BOILING HOUSE EQUIPMENT
BOILING HOUSE EQUIPMENT
Application
They are used for heating raw, Sulphur & clear Juice from 300C up to about 900C depending upon the requirement and process parameters. Typically, in a sugar plant application, the screened juice obtained is heated to 65-700 C in a tubular juice heater. Through an air floatation process, the juice is clarified and clear juice is obtained which is then sent to triple set evaporator.
Juice heaters generally utilize steam from the boilers to generate the heating action, and if possible, preferably bled vapour from the evaporators. It is thus necessary to have a heat exchanger between vapour and juice which is provided by the juice heaters.
Working Principal
The basic calculation of the juice heater is to calculate the amount of heat transferred using the overall heat transfer co-efficient (OHTC), the log mean temperature difference (LMTD) and the heating surface area.
Q = h· A· ΔTlog
where
• Q= heat transfered [kW]
• h= OHTC [kW/m2K]
• A= heat transfer area [m2]
• ΔTlog= LMTD
The amount of heat transferred is calculated by Q = m· (h1 - h0)
It is important to keep the juice velocity in the tubes in the range 1.5 m/s to 2 m/s; if the juice velocity is too low the OHTC is low and the heater is prone to scaling of the tubes, if the juice velocity in the tubes is too high there will be a high pressure drop across the heater resulting in a higher pumping load on the juice pumps.
Q = h· A· ΔTlog
where
• Q= heat transfered [kW]
• h= OHTC [kW/m2K]
• A= heat transfer area [m2]
• ΔTlog= LMTD
The amount of heat transferred is calculated by Q = m· (h1 - h0)
It is important to keep the juice velocity in the tubes in the range 1.5 m/s to 2 m/s; if the juice velocity is too low the OHTC is low and the heater is prone to scaling of the tubes, if the juice velocity in the tubes is too high there will be a high pressure drop across the heater resulting in a higher pumping load on the juice pumps.
Design Features
Juice heaters are steel fabricated tubular shell structures. Consisting of an assembly of tubes. Juice circulates through the tubes, and the vapour outside them. Suitable headers force the juice to pass a certain number of times from bottom to top and from top to bottom of the heater by restricting the juice each time to a few of the tubes.
Juice heaters are of various types such as-
• Vertical juice heaters
• Vapour line juice heaters
• Dynamic juice heaters
• Condensate juice heaters
These juice heaters are in capacities from 60 m2 H.S. (heating surface) to about 500 m2 H.S. These can be designed and sized as per the capacity of the process & customer requirement.
The following are some advantages of the juice heaters offer by ASHOKA-
• Efficient multiple passage steam distribution and circulation
• Quick cover opening with balancing device for easy opening
• High pressure tested leak proof passes for maximum efficiency
• Interchangeability
• Positive removal of condenset
• Removal of heavy & light nox gasses and adequate venting
• Low maintenance
• Vertical juice heaters
• Vapour line juice heaters
• Dynamic juice heaters
• Condensate juice heaters
These juice heaters are in capacities from 60 m2 H.S. (heating surface) to about 500 m2 H.S. These can be designed and sized as per the capacity of the process & customer requirement.
The following are some advantages of the juice heaters offer by ASHOKA-
• Efficient multiple passage steam distribution and circulation
• Quick cover opening with balancing device for easy opening
• High pressure tested leak proof passes for maximum efficiency
• Interchangeability
• Positive removal of condenset
• Removal of heavy & light nox gasses and adequate venting
• Low maintenance
MULTIPLE EFFECT EVAPORATORS
Application
A multiple-effect evaporator, is an apparatus for concentrating dilute liquid for increasing the solid contents and for reducing the volume of evaporating liquid. It is widely used for the concentration of liquids in the form of solutions, suspensions and emulsions. This equipment utilizes the heat from steam for evaporation.
In addition to the sugar mills there are other industrial sectors such as textile dying, pharmaceutical & drug industries, pulp mills etc. which generate huge quantity of high toxic effluents which has high BOD, COD, TS and TDS level with black coloured and odour effluent. Special evaporators for effluent evaporation are used for such applications as well.
Working Principal
In a multiple-effect evaporator, water is boiled in a sequence of vessels, each held at a lower pressure than the previous. Because the boiling temperature decreases as pressure decreases, the vapor boiled off in one vessel can be used to heat the next, and only the first vessel (at the highest pressure) requires an external source of heat. While in theory, evaporators may be built with an arbitrarily large number of stages, evaporators with more than four stages are rarely practical.
Manufacturing Range
Multiple effect evaporators are designed for heating surface areas as per process requirements. These can be supplied within a general range of 100 m2 to 4000 m2. Tubes made out of stainless steel are within the range of 3 m to 6 m length.
Design Features
Evaporators are steel fabricated in vertical tubular construction with stainless steel pipes fixed along its length. All pipes and joints are high pressure tested for maximum heating and efficiency.
The following are some key features and advantages of the evaporators supplied by ASHOKA-
• Efficient distribution of steam with baffle plates
• Efficient removal of non-condensable gases hence better heat transfer
• Less space required due to long tube design
• Less inversion losses because of less retention time of juice at high temperature
• Calendria is designed by keeping sufficient annular space & to give the tangential steam entry of exhaust and exit of non condensate gasses from the centre
• Umbrella above top tube plate is given to avoid carry over juice particles through vapour
• Attainment of high brix of the syrup
The following are some key features and advantages of the evaporators supplied by ASHOKA-
• Efficient distribution of steam with baffle plates
• Efficient removal of non-condensable gases hence better heat transfer
• Less space required due to long tube design
• Less inversion losses because of less retention time of juice at high temperature
• Calendria is designed by keeping sufficient annular space & to give the tangential steam entry of exhaust and exit of non condensate gasses from the centre
• Umbrella above top tube plate is given to avoid carry over juice particles through vapour
• Attainment of high brix of the syrup
VACUUM PANS
Application
The syrup coming out from evaporator section of 60O Brix is converted into 90O Brix. To 100O Brix for formation of sugar crystal in Pan The pan are used for three types of massecuite, ‘A’, ‘B’ & ‘C’ massecuite. ASHOKA offers two types of Pans:
• Low Head Batch Type Vacuum Pan
• Continuous Vacuum Pan
Pans are used for attaining consistent formation of crystals by means of competent removal of noxious gases and condensate. These operate on hydraulic and pneumatic operated discharge valves, which ensure low steam consumption and better performance.
• Low Head Batch Type Vacuum Pan
• Continuous Vacuum Pan
Pans are used for attaining consistent formation of crystals by means of competent removal of noxious gases and condensate. These operate on hydraulic and pneumatic operated discharge valves, which ensure low steam consumption and better performance.
Working Principal
At the pan stage the syrup from the evaporators is converted to crystal sugar. A charge of syrup is taken into a vacuum pan and again boiled under a vacuum. A quantity of very fine “seed” crystal is introduced. As water is evaporated fresh syrup is added and sugar is deposited on the seed crystal. This process continues until the crystals have reached the desired size (approx. 1 mm square). The resulting semi liquid mass of sugar crystals and molasses is called ‘massecuite'.
Manufacturing Range
Pans can be customized and supplied as per process requirement generally within the range of 20MT to 120 MT. Diameter of the pans can vary from 2 m to 4.5 m and the height from 4 m to 9 m.
Design Features
Vacuum pans are steel fabricated vertical cylindrical constructions with stainless steel pipes fixed along its length. Pans are high pressure tested prior to completion. Calendria is generally supplied separately along with the body in parts and site assembly is a common occurance due to convenience of transportation.
The following are some key features and advantages of Vacuum Pans supplied by ASHOKA-
• Increased evaporation rate due to fast boiling
• High heating surface volume ratio
• Quicker & higher circulation resulting of uniform grain size
• Boiling period of massecuite is minimized resulting in better pan capacity
• Steam consumption reduced about 25% in comparison to a high head pan
• Uniform steam distribution in Calendria by providing annular space around the tube plate
DISCHARGE VALVE
Pan hydraulic discharge valve are used to minimize the pan dropping / washing time & alternatively increases the pan capacity by 5 to 10%.
Some key features are-
• Save 10 minutes during pan dropping thus increases pan capacity
• Easy for operation
• Single person operation
• Less maintenance by avoiding gear mechanism.
The following are some key features and advantages of Vacuum Pans supplied by ASHOKA-
• Increased evaporation rate due to fast boiling
• High heating surface volume ratio
• Quicker & higher circulation resulting of uniform grain size
• Boiling period of massecuite is minimized resulting in better pan capacity
• Steam consumption reduced about 25% in comparison to a high head pan
• Uniform steam distribution in Calendria by providing annular space around the tube plate
DISCHARGE VALVE
Pan hydraulic discharge valve are used to minimize the pan dropping / washing time & alternatively increases the pan capacity by 5 to 10%.
Some key features are-
• Save 10 minutes during pan dropping thus increases pan capacity
• Easy for operation
• Single person operation
• Less maintenance by avoiding gear mechanism.
Frequently Asked Questions
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