group b sdl presentation
TRANSCRIPT
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Not All Juices are Created Equal!Not All Juices are Created Equal!• 100% Pure or 100% Juice
Guarantees 100% pure fruit juice
• “Cocktail”, “Punch”, “Drink”, “Beverage”
Terms which indicate diluted juice containing less than 100% juice, often with added sweeteners
• “From Concentrate”
Water is removed from whole juice to make concentrate; water is then added back to reconstitute juice
• Fresh Frozen
Freshly squeezed, packaged and frozen without pasteurization
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Main FunctionsMain FunctionsFocus• Pre-concentrate foods prior to drying, freezing or
sterilization: fruit juices, milk, coffee• Preservation by reducing water activity: molasses,
condensed milk, evaporated milk• Convenient food for consumers or manufacturers:
soups, pastes, fruit concentrates• Reduce transportation and storage cost Other Uses• Reboilers at bottom of distillation column
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Elements of EvaporatorsElements of Evaporators
Essentially evaporators consist of:
• A heat exchanger (calandria): to transfer heat from low-pressure steam to the product under vacuum
• A means of separating the vapours produced • Mechanical or steam ejector vacuum pump
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Purpose of Vacuuming the Purpose of Vacuuming the Product SideProduct Side
• Decreases boiling point of the liquid, thereby, the product boils relatively at low temperatures, thus minimising the heat damage
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Types of evaporators Types of evaporators for food processing include:for food processing include:
Most Common• Natural Circulation• Rising Film • Falling Film• Forced Circulation
Special Purpose• Batch pan• Wiped film• Plate tubular• Rising/Falling Film
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Natural CirculationNatural Circulation
Advantages:• Low capital and
maintenance cost
Disadvantages:• Unsuited for high
viscosity products
100% LiquidPartial Vapour
http://www.apv.com/Technologies/Downloads/Evaporator_HB.pdf
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Rising FilmRising Film Advantages:• Good for highly viscous
productsDisadvantages:• Low heat transfer
coefficient due to slow film development
• Requires T difference greater than 25°F
• Long residence times
Vapour/Liquid Separator
Preheater
http://www.apv.com/Technologies/Downloads/Evaporator_HB.pdf
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Falling FilmFalling Film
Advantages:• Operates with low T
difference• Very short residence
times
Disadvantages:• Not suitable for highly
fouling products
http://www.apv.com/Technologies/Downloads/Evaporator_HB.pdf
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Forced CirculationForced Circulation
Advantages:• Suitable for products
susceptible to scaling or crystallization
Disadvantages:• High costs due to
pump and piping requirements
http://www.apv.com/Technologies/Downloads/Evaporator_HB.pdf
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Which is right for you?Which is right for you?
Two Major Criteria:
•Is this equipment best suited for the duty?
•Is the equipment arranged for the most efficient and economic use?
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Concentrated Orange Juice PlantConcentrated Orange Juice Plant
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CLASS EXCERISE!!!
Which evaporator is right for making concentrated OJ?
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Advantages of Falling Film Evaporators Advantages of Falling Film Evaporators for Orange Juice Concentrationfor Orange Juice Concentration
• Juice is fed from the top over the heating surface in a thin film, and falls with gravity, so low energy costs
• Very small retention time, avoiding sugar loss• No stagnation of juice over the tube surfaces and
minimized scaling• High evaporation rates
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Falling Film EvaporatorsFalling Film Evaporators used in the making of
Concentrated Orange JuiceConcentrated Orange Juice
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Falling Film EvaporatorFalling Film Evaporator
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Falling Film EvaporatorFalling Film Evaporator
Production Rate?
Typical Size?
Typical Cost?
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Falling Film EvaporatorFalling Film Evaporator
Production Rate?
1,890,000 liters per day
500,000 gallons per day
Typical Size?
Typical Cost?
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Falling Film Evaporator
Production Rate?
1,890,000 liters per day
500,000 gallons per day
Typical Size?
23 m high X 3 m wide or
75 ft high X 10 ft wide
Typical Cost?
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Falling Film Evaporator
Production Rate?
1,890,000 liters per day
500,000 gallons per day
Typical Size?
23 m high X 3 m wide or
75 ft high X 10 ft wide
Typical Cost?
$2,000,000
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Juice contains 12% soluble solids. You want to obtain a concentrate of 65% soluble solids. How much water has to be removed?
Q1 =100 kg/h
X2 = 65%
Q3 = ?
Q2= ?
X1 = 12%
Assume 1 hr
0.12(100kg/hr) = 12 kg soluble solid 0.65Q2 = 12kg Q2 = 18.46 kg/hr
Q1 = Q2 + Q3 Q2 = 81.54 kg/hr
Mass BalanceMass Balance
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iio
oo hf
r
r
k
rf
hU
1ln
11
2
12
Tk
Lg
k
hl
L
VLL
3
13.1
TUAQ
The heat transfer coefficient of the steam
Governing EquationsGoverning Equations
Q Q
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The heat transfer coefficient of the orange juice
L
V
V
LVLLbD
k
hL
25.0
34.09.09.0 ReRe(Pr)3.1
b = 128 (for SI units)
k
C pPrKorange= 0.148 + 0.00493W
D = Tube diameter
DV
Re
V = Velocity
W is % water content
Cporange= 3851J/kg K
orange = 1.03g/l
orange(70°F) = 89x - 2040
Governing EquationsGoverning Equations
Where x = ° Brix
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Operability IssuesOperability Issues
• Operating window• Maintain plant operation during failures• Safe operation• Prevent damage to equipment• Startup and shutdown• Flexibility• Resiliency to disturbances• Monitor process and diagnose problems
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Operability-FlexibilityOperability-Flexibility
• Q=UAT
Change Q by:• Affecting U• Affecting A• Affecting T T = Tsteam – Tproduct)
http://www.cheresources.com
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Affecting UAffecting U
• Decrease velocity of feed (Increases U)– Increases residence time – Feed pipe sizing– Tube length
****Must be done during Design Stage****
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Affecting AAffecting A
• Use larger (smaller) tubes– Permitting more (less) H.T.
• Nozzle– At top of evaporator– Can spread liquid out more– Caution: we must maintain even wetting
****Must be done during Design Stage****
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Affecting Affecting TT
• Temperature Sensitivity– Juice spoiling temperature
– Tsteam has a maximum
• Preheating– Bring fresh juice closer to boiling point
decreasing T
• Increase Steam Pressure
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CLASS EXCERISE!!!
What special hygienic considerations must be taken into account when
working with food products?
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Hygiene ConsiderationsHygiene Considerations
• Cleaning of equipment daily• Stainless Steel Construction• Ensure sanitary plant and working conditions• Food grade lubricants• Food grade storage containers/utensils
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TroubleshootingTroubleshooting
Falling Film - Orange Juice
• Steam Hammer
• Metal Erosion
• Fouling & Solids Content
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ReferencesReferences
• http://www.niroinc.com/evaporator/esys.html
• http://www.cheresources.com/evapzz.shtml
• Geankoplis, Christie J., Transport Processes and Unit Operations, 3rd Ed., Prentice Hall, 1993, p. 263-267
• http://www.apv.com/Technologies/Downloads/Evaporator_HB.pdf