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Forced-circulation selection and utility cost calculator
Compare four editable energy scenarios and an indicative heat-transfer area.
Build the duty, then compare energy costs
Calculation basis: P = F × xin/xout; V = F − P; Q = V × λ/3600; A = Q × 1000/(U × ΔT). Utilities per tonne = steam ratio × steam price + specific electricity × power price. Area is a latent-load illustration only, not vessel dimensions. It excludes sensible heating, boiling-point elevation, losses, fouling allowances and geometry constraints. Total cost also includes capital, cooling, chemicals, labour, downtime and maintenance.
Decision sequence: characterize the concentrate → confirm circulation, heat and shear limits → obtain feasible steam/MVR/TVR proposals → compare annual hours and full costs. A utility ranking alone cannot select a machine.
Four energy systems, one material duty
| Energy arrangement | Steam / electricity | Investment and operating considerations | Capacity decision |
|---|---|---|---|
| Single effect | Direct steam; circulation and vacuum electricity | Simpler thermal integration; compare steam cost over annual hours | No universal range: define water removal and turndown |
| Multiple effect | Vapour reused across effects; more auxiliaries | Additional vessels and area; pressure/temperature budget limits effect count | Validate minimum operating load for every effect |
| TVR assisted | Motive steam entrains part of process vapour | Compare available steam pressure, load variation and ejector operating envelope | Obtain verified ejector design points |
| MVR assisted | Compressor electricity replaces part of thermal input; start-up heat remains | Include compressor, electrical connection, maintenance and steam-price sensitivity | Verify vapour flow and required temperature lift |
These are heat strategies, each potentially paired with forced circulation. Obtain project quotations for capital cost and capacity; the table does not invent equipment ratings.
Heat-recovery principle: GEA heating options for thermal separation.
Why circulation changes the material decision
Forced circulation pumps liquid through a heater and separates vapour in a flash vessel. It can be a useful option when viscosity rises or deposits and crystallization need controlled circulation. It still requires sufficient passage size, stable pumping and a validated cleaning procedure.
| Condition | Falling film | Forced circulation |
|---|---|---|
| Clean, low-viscosity liquid | Evaluate distribution and thermal exposure | Extra recirculation energy may be unnecessary |
| Fibres / suspended particles | Check distribution and passage restrictions | Review clearances, wear and blockage; no no-clog guarantee |
| Concentrate viscosity rises | Check wetting at final concentration | Assess finishing stage, pressure drop and cold restart |
| Heat or shear sensitivity | Consider short liquid hold-up | Include repeated pump passes and total hold-up in trials |
Can carrot concentrate use falling film?
The crop name does not decide. Clarification, fibre content, final viscosity and fouling determine the comparison. A fibrous puree may need a different flow path from clarified carrot juice.
How do we keep crystallizing sugar liquor moving?
Measure solubility and crystal size, select passages and circulation from those data, and design start-up, shutdown and flush sequences. High velocity alone does not prove freedom from deposits.
Technical basis: GEA forced circulation and GEA falling film.
Fouling and cleaning are part of the selection
Separate mineral deposits, organic films and crystallization before choosing a cleaning programme. Trend heater duty, normalized heat-transfer coefficient, pressure drop and circulation flow against a clean baseline. Inspect heat surfaces and difficult return paths when those signals change.
Set CIP intervals from product trials and operating history. Validate concentration, time, return temperature, hydraulic action and final rinse; release the circuit only after the agreed hygienic checks. A circuit being cleaned must be safely isolated from product. Continuous plant production requires separate, suitably isolated redundant circuits; it is not an inherent feature of a single evaporator.
A thermal-efficiency decay curve needs dated process measurements. Send clean and end-of-run duty data for assessment instead of relying on an invented curve.