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MODIFICATION TO THE EVAPORATOR STATION


IN PREPARATION FOR A CO-GENERATION
FACTORY AT BROADWATER MILL
Conference Paper January 2003
DOI: 10.13140/RG.2.1.2260.7208

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Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________

MODIFICATION TO THE EVAPORATOR STATION IN PREPARATION


FOR A CO-GENERATION FACTORY AT BROADWATER MILL
By
D. MOLLER, S. WAGNER, R. BROADFOOT1 and D.W. STEPHENS1
New South Wales Sugar Milling Co-Operative, Broadwater, NSW
1
Sugar Research Institute, Mackay Qld
KEYWORDS: Cogeneration, Evaporator, Expansion,
Steam Efficiency, Vapour Bleeding.
Abstract
Broadwater Sugar Mill commissioned a 4000 m2 SRI-designed Roberts evaporator for
the 2002 crush. The evaporator is the crucial first stage of a cogeneration plant, which
will comprise a high-pressure boiler and turbo-alternator producing renewable electrical
energy for sale. To achieve this, steam consumption by all process plant will need to be
minimised and condensate quality for boiler feed water will need to be guaranteed. This
paper describes the installation, control system and operating performance of the new
SRI Roberts evaporator and the associated arrangement of vapour bleeding to pans and
heaters used to optimise the steam efficiency in the 2002 season.
Introduction
Broadwater Sugar Mill implemented several factory changes prior to the 2002 season in
preparation for the installation of a cogeneration plant. The major changes were to install a new #1
SRI Roberts evaporator and to modify the vapour bleed arrangements.
Factory layout prior to the 2002 season
Evaporators and heaters
Prior to 2002, the evaporators and heaters at Broadwater Sugar Mill consisted of the
equipment and layout shown in Tables 1 and 2 and Figure 1.
Table 1Pre 2002 evaporator configuration.
Position in the set

Number of vessels

Heating surface area (m2)

1570

1360

1512

1521

1360

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________
Table 2Pre 2002 juice heater configuration.
Duty

Number of heaters

Total surface area (m2)

Pre primary

400

Primary

186 +139 = 325

#3 Vapour/LP

Secondary

400 + 400 = 800

#2 Vapour

Tertiary

3 * 85 = 255

ESJ heater

151

Heating source
#4 Vapour

LP
#1 Vapour

The vapour flows to the pre primary and the secondary heaters were uncontrolled, while the
primary and tertiary heater temperature control was achieved using modulating valves on exhaust
(low pressure (LP)) steam and #3 vapour. The exhaust steam pressure to the evaporators was
maintained at 250 kPa (abs). Prior to the 2002 season, the pan stage steam supply was a separate
steam main to that supplying the No. 1 evaporator, and this was controlled to a maximum of 200
kPa (abs). The tertiary heater also took its steam supply from the pan stage mains.

Fig. 1Pre 2002 evaporator and heater configuration.

Condensate handling
The condensate from each of the heaters was pumped to the process water tank for use
throughout the factory. The condensate from #1 evaporator was pumped directly to the boiler water
storage tank, if the control parameters were metthese being calandria pressure and conductivity.
If either of these two conditions was not reached, the condensate was dumped to the hotwell
where the conductivity was again measured. If the conductivity from the hotwell was below the set
point, the condensate was directed to the boiler water storage or to the process water storage, as
determined by the level in the boiler water storage tank. If the conductivity of the condensate in the
hotwell was above the set point, the condensate was directed to the process water storage tank.
The condensates from #2 and #3 evaporators were sent directly to the hotwell where the final
destination was determined by the conductivity. The condensate from #4 and #5 evaporators was
pumped directly to the maceration tank. Any excess water from the maceration tank overflowed to
the process water tank.

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________
Changes for the 2002 season
Evaporators and heaters
For the 2002 season, a new SRI designed 4000 m2 evaporator was installed as the first
evaporator in the set and the three old #3 evaporators were removed from service, giving the
configuration shown in Table 3.
Table 32002 evaporator configuration for the 2002 season.
Position in the set

Number of vessels

Total surface area (m2)

4000

1570

1360

1521

1360

Description of the SRI evaporator design


The main features of the SRI Roberts design evaporator installed at the first effect position
are:

central downtake for the preferential collection of outflowing juice;

numerous small downtakes distributed among the heating tubes of the calandria;

peripheral feed of juice near the outer edge of the vesselthis feed arrangement,
combined with the central juice off-take, provides a uniform flow of juice within the
vessel;

steam supply to the full circumference of the vessel via a steam annulus around the
outer calandria wallthere are two diametrically opposed steam supply pipes; and

central off-takes for removal of condensate and noxious gases.

Further descriptions of evaporator designs and modelling work undertaken by SRI are
provided by Steindl (2003) and Wright et al. (2003).
Operating arrangements
Low pressure exhaust steam is supplied to the calandria of the #1 evaporator at approximately
240 kPa (abs) (saturation temperature 126.0oC) and the first vapour pressure is normally 195 kPa
(abs) (saturation temperature 119.5oC). The LP steam supplied to the evaporator station contains
superheat of 2040oC. The ESJ temperature is normally 9798oC and can be passed through a preheater running on first vapour to raise its temperature (the pre-heater is not normally used). The ESJ
flow rate is typically between 280 and 380 m3.h1 with an ESJ%cane of approximately 130%. The
ESJ flow rate and the #1 condensate flow rate are measured by magnetic flow meters and the
headspace and calandria pressures are measured by pressure transmitters.

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________

Pan Stage Steam Main

Fig. 22002 evaporator control schematic.

The vapour from #1 evaporator is also used for the supply of pan stage steam for normal
operations. The pan stage can also be supplied with LP steam through a reducing valve if the
evaporators are shut down. In Figure 2, the pan stage steam main can be seen with the steam supply
from either #1 vapour or LP steam. At the end of the pan stage steam main, there is a vent to control
the #1 vapour pressure in the pan stage steam/vapour main.
For the 2002 season, the pan stage vapour pressure was controlled to a maximum of 190 kPa
(abs) through the use of the controlled vent at the pan floor. The only change to the heater
configuration for the 2002 season was that the tertiary heater was supplied from the pan
steam/vapour main in the configuration shown in Figure 3. Steam pressure to the evaporators set is
still maintained at 250 kPa (abs).

Fig. 3Evaporator and heater configuration for the 2002 season.

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________
Condensate handling
The condensate from each of the heaters is pumped to the process water tank for use
throughout the factory and the condensate from #1 evaporator is controlled in the same manner as
before 2002. The condensate from #2 is sent directly to the hotwell. If the conductivity is below set
point, a measured amount of the condensate may be directed to the low-pressure boiler feedwater
tank. This condensate is used to account for all steam and boiler blowdown losses.
The process water storage tank is now used as the only hot water storage tank for the factory.
Maceration, pan stage water, fugal water and filter wash water are all sourced from this tank.
The #3 evaporator condensate is sent directly to the process water storage tank, while the
condensate from #4 evaporator is sent to a small header tank, from which the water is cooled in a
heat exchanger to be used for cool process water (e.g. flocculant mixing). The condensate from #5
evaporator is also directed to a small header tank and then used for warm hosing water. This water
is controlled to an appropriate temperature to reduce the risk of injury to the people using this warm
water. Both the small header tanks for the #4 and #5 condensates overflow to the process water
storage.
The condensate from each of the evaporators is measured using a magnetic flowmeter. These
data are used for the calculation of on-line heat transfer coefficients.
Performance during the 2002 season
Performance of the SRI designed #1 evaporator
The performance of the new #1 evaporator was evaluated by SRI staff during two periods of
the season (August and November). Table 4 presents averaged data from the trials conducted in
August 2002.
Table 4Averaged heat transfer performance data for the SRI evaporator in August 2002.
Parameter
Juice brix at inlet
ESJ temperature, oC
Juice brix at outlet
Condensate volumetric flow rate, m3.h1
Calandria pressure, kPa abs
Headspace pressure, kPa abs
Effective temperature difference, K
Heat transfer coefficient (HTC), W.m2.K1
Heat transfer ratio (HTR)
Vapour condensation coefficient (VCC), kg.h1.m2

Two days following


a caustic clean*
11.9
97.4
18.1
131.4
235.4
193.1
5.9
3262
1.04
30.9

After 12 days
operation since a
caustic clean
13.8
98.2
20.0
129.5
245.1
195.5
6.78
2807
0.92
30.4

*The clean was not very effective and a thin coating of very light grey scale covered the
tubes over the whole length and the cross-section of the vessel.

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________
The parameters defining the heat transfer performance are:

Heat transfer coefficient (HTC) (calculated on the heat flux in the condensate flow, the
temperature difference between the head space vapour temperature and the boiling
temperature of the juice, and the area of the vessel calculated according to the industry
standard (BSES, 1984)).

Heat transfer ratio (HTR). HTR is the ratio of the measured HTC value to that predicted
by an industry average HTC correlation (which is a function of juice brix and
temperature). For all except first effect vessels, the HTC values on which the correlation
is based are boosted by the flash of vapour with the entering juice.

Effective temperature difference (saturated vapour temperature in the calandria minus


the boiling temperature of the juice. The boiling temperature of the juice is estimated
from the saturated vapour temperature in the head space of the vessel plus the predicted
boiling point elevation of the juice).

Vapour condensation coefficient (VCC). This coefficient is the steam supply rate to the
evaporator divided by the heat transfer area.
The main conclusions from the evaluation programs are:

(1)

The heat transfer performance of the evaporator is good with a heat transfer coefficient
ranging from about 3250 W.m2.K1 after a clean to about 2800 W.m2.K1 after two weeks
of operation. These values correspond to heat transfer ratios of 1.04 when clean, reducing to
0.92 after two weeks of operation. This is considered to be very good for a #1 vessel which
commonly has a HTR value lower than 1.0 owing to the need to preheat ESJ to the boiling
point. The #1 evaporator at Broadwater Mill preheats the ESJ by approximately 20oC which
equates to about 8% to 9% of the total heat flux being used for sensible heating of the juice.
Of particular importance is the low effective temperature difference for the evaporator,
ranging from 5.9 K when clean to 6.8 K after two weeks of operation. These are very low
values, particularly for VCC values of 30 kg.h1.m2. For a cogeneration factory with the pan
stage operating on vapour 1, the low values of temperature difference are beneficial as they
allow bleed vapour to be supplied to the pan stage at a high saturation temperature.
A few comments on the magnitude of the temperature difference are relevant. The
magnitude of the temperature difference would be increased by the need to preheat the ESJ
and be reduced due to operation of the #1 evaporator at a high head space pressure. The high
head space pressure would reduce (slightly) the viscosity of the boiling juice relative to the
usual evaporation conditions in a first effect vessel.

(2)

The flow pattern of juice above the top tube plate was quite changeable and exhibited
several different patterns. These included the formation of clockwise, anticlockwise, back
and forth and no wave (flat) patterns. The cause of the different wave actions was not
definitively established, but factors which appeared to influence the pattern included juice
level, temperature of the ESJ feed and fluctuations in LP steam supply pressure.

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________
Under no wave conditions, the boiling action of the juice above the top tube plate was
observed to be very uniform. This confirmed that the flow arrangements for steam,
condensate and noxious gases produced a uniform condensation of steam throughout the
vessel. Viewing of the boiling surface showed no evidence of any asymmetrical distribution
of ESJ among the peripheral feed points. A froth head was observed to form above the small
downtakes indicating that there was (generally) a downward flow of juice in these
downtakes. At normal juice operating level, a froth head is established above the central
downtake.
(3)

The recommended minimum safe operating level corresponds to a static level of 46% of
the tube length. This boiling height ensures that there is adequate buffer volume held in #1
evaporator to accommodate the fluctuations in juice flow during normal operation of the
control system.

(4)

Sampling of juice from within the vessel was undertaken to allow the brix of the juice to be
measured at two different locations. These locations were at a radius of 1020 mm from the
centre of the vessel (location A) and at a radius of 2040 mm from the centre of the vessel
(location B). Both these sampling positions were on a radiant and between the juice feed
position and the central outlet. Juice samples were withdrawn continuously over a 30-minute
period using a variable speed peristaltic pump. Samples of ESJ and the juice outlet from the
vessel were also obtained during the test period.
The results of a brix sampling test (refer Figure 4) show that, at the test locations within the
base of the vessel, the brix of the juice is intermediate between the inlet and outlet brix.
Importantly, in terms of enhancing heat transfer efficiency, the juice flow path in the vessel
ensures that the juice within the base of the vessel is at a lower brix than the brix of the
outflowing juice.
20
ESJ
Point A

19

Point B

18

Oulet

Brix of juice

17
16
15
14
13
12
11
10
0

10

15

20

Time from test start (minutes)

Fig.4Plot of brix data obtained at different locations on the SRI evaporator


during a 30-minute interval.

25

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________
Heat transfer coefficients on #1 evaporator during the 2002 season
Figure 5 shows the calculated HTC values for the new evaporator for the period late August
to late November 2002. The graph is broken up into four periods to explain the different operating
circumstances for the evaporator during the season.

-2

Heat transfer coefficient, W.m .K

-1

4000
3500

Period 1

Period 2

Period 3

Period 4

3000
2500
2000
1500
1000
500
0
27.Aug

11.Sep

26.Sep

11.Oct

26.Oct

10.Nov

25.Nov

Fig. 5Heat transfer coefficients for #1 evaporator during the latter part of the 2002 season.

Period 1
In this period, the rapid drop in HTC was the result of a substantial quantity of final molasses
being recycled into the ESJ tank. This happened on the day following a maintenance break. The
evaporator was still performing well but there was a higher than normal temperature drop across the
vessel which led to the reduction in heat transfer. Due to the #1 vapour pressure being controlled
through the vent at the pan floor, this drop in performance had little effect on the rest of the set.
The #1 and #2 evaporators were given a sulfamic acid boil at the next maintenance period.
Period 2
In this period, little decline in HTC values was evident.
Period 3
HTC values gradually declined throughout the period. During this time the evaporator cleans
were only undertaken using standard caustic formulations. The peaks in HTC values correspond to
evaporator cleaning.
Period 4
Following the substantial decline in the HTC values during period 3, sulfamic acid was used
to clean the vessels. It can be seen that the HTC is maintained at a high level throughout this period.

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________
Control strategy for the 2002 season
Overview
The strategy for the 2002 season was to use the #1 evaporator as the only user of LP steam in
the factory. This was to guarantee condensate quality and to maximise the factory efficiency. The
pans ran on #1st vapour and during maintenance days or evaporator cleaning operated on LP steam.
The heaters used vapour with the primary and tertiary heaters being able to be switched to LP steam
during an evaporator start up.
The steam valve on #1 evaporator is operated at 100% open at all times during normal
operation. When the evaporators are being shut down, the pan steam main is isolated from #1
vapour and supplied with reduced LP steam.
ESJ processing rate / ESJ level control
To control the juice rate through the evaporators the ESJ level is used to regulate a control
valve on the vapour line between #1 and #2 evaporators. Due to problems with cycling of the brix
in #5 vessel, the control was changed. The ESJ tank level is now used to regulate the calandria
pressure set point for #2 evaporator. The vapour control valve between #1 and #2 vessels now
modulates between 1060% opening to achieve the calandria pressure set point. The limit of 10%
was chosen to ensure that there was sufficient vapour flow to keep the evaporator set boiling. If the
level in the ESJ tank cannot be maintained with this valve setting, water is added to the ESJ tank.
The upper limit of 60% valve opening was chosen, as near maximum vapour flow occurs at this
opening.
Evaporator level and brix control
The preceding feed valve on each vessel is used for level control, except for #5 vessel in
which the feed valve is used to control the brix and the liquor pump is used to control the level. The
brix is measured using a mass flowmeter on the sample line and the total liquor flow is measured
using a magnetic flowmeter.
Condensate control
Condensate from each of the evaporators flows directly to a separate condensate monte. The
level in each monte is measured using a differential pressure transmitter and controlled using a
modulating butterfly valve. Condensate flow is measured using a magnetic flowmeter, located
between the pump and the control valve. The condensate flow measurement has proved to be an
invaluable tool in the operation of the evaporators, both during caustic boiling and normal
operation. The flow measurement also provides a quantitative measurement for determining the
HTC performance of each of the evaporators throughout the season.
Chemical cleaning of the evaporators during the 2002 season
The standard caustic cleaning regime at Broadwater Mill is a maintenance/cleaning stop
every two weeks. The aim is to contain the stop to eight hours; however, due to a number of

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________
problems with the boilers and the injection water mains during 2002, the length of the stoppages
tended to be slightly longer. The caustic cleaning solution used is a standard caustic formulation.
The caustic formulation is used due to a significant calcium oxalate scaling problem in the last
two effects. This method of cleaning was also used for the two seasons prior to the 2002 season.
During the caustic boil, the condensates from all the evaporators, except #1 are recycled into
the evaporators to assist in maintaining the boiling levels. The caustic is recirculated from #5 to #1
evaporator using the liquor pump. Any additional water is added to the feed line of #1 evaporator to
maintain its level.
Prior to 2002, it was found to be necessary to boil the first effects with acid in order to remove
a build-up of calcium scale. The caustic recirculation was set up so that the caustic could be
recirculated back to #1 evaporator for a normal caustic boil, or back to #3 evaporator to allow #1
and #2 evaporators to be boiled with acid.
An acid recirculation pump was also installed to allow acid from #2 evaporator to be pumped
back to #1 while the caustic mixture was being boiled in #3, #4 and #5.
Sulfamic acid was boiled three times during the 2002 season. However, after analysis of the
HTC data in Figure 5 for the #1 vessel, it may be necessary to undertake an acid boil on a more
frequent basis.
Problems and solutions
Heat transfer decline in #1 and #2 evaporators
In order to maintain a high heat transfer efficiency throughout the season, cleaning with
sulfamic acid in #1 and #2 evaporators will be used more frequently.
Heater temperatures
The small temperature difference across the #1 evaporator and the unrestricted flow of vapour
to the secondary and pre-primary heaters has resulted in these heaters achieving higher juice
temperatures than desired. At times, the juice from both of these heaters is hotter than the set point
of the following heater, resulting in a loss of control.
For the 2003 season, vapour control valves will be installed in the #4 vapour line to the preprimary heater and in the #2 vapour line to the secondary heater to control the juice temperatures
from each of the heaters.
Condensate flashing from #1 evaporator
The temperature of the condensate being pumped from #1 evaporator was approximately 116
to 119oC. When this was pumped into the boiler water storage tank, it flashed violently and, at times
caused the walls of the tank to shake considerably. The energy liberated by the flashing caused the
tanks contents to boil. To reduce the amount of flashing in the tank a heat exchanger was installed
between the pump and the tank to reduce the temperature of the condensate.

Moller, D., Wagner, S., Broadfoot, R. and Stephens, D.W.


Proc. Aust. Soc. Sugar Cane Technol., Vol. 25, 2003
________________________________________________________________________________
For the 2003 season, this heat source may be used in the ESJ heater to preheat the ESJ before
entering #1 evaporator.
Condensate pumping
Varying degrees of success were experienced with the pumping of the condensate from the
final three evaporators during commissioning. The high vacuum in the calandrias, combined with
vapour locking, resulted in waterlogging of the calandrias.
Balance lines were installed from the top of the montes to the top of the calandrias to equalise
the vacuum and break the vapour lock. After these lines were installed, the system worked without
any further problems.
Conclusions
The preparations at Broadwater Sugar Mill for the implementation of cogeneration have
progressed well during the 2002 season. The commissioning of the 4000 m2 SRI evaporator at #1
effect position has been very successful with operation demonstrating small temperature differences
on vapour across the unit and the ability to supply vapour at 190 kPa abs for pan stage operation.
During the 2002 season, several operational and control issues for the factory have been
successfully addressed.
Acknowledgments
The provision of facilities on the SRI evaporator vessel by Walkers Ltd to assist with the test
program is acknowledged. The Department of State Development of the Queensland Government
provided funding assistance to allow SRI to undertake the performance evaluation of the new SRI
evaporator.
The assistance of the staff of NSW Sugar Milling Co-op Ltd in the preparation of this paper
and in the commissioning of the evaporator are gratefully acknowledged
REFERENCES
BSES (1984). Laboratory Manual for Australian Sugar Mills, Volume 1.
Steindl, R.J. (2003). Improved Roberts evaporator performance through circulation modelling with
CFD. Proc. Aust. Soc. Sugar Cane Technol., 25: (These Proceedings).
Wright, P.G., Silva, T.A. and Pennisi, S.N. (2003). The SRI evaporatora new Roberts design.
Proc. Aust. Soc. Sugar Cane Technol., 25: (These Proceedings).

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