computational Fluid Dynamics (CFD) we have
tried to investigate the effect of adding flow
turbulator (baffles) on the inner side of the
tubes and assess the key parameters for
increasing the efficiency of the evaporator.
The simulation was conducted using ANSYS
FUENT.

Results indicate that placing baffles would

have a significant effect on increasing
evaporator efficiency.

The results of the parametric study showed

that by installing baffles, the amount of juice evaporation rate can be increased,
however, both the evaporator length and volume fraction can be reduced.

The results showed that the heat transfer coefficient has increased from 10000 W/m
2 °C in the case of the typical evaporator to 25000 W/m 2 °C in the case of a baffled
tube wall.

CONCLUSIONS:
This work was conducted with the aim of maximizing heat transfer by the help of
ANSYS FLUENT software to analyses computational fluid dynamics. The
geometry of the model was generated in 2D and axial symmetry, using a structural
grid. In the first step of the simulation, wall temperature was set to 8 °K different
from the saturation temperature of the juice, which is equal to 371 K and feed flow
rate of m=0.0167kg/s. After validation of the model with existing experimental
correlations, it was shown in a parametric study of the falling film evaporator
that by the installation of baffles inside the tube, it is possible to reduce evaporator
length, increase juice evaporation rate, decrease the outlet volume fraction, and
eventually reducing capital cost.

january 2019

• IRANIAN JOURNAL OF CHEMISTRY & CHEMICAL ENGINEERING-INTERNATIONAL ENGLISH EDITION 38(4):237

Rotary evaporator
The rotary evaporator, commonly referred to as a rotavap, is a versatile piece of
equipment used in laboratories for solvent removal through evaporation under
reduced pressure. This report provides an overview of the principle behind the rotary
evaporator, its applications, and a step-by-step operating procedure.

Principle: The rotary evaporator operates by utilizing reduced pressure to

lower the boiling point of the solvent. The sample, contained in a round bottom flask,
is subjected to rotation, which increases the
liquid's surface area and enhances the rate of
evaporation. The solvent vapor generated
travels into a water-cooled condenser, where
it condenses and collects in a separate
receiving flask. This process allows for
solvent removal, leaving behind a
concentrated compound in the round bottom
flask.

Applications: The rotary evaporator is

commonly employed for removing solvents with low boiling points, such as ethyl
acetate (EtOAc) and n-hexane, from a sample. It is widely used in organic
laboratories due to its simplicity, relatively quick solvent removal (depending on
volume and solvent), and widespread availability. Rotary evaporation is more
efficient compared to evaporation under atmospheric pressure.

Operating Procedure:
▪ Turn on the water bath and set it to the desired temperature.
▪ Ensure a continuous flow of water into the water condenser.
▪ Connect the round bottom flask to the rotavap securely using a clip to prevent
slippage.
▪ Turn on the vacuum pump and promptly close the tap to establish reduced
pressure in the system.
▪ Start the rotation of the round bottom flask.
▪ The round bottom flask can now be safely removed from the rotavap.

Conclusion: The rotary evaporator is a valuable tool for solvent removal in

laboratory settings. By utilizing reduced pressure and rotation, it enables efficient
evaporation of solvents with low boiling points. This report has provided an
understanding of the rotary evaporator's principle, its applications, and a detailed
operating procedure to ensure safe and effective operation.
Agitated Thin Film Evaporator
Introduction: This report provides an overview of the Agitated Thin Film
Evaporator (ATFE), its principle of operation, special features, and a comprehensive
list of applications. The ATFE is a mechanically
aided evaporator that utilizes turbulent flows and
high-speed rotors to achieve efficient heat and mass
transfer, making it suitable for a wide range of
industries and processes.

Principle of Operation: The ATFE

operates by generating turbulent flows with the help
of high-speed rotors. The liquid feed enters the
evaporator and is spread across the thermal surface
of a tube using mechanical blades. The turbulent
flow generated by the rotor blades forms a thin film of
the liquid on the tube surface, enabling intense heat
and mass transfer. This turbulence facilitates the
efficient disengagement of the liquid and vapors,
concentrating the liquid and reducing fouling on the
heat transfer surfaces.

Special Features:
▪ High heat transfer rate with shorter drying time.
▪ Wide range of operating pressures, from vacuum to atmospheric.
▪ Self-cleaning heating surfaces with minimal maintenance requirements.
▪ Constant renewal of the liquid film near the wall, reducing fouling.
▪ Full recovery of solvents with inert process conditions.

Applications: The Agitated Thin Film Evaporator (ATFE) finds application in

various industries and processes, including but not limited to:
▪ Concentration of Pharmaceutical Bulk Drugs.
▪ Vacuum Distillation of Intermediates, Fine Chemicals, Glycols, and Used
Lubricating Oils.
▪ Concentration of Oleoresins, Enzymes, Milk Products, Juices, and Sugars.
▪ Stripping of Silicone Oils, Pesticides, Plasticizers, and Monomers.
▪ Recovery of Contaminated Solvents and Products from Residue.
▪ Evaporation of Bio-diesel and Glycerin.

Conclusion: The Agitated Thin Film Evaporator (ATFE) is a highly efficient

and versatile equipment used for concentration, distillation, and solvent recovery in
various industries. Its principle of operation, special features, and wide range of
applications make it a valuable asset in processes requiring efficient heat and mass
transfer, reduced fouling, and high product quality control.
 Air-Cooled Condensers
Research work on Comparative Analysis of Air-
Cooled for Geothermal Power Plants
A. Chiasson, in Geothermal Power Generation, 2016

Introduction: Geothermal power plants utilize condensers to reject heat

directly to the ambient air in air-cooled systems, which offers advantages over water-
cooled condensers, particularly in regions where water scarcity is a concern, such as
desert areas in the western United States. This report aims to provide a
comprehensive analysis of air-cooled condensers and their performance relative to
water-cooled condensers in geothermal power plants.

Advantages of Air-Cooled
Condensers: 2.1 Water Conservation: Air-
cooled condensers eliminate the need for cooling
water, making them an ideal choice in water-
scarce areas. 2.2 Operational Simplicity: Absence
of cooling towers and associated maintenance
reduces complexity and operational costs. 2.3
Environmental Impact: Air-cooled systems have a
lower environmental impact due to the absence of
water withdrawal and discharge.

Disadvantages of Air-Cooled Condensers: Higher

Capital Costs: Air-cooled systems generally require larger heat rejection equipment
compared to water-cooled systems, resulting in higher upfront costs. Lower Heat
Transfer Efficiency: Water is a superior heat transfer medium compared to air,
necessitating larger heat rejection equipment. Increased Parasitic Losses: Air-cooled
systems have higher fan power requirements, leading to higher parasitic losses
compared to water-cooled systems.Performance in Hot Weather: Air-cooled systems
may experience reduced efficiency in hot summer weather due to increased ambient
air temperatures.

Conclusion: Air-cooled condensers offer significant advantages in

geothermal power plants located in water-scarce regions. Despite higher capital
costs and potential performance limitations in hot weather, air-cooled systems
eliminate the need for cooling water and provide operational simplicity. Future
research should focus on improving heat rejection equipment efficiency and
exploring innovative approaches to enhance heat transfer in air-cooled systems.
Water-Cooled Condensers
Introduction: Water-cooled condensers play a crucial role in industrial chiller
systems by removing heat generated during various processes. This report provides
an overview of water-cooled condensers, their working principles, benefits, and
applications across different industries.

Water-Cooled Condenser Function: Water-cooled

condensers act as specialized heat
exchangers, transferring heat from refrigerant
vapor to water. The condenser's design allows
it to convert hot, high-pressure gas from the
compressor into a liquid state. The heat
rejection loop dissipates the condenser heat
to the surrounding environment via water,
enabling efficient cooling.

Types of Water-Cooled
Condensers
▪ Tube in Tube (Double-Tube) Condensers: These condensers maintain
countercurrent flows between the refrigerant and water tubes, achieving high
heat transfer efficiencies.
▪ Shell and Coil Condensers: Consisting of coils enclosed in a welded shell, this
compact and cost-effective condenser type can be arranged horizontally or
vertically.
▪ Shell and Tube Condensers: Water flows through the tubes while refrigerant
flows in the shell. Fins can be added to the shell for improved heat transfer.
They are commonly used in large chemical processing plants.

Applications of Water-Cooled Condensers: Water-

cooled condensers find applications in various industries, including: Medical
Manufacturing, Dairy Production ,Food Processing ,Brewing,Drying Processes
,Process Heating,Space Heating,Domestic Hot Water .

Conclusion: Water-cooled condensers play a vital role in industrial chiller

systems, effectively removing heat generated during various processes. Their
efficient heat transfer capabilities, energy efficiency, and compact size make them
suitable for a wide range of applications across industries. Understanding the
working principles and benefits of water-cooled condensers helps in optimizing
cooling systems and improving overall operational efficiency in industrial settings.
Evaporative Condensers
Introduction: Evaporative condensers are cooling units integrated into
cooling towers, designed to extract heat from refrigerants through a combination of
evaporation and heat exchange with water and air. This report provides an overview
of the construction, working principles, and advantages of evaporative condensers.

Construction:
▪ Evaporative condensers consist of a coil, water distribution system, drift
eliminators, and a fan.
▪ The coil, made of continuous tubing
without welded joints, carries the
refrigerant and is located in the upper
part of the unit.
▪ Water is sprayed onto the coil from the
top, forming a thin film around the
tubes.
▪ The air, induced upwards by the fan,
passes through the coil, causing
evaporation of a small quantity of
water.
▪ Drift eliminators prevent water droplets from escaping with the air.
▪ The saturated air is forced out of the condenser by the fan.

Working:
The refrigerant in the coil transfers heat to the water film due to the temperature
difference.
▪ Evaporative cooling takes place as a small quantity of water evaporates from
the film, absorbing heat from the refrigerant.
▪ The evaporation process increases the rate of heat transfer, allowing the
refrigeration system to operate at lower condensing temperatures.
▪ The water spray counteracts the airflow, acting as a cooling tower.
▪ The air's primary role is to enhance water evaporation, increasing the cooling
efficiency.
▪ Optimal air flow rates, typically ranging from 350 to 500 m3/h per ton of
refrigeration capacity, are required.

Benefits of Evaporative Condensers:1) Continuous Coil

Design: The absence of welded joints in the coil ensures robustness and minimizes
the risk of leakage. 2) Corrosion Resistance: Evaporative condensers are
constructed using corrosion-resistant materials, resulting in a long lifespan. 3) Clog-
Free Operation: Large-diameter laminar flow nozzles are used to distribute water,
reducing the risk of clogging.