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CITATIONS
READS
32
6 authors, including:
R. Broadfoot
Darrin Stephens
Applied CCM
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Some of the authors of this publication are also working on these related projects:
Development of a general purpose, open-source overset library for Caelus View project
Number of vessels
1570
1360
1512
1521
1360
Number of heaters
Pre primary
400
Primary
#3 Vapour/LP
Secondary
#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.
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.
Number of vessels
4000
1570
1360
1521
1360
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
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.
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).
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.
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.
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.
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
25
-2
-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.