T H E ECONOMICS O F USING MECHANICAL

VAPOR RECOMPRESSION EVAPORATORS

TO CONCENTRATE ORANGE J U I C E

BY

L a r r y R. K e l s o
DOE, Office of Industrial P r o g r a m s
Agriculture & Food P r o c e s s Branch
Washington, D. C &
and

C h a r l e s M. Rowan, J r . , - V i c e P r e s ~ d e n t
Kenneth L. Holladay -- P r o j e c t s E n g l n e e r
CENTEC Corporation
F o r t Lauderdale, Florida
R e s t o n , Virginia

SUMMARY

E v a p o r a t o r s using M e c h a n i c a l Vapor R e c o m p r e s s i o n ( M V R )
have b e e n o p e r a t i n g s u c c e s s f u l l y in v a r i o u s food i n d u s t r i e s f o r s e v e r a l
y e a r s . Growing c o n c e r n o v e r f u e l a v a i l a b i l i t y a n d r i s i n g e n e r g y c o s t s
h a s c r e a t e d a n i n t e r e s t in the f e a s i b i l i t y of applying t h i s technology t o
c i t r u s processing. T h e r e a r e s e v e r a l p r o b l e m s , however, inherent t o
c o n c e n t r a t i n g o r a n g e j u i c e , which m a k e t h e e c o n o m i c a l a p p l i c a t i o n of
MVX e v a p o r a t i o n difficult. T h e s e include t h e s h o r t p r o c e s s i n g s e a s o n ,
a p p r e c i a b l e boiling point r i s e of t h e c o n c e n t r a t e d j u i c e , a n d t h e q u a l i t y
p r o b l e m s a s s o c i a t e d with long r e s i d e n c e t i m e s a n d high t e m p e r a t u r e s .

55.
One p o s s i b l e a p p r o a c h i s t o o p e r a t e t h e c o m p r e s s o r u n d e r v a c c u m ,
u s e the MVR unit a s a p r e c o n c e n t r a t o r , a n d f i n i s h t h e c o n c e n t r a t i o n
in a s t a n d a r d m u l t i p l e - e f f e c t e v a p o r a t o r .

Two v e r s i o n s of t h i s s y s t e m , e a c h with a d i f f e r e n t p r e -
c o n c e n t r a t i o n l e v e l , w e r e c o m p a r e d t o T A S T E e v a p o r a t o r s . An
a n a l y s i s s h o w e d t h a t if the e c o n o m y r a t i o , pounds of w a t e r e v a p o r -
a t e d p e r pound of s t e a m , f o r t h e TASTE e v a p o r a t o r w a s g r e a t e r
than 3. 5, t h e n t h e p a y b a c k p e r i o d f o r an MVR s y s t e m would b e
g r e a t e r than 6 y e a r s . A s the e c o n o m y r a t i o f o r t h e TASTE e v a p o r -
a t o r d e c r e a s e s , t h e p a y b a c k f o r t h e MVR s y s t e m i m p r o v e s .

INTRODUCTION
-

S i n c e 1976, m a n y v e n d o r s have b e e n a c t i v e l y m a r k e t i n g
M e c h a n i c a l Vapor R e c o m p r e s s i o n ( M V R ) e v a p o r a t o r s in t h e food
p r o c e s s i n g i n d u s t r y . MVK u n i t s a r e u s e d f o r t h e high s o l i d s con-
c e n t r a t i o n of whey, s k i m m i l k , a n d d i s t i l l e r y p r o d u c t s a s w e l l a s
in the pulp a n d p a p e r a n d c h e m i c a l i n d u s t r i e s . T h e a d v a n c e s in
c o m p r e s s o r technologies and operating cost savings have been t h e
p r i m a r y driving f o r c e s toward acceptance by s o m e food p r o c e s s o r s .
The MVR u n i t s in e a c h c a s e m u s t b e c o m p a r e d with t h e o p e r a t i n g
c o s t s a n d i n v e s t m e n t f o r m u l t i p l e - e f f e c t e v a p o r a t o r s a n d , in s o m e
c a s e s , membrane concentration systems.

T h e p r i m a r y r e a s o n s f o r i n s t a l l i n g M V K s y s t e m s include
f a v o r a b l e e c o n o m i c s a n d c o n c e r n s o v e r the f u t u r e a v a i l a b i l i t y of
f o s s i l f u e l s . T h e p r i m a r y o b j e c t i o n s u s u a l l y include c o n c e r n s
about t h e o p e r a t i o n a n d m a i n t e n a n c e of t h e c o m p r e s s o r .

When t h e o p e r a t i n g conditions f o r the e v a p o r a t o r m a t c h

t h e l i m i t a t i o n s of s i n g l e - s t a g e c o m p r e s s i o n , t h e e n e r g y a n d o p e r a t i n g
c o s t b e n e f i t s a r e s i g n i f i c a n t . L i t e r a t u r e s o u r c e s usually s t a t e t h a t
a n MVR s y s t e m will a c h i e v e t h e s a m e t h e r m a l e f f i c i e n c y a s a 1 2 -
effect e v a p o r a t o r . T h i s e f f i c i e n c y can be a c h i e v e d only iinder t h e
m o s t i d e a l c o n d i t i o n s ; the p h y s i c a l p r o p e r t i e s of t h e p r o d u c t s u c h
a s boiling point r i s e r e d u c e t h e efficiency. Of c o u r s e , the
t h e o r e t i c a l e f f i c i e n c i e s of m u l t i p l e - e f f e c t e v a p o r a t o r s a r e s e l d o m
reached for the s a m e reason.

In o r d e r t o a s s e s s i t s t r u e p o t e n t i a l , t h e r e f o r e , MVR
m u s t b e e v a l u a t e d f o r e a c h p r o c e s s . Although t h e e v a l u a t i o n of
o r d e r -of - m a g n i t u d e e c o n o m i c s a n d s i z i n g of c o m p r e s s o r s i s not
difficult, t h e a p p l i c a t i o n of MVR t o c i t r u s p r o c e s s i n g m u s t b e
e v a l u a t e d u l t i m a t e l y by v e n d o r s a n d t h e r e a f t e r f i e l d t e s t e d . The
ECONOMICS

T h e following a s s u m p t i o n s w e r e u s e d a s the b a s i s f o r
e v a l u a t i o n of MVR s y s t e m s :

I n v e s t m e n t Cost: e q u a l t o the c o s t of a m u l t i p l e
e f f e c t TASTE e v a p o r a t o r p l u s t o t a l i n s t a l l e d c o s t s
f o r the c o m p r e s s o r . T h e t o t a l i n s t a l l e d c o s t i s
a s s u m e d t o b e 150 p e r c e n t of the h a r d w a r e c o s t .

M a i n t e n a n c e C o s t : 3 p e r c e n t of the t o t a l i n s t a l l e d
c o s t of the c o m p r e s s o r .

Depreciation: s t r a i g h t l i n e , 10 y e a r s .

I n v e s t m e n t T a x C r e d i t : 10 p e r c e n t of t o t a l i n s t a l l e d
c o s t of t h e c o m p r e s s o r .

Maintenance Labor S a l a r i e s : 37 p e r c e n t of t o t a l
maintenance costs.

G e n e r a l P l a n t O v e r h e a d : 58 p e r c e n t of t h e o p e r a t i n g
l a b o r and supervision s a l a r i e s plus maintenance
salaries.

S t e a m C o s t s f o r 1980: $4/1000 l b s . E c o n o m i c s will

b e p r e s e n t e d showing 20 p e r c e n t e s c a l a t i o n in s t e a m
costs p e r year.

P r i c e of E l e c t r i c i t y : 3. 5 $ p e r k w h . E c o n o m i c s
will b e p r e s e n t e d indicating a 10 p e r c e n t a n n u a l
increase.

T a x e s a n d I n s u r a n c e : 2 p e r c e n t of t o t a l i n s t a l l e d
costs for compressor.

C o s t s f o r Cooling W a t e r , Condensing W a t e r , O p e r a t i n g
Labor and E l e c t r i c i t y for Pumps: equivalent to multiple-
effect evaporators.

Plant Operates: 3, 000 h r s / y r .

Corporate Income Tax Rate: 45 p e r c e n t .

p u r p o s e of t h i s p a p e r i s to r e v i e w t h e e c o n o m i c s t o d e t e r m i n e if
s u c h e f f o r t s a r e j u s t i f i e d . T h e e v a l u a t i o n will b e b a s e d on
c o m p a r i s o n s of p r o j e c t e d o p e r a t i n g a n d i n v e s t m e n t c o s t s f o r MVR
e v a p o r a t o r s with p r e s e n t m u l t i p l e - e f f e c t T A S T E e v a p o r a t o r s .

MVR e v a p o r a t o r s u s u a l l y a r e m o r e e n e r g y e f f i c i e n t t h a n
m u l t i p l e - e f f e c t units f o r two r e a s o n s . All of t h e w a t e r v a p o r f r o m
the evaporator i s c o m p r e s s e d and reused to concentrate the feed,
a n d a p p r o x i m a t e l y 9 5 t o 9 8 p e r c e n t of t h e e l e c t r i c i t y s u p p l i e d t o
the c o m p r e s s o r i s t r a n s f e r r e d a s t h e r m a l energy to the compressed
v a p o r s . T h e b e s t a p p l i c a t i o n s f o r MVR o c c u r u n d e r t h e following
conditions:

Low c o m p r e s s i o n r a t i o s : m a x i m u m of 2 / 1 f o r s i n g l e -
stage compressors

Low l i q u o r B o i l i n g P o i n t R i s e ( B P R )

Near atmospheric p r e s s u r e for suction p r e s s u r e s

Cheap electricity for drives

High-pressure steam available for turbine drive

Condensate heat recovery possible

Low c o r r o s i v e v a p o r c a r r y - o v e r

S i n g l e - e f f e c t e v a p o r a t o r duty

High s t e a m c o s t s

U n f o r t u n a t e l y , t h e a p p l i c a t i o n of MVR f o r c i t r u s c o n c e n -
tration has several major drawbacks.

B P R i s a p p r e c i a b l e e s p e c i a l l y a t O ~ r i xa b o v e 35.

P r o d u c t degradation dictates that t h e c o m p r e s s o r s

o p e r a t e under vacuum.

F e e d stabilization t e m p e r a t u r e above 1 ~ m u s5t b e ~ ~

reached.

T h e c o s t s of e l e c t r i c i t y r e l a t i v e t o s t e a m c o s t s a r e
high.

Annual o p e r a t i n g t i m e i s only a b o u t 3 , 000 h o u r s .

 Ejecause of the p r o d u c t d e g r a d a t i o n proble113 a n d B P R ,
t h i s e v a l u a t i o n i s confined t o d e t e r m i n i n g t h e o p e r a t i n g c o s t s a n d
e c o n o m i c s f o r using a n MVR s y s t e m a s a p r e c o n c e n t r a t o r . Two
c a s e s a r e e v a l u a t e d f o r MVR: p r e c o n c e n t r a t i n g the f e e d t o 20°
B r i x a n d p r e c o n c c n t r a t i n g the f e e d t o 35O B r i x . F o r t h e s e conditions,
i t a p p e a r s t h a t t h e i n v e s t m e n t c o s t s f o r t h e e v a p o r a t o r s t a g e s of the
MVR unit would b e t h e s a m e a s f o r m u l t i p l e - e f f e c t units. T h e
d i f f e r e n t i a l i n v e s t m e n t , t h e r e f o r e , i s a s s u m e d t o be t h e t o t a l i n s t a l l e d
c o s t s for the c o m p r e s s o r .

CALCULATING MVR P E R F O R M A N C E
-

A r e p o r t i s s u e d b y t h e E n e r g y R e s e a r c h a n d Development
A d m i n i s t r a t i o n , p r e s e n t l y t h e D e p a r t m e n t of E n e r g y , d e s c r i b e d in
# d e t a i l t h e o p e r a t i n g c h a r a c t e r i s t i c s of c o m p r e s s o r s . A copy of t h i s
r e p o r t , Upgrading E x i s t i n g E v a p o r a t o r s t o R e d u c e E n e r g y Consumption,
i s a v a i l a b l e f r o m t h e D e p a r t m e n t of E n e r g y , T e c h n i c a l I n f o r m a t i o n
C e n t e r , Po 0. B o x 62, O a k Ridge, T e n n e s s e e 37830; t h e r e f o r e , t h e
1 t y p e s of c o m p r e s s o r s a n d t h e i r o p e r a t i n g c h a r a c t e r i s t i c s w i l l not b e
d i s c u s s e d . S i n c e t h e c o m p r e s s i o n r a t i o s f o r t h i s study w e r e s e t a t
1. 5, a s i n g l e - s t a g e c o m p r e s s o r could b e u s e d in e a c h c a s e .

A s i n g l e - s t a g e MVR e v a p o r a t o r i s shown in F i g u r e 1. In
0
t h i s e x a m p l e , o r a n g e j u i c e i s c o n c e n t r a t e d f r o m 12. 6 B r i x t o 19. 7O
B r i x . T h e s u c t i o n p r e s s u r e ( P I )t o t h e c o m p r e s s o r i s 8. 8 p s i a a n d
t h e d i s c h a r g e p r e s s u r e ( P 2 )i s 13. 2 p s i a , yielding a c o m p r e s s i o n
r a t i o of 1. 5 ( P Z / P 1 ) "

T h e rnethodolog y f o r c a l c u l a t i n g t h e e n e r g y a n d m a t e r i a l
b a l a n c e i s shown in T a b l e 1. S t e a m c o m p r e s s e d t o a h i g h e r p r e s s u r e
b e c o m e s s u p e r h e a t e d , but i d e a l l y the e n t r o p y of t h e v a p o r r e m a i n s
constant. S i n c e t h e v a p o r i s being c o m p r e s s e d m e c h a n i c a l l y , a d d i t i o n -
a l thermal energy i s added to the compressed vapor to further increase
the vapor t e m p e r a t u r e .

A s i n d i c a t e d in T a b l e 1, t h e f i r s t s t e p i s t o d e t e r m i n e the
suction p r e s s u r e , P I , a n d v a p o r m a s s flow r a t e . T h e n t h e t h e o r e t i c a l
amount of e n e r g y ( d i f f e r e n c e b e t w e e n enthalpy a t d i s c h a r g e ( H Z )a n d
suction p r e s s u r e ( H I ) a t c o n s t a n t e n t r o p y ) i s found using s t e a m s t a b l e s .
Since c o m p r e s s ion t r a n s f e r s a d d i t i o n a l e n e r g y t o t h e v a p o r s t h r o u g h
m e c h a n i c a l w o r k , t h e t o t a l enthalpy i n c r e a s e i s c a l c u l a t e d by the
formula:

T o t a l c n t h a l p y r i s e = ( ~ ~ - H ~ ) / c o m ~ r eefficiency
ssor
 Steam --

V
Condensate

Figure 1. M V R Unit For Preconcentrating Orange Juice

60.
 Table 1
P r o c e d u r e f o r C a l c u l a t i n g MVR P e r f o r m a n c e
I
I
I
1. Basis
I
F = 83,000 lb/hr ( f e e d r a t e a t 12' B r i x )
p = 53,130 l b / h r ( p r o d u c t r a t e a t 19.7' B r i x )
V1 = 2 9 , 8 7 0 l b / h r (vapor r a t e from e v a p o r a t o r )

I Process Conditions: 1
T1 = 187OF ( v a p o r t e m p e r a t u r e f r o m e v a p o r a t o r )
P1 = 8 . 8 p s i a ( v a p o r p r e s s u r e f r o m e v a p o r a t o r )
= 1 8 8 ° F ( t e m p e r a t u r e of p r o d u c t )
T~
Tf = 1 9 0 ° F ( t e m p e r a t u r e o f f e e d )

I Thermal P r o p e r t i e s

C = 0.93 Btu/lb°F ( h e a t c a p a c i t y of l i q u o r )
h: = (190 - 32OF)(0.93 Btu/lb) = 147 Btu/lb (enthalpy of feed)
hk = 1 4 5 B t u / l b ( e n t h a l 3 y o f p r o d u c t )

Vapor e n t h a l p i e s a r e from s t e a m t a b l e s .
!
2. Solve
- for

Compressor Discharge P r e s s u r e
P2 -
Compressor Discharge Temperature
T2 -
- S a t u r a t e d T e m p e r a t u r e a t P2
- Water flow r a t e t o desuperheater
S - Make u p s t e a m r e q u i r e d
V - Steam r e q u i r e d to d r i v e e v a p o r a t o r
~6 - C o m p r e s s i o n Work

3. Procedure

Assume t h e c o m p r e s s i o n r a t i o ( P 2 / P 1 ) e q u a l s 1.5

p2 = ( 1 . 5 ) P l P2 = 1 3 . 2 p s i a

The change i n e n t h a l p y f o r i s e n t r o p i c c o m p r e s s i o n c a n
b e f o u n d u s i n g s t e a m t a b l e s or a M o l l i e r d i a g r a m .

H = 1 , 1 4 1 ~ t u / l b( e n t h a l p y o f s a t u r a t e d v a p o r s a t P1)
1
H2 = 1 , 1 7 1 n t u / l b (enthaipy of c c n ~ a e s s e dv a p o r , i s e n t r o p i c
compression )
 Table 1
P r o c e d u r e f o r C a l c u l a t i n g MVR P e r f o r m a n c e
(Continued)

I Assume t h e c o m p r e s s o r e f f i c i e n c y = 7 5 p e r c e n t

I Then a c t u a l energy r e q u i r e d = -O'

0.75
- 40 B t u / l b

II A c t u a l e n t h a l p y a f t e r c o m p r e s s i o n = H,, + 40 = 1 , 1 8 1 B t u / l b

Prom t h e s t e a m t a b l e s a t P2 = 1 3 . 2 p s i a a n d H = 1 , 1 8 1 B t u / l b

C o n p r e s s i o n Work
1
CW = 4 0 B t u 29,870 l b 1 hp-hr
l b hr 2,545 Btu

CW = 470 h p ( 3 5 0 k w h / h r )

D-
-e s-
u-perheater

M a t e r i a l B a l a n c e V1 + W = V 2 - S

Energy Balance H W
W
+
H v V1 = Hs(VS - S )
1
a t P2 = 1 3 . 2 p s i a , T j = S a t u r a t i o n T e m p e r a t u r e

f r o m steam t a b l e s T3 = 207OF

and H = 1,148 ~ t u / l b(Saturated vapor enthalpy)

s
Assume w a t e r s p r a y a t 8 0 ° F

W = 896 l b / h r

Evaporator
-

Energy Balance V H
2 s + F h F = Chc + PhL + VIHvl

C = c o n d e n s a t e rate l b / h r

h = e n t h a l p y of c o n d e n s a t e ( a s s u m e s a t u r a t e d )
C

6 2.
 Table 1
P r o c e d u r e f o r C a l c u l a t i n g MVR P e r f o r m a n c e
(Continued)

S i n c e S i s n e g a t i v e , t h e MVR u n i t is g e n e r a t i n g
a p p r o x i m a t e l y 3 7 0 l b / h r more s t e a m t h a n i t r e q u i r e s f o r
evaporation. T h i s steam can be used to p r e h e a t feed.
F o r e x a m p l e , a s s u m e t h e f e e d i s p r e h e a t e d t o 1 2 g ° F by
the finishing stages' preheaters. Then

T. = 12g°F
In
Energy B a l a n c e
-
SH
s - Chc - F (Tout - Tin)Cp

Since S = C

870(1,148 - 175) = 83,00O(T

out - 129)'93
 T h e total e n e r g y available for evaporation is determined
by multiplying t h e total enthalpy r i s e by the vapor r a t e e n t e r i n g the
c o m p r e s s o r . T h e power demands a r e d e t e r m i n e d using the total
e n e r g y available and converting B t u / h r to horsepower using the
appropriate conversion factor. B e c a u s e the c o m p r e s s e d v a p o r s
a r e s u p e r h e a t e d , a w a t e r s p r a y is u s e d t o r e d u c e the t e m p e r a t u r e
t o the s a t u r a t i o n t e m p e r a t u r e .

A l s o shown i n T a b l e 1 i s t h e o v e r a l l e n e r g y a n d m a t e r i a l
b a l a n c e . In t h i s c a s e , t h e e n e r g y s u p p l i e d by t h e c o m p r e s s o r
e x c e e d s the e n e r g y r e q u i r e d t o r u n the e v a p o r a t o r . The e x t r a
s t e a m m a y b e u s e d t o h e l p p r e h e a t i n c o m i n g f e e d , b u t it i s i n s u f -
ficient to r a i s e the feed t o the r e q u i r e d stabilization t e m p e r a t u r e
of 190°F. 'The u s e of l i v e s t e a m t o r a i s e f e e d t o t h e s t a b i l i z a t i o n
t e m p e r a t u r e i s a m a j o r cost f a c t o r affecting the economical application
of MVR s y s t e m s . In t h i s e x a m p l e , t h e p o w e r d e m a n d s f o r t h e MVR
unit a r e a p p r o x i m a t e l y 470 hp.

COMPRESSOR COSTS

C o m p r e s s o r c o s t i s b a s e d p r i m a r i l y on t h e v o l u m e t r i c
flow r a t e of t h e v a p o r , t h e c o m p r e s s i o n r a t i o , t h e d r i v e , a n d
auxiliary controls. T h e capital c o s t s for c o m p r e s s o r s , a s a function
of i n l e t v o l u m e t r i c flow r a t e , a r e shown in F i g u r e 2. T o t a l i n s t a l l e d
i n l ~ e s t m e n tf o r c o m p r e s s o r s i s 1 5 0 t o 200 p e r c e n t g r e a t e r t h a n h a r d -
w a r e c o s t s . F o r e x a m p l e , a t a m a s s flow r a t e of 40, 000 l b s / h r w a t e r
v a p o r , t h e v o l u m e t r i c f l o w r a t e a t a t m o s p h e r i c p r e s s u r e i s 1 7 , 900 c f m .
If t h e p r e s s u r e i s 3 p s i a , t h e v o l u m e t r i c flow r a t e b e c o m e s 79, 000 c f m .
The capital c o s t s f o r c o m p r e s s o r s operating a t a t m o s p h e r i c and 3 psia
s u c t i o n p r e s s u r e s a r e a p p r o x i m a t e l y $ 1 3 0 , 0 0 0 a n d $280, 000, r e s p e c -
t i v e l y . A s s u m i n g t h a t t h e t o t a l i n s t a l l e d c o s t s a r e 150 p e r c e n t of t h e
c a p i t a l c o s t , t h e c o m p r e s s o r o p e r a t i n g a t 3 p s i a would c o s t a p p r o x i -
m a t e l y $225, 000 m o r e t h a n a c o m p r e s s o r o p e r a t i n g a t a t m o s p h e r i c
p r e s s u r e . T h e v o l u m e t r i c flow r a t e o v e r a r a n g e of m a s s flow r a t e s
f o r w a t e r v a p o r i s s h o w n i n F i g u r e 3. T h e e f f e c t of s u c t i o n p r e s s u r e
on t h e h a r d w a r e a n d on t h e t o t a l i n s t a l l e d i n v e s t m e n t c o s t s f o r c o m -
p r e s s o r s is significant.

TASTEEVAPORATOR ANDMVRPRECONCENTRATOKS -
PERFORMANCE - -

T h e e v a l u a t i o n of MVR a p p l i c a t i o n s w a s m a d e a s s u m i n g
two a p p r o a c h e s . In b o t h c a s e s , t h e f i n a l c o n c e n t r a t i o n of t h e p r o d u c t
f r o m t h e MVR p r e c o n c e n t r a t o r w a s a c h i e v e d u s i n g t h e c o n d i t i o n s
 INLET SUCTION VOLUME (1,000 c f m l

Compression Ratio = 1.5

Quotes Supplied b y Allis Chalmers - January 1 9 8 0
Figure 2. Hardware Cost For Centrifugal Compressor
 V A P O R R A T E (1,000 I b / h r )

Figure 3. Relationship of Mass Flow Rate And Volumetric

Flow R a t e at Different Pressures for
Saturated Steam

66.
 t y p i c a l of the m u l t i p l e - e f f e c t TASTE e v a p o r a t o r s . A s c h e m a t i c of
a f i v e - e f f e c t TASTE e v a p o r a t o r is shown in Fi.gure 4. 'The o p e r a t i n g
conditions a n d m a t e r i a l b a l a n c e a s s u r n e d f o r the f i v e - e f f e c t e v a p o r a t o r
i s shown in T a b l e 2.

The TASTE e v a p o r a t o r s a r e e n e r g y efficient units. The

s t a n d a r d d e s i g n s include feed p r e h e a t e r s , c o n d e n s a t e f l a s h i n g , and
m u l t i p l e - e f f e c t s . T h e economy r a t i o ( r a t i o of pounds of w a t e r
e v a p o r a t e d p e r pound of s t e a m ) f o r t h e l o u r , flvt., and s i x - e f f e c t
units will r a n g e between 2. 4 a n d 5. 5. The a n n u a l s t e a m c o s t s f o r
m u l t i p l e - e f f e c t e v a p o r a t o r s a s a function of the economy r a t i o a n d
c o s t p e r thousand pounds f o r s t e a m a r e shown in F i g u r e 5. If s t e a m
c o s t s $3. 50 p e r 1 , 000 l b s , then the a n n u a l s t e a m c o s t f o r a f i v e - e f f e c t
e v a p o r a t o r o p e r a t i n g with a n economy r a t i o of 3. 5 a n d e v a p o r a t i n g
40, 000 l b s / h r of w a t e r would b e $1 20, 000 ($30, 000/10, 000 l b s w a t e r
I
e v a p o r a t e d x 40, 000 / l o , 000 l b s / h r w a t e r e v a p o r a t e d ) .

F i g u r e 5 a l s o can b e u s e d t o p r e d i c t s t e a m s a v i n g s for
adding e f f e c t s t o i m p r o v e s t e a m economy. If t h e e v a p o r a t i o n r a t e
r e q u i r e d i s 50, 000 l b s / h r and t h e f o u r - e f f e c t economy r a t i o i s 2. 5,
then the a n n u a l s t e a m c o s t would b e $210, 000 ($42, 0 0 0 / 1 0 , 000 l b s / h r
x 50, 000 / l o , 000 l b s / h r ) . If the f o u r - e f f e c t unit i s c o n v e r t e d to a
f i v e - e f f e c t s y s t e m with a n economy r a t i o of 3. 5, the a n n u a l s t e a m
c o s t would b e c o m e $150, 000. T h e r e f o r e , the a n n u a l s a v i n g s would
be $60, 000 when the s t e a m c o s t i s $ 3 . 50 p e r 1000 l b s .

Theoretical economies a r e r a r e l y achieved. The r e a s o n s

f o r d i f f e r e n t e c o n o m y r a t i o s a r e n u m e r o u s , but they p r i m a r i l y depend
on the c a p a c i t y , fouling of h e a t t r a n s f e r s u r f a c e s , o p e r a t i n g conditions,
and v a r y i n g o p e r a t o r p r a c t i c e s . S t u d i e s have indicated t h a t s t e a m
economy c a n b e i m p r o v e d by using t h e r m a l v a p o r r e c o m p r e s s i o n
( s t e a m e j e c t o r s ) , i n s t a l l i n g insulation, improving h e a t t r a n s f e r c o -
e f f i c i e n t s , a n d i n c r e a s i n g the s i z e of p r e h e a t e r s , F o r t h e evaluation
of e c o n o m i c s , t h e following economy r a t i o s f o r t h e TASTE e v a p o r a t o r s
w e r e s e l e c t e d f r o m s t u d i e s b a s e d on f i e l d data:

5 - e f f e c t - 3 . 0 and 3. 7

The t e m p e r a t u r e s , vapor p r e s s u r e s , and product concen-

t r a t i o n s f o r e a c h effect of a TASTE e v a p o r a t o r w e r e the b a s i s f o r
the evaluation of the MVR p r e c o n c e n t r a t o r . T h e MVR s y s t e m d e s i g n ,
t h e r e f o r e , included the MVR p r e c o n c e n t r a t o r followed by one o r m o r e
 Tab1.e 2

Summary of C o n d i t i o n : ; for a Five-Ef f e c t , Seven-Stage TASTE E v a p o r a t o r

Feed Rate = 83,000 l b / h r

Feed Brix = 12.6
Product Rate = 17,207 lb/hr
Product Brix = 60.8

S t e a m Economy = 3 . 2 l b s o f w a t e r e v a p o r a t e d / l b steam

E f f e c t Number

Steam R a t e l b / h r 23,117
S t e a m T e m p e r a t u r e OF 220

L i q u o r Temp. O u t OF
Liquor Out lb/hr 67,012 53,128 40,817 28,949 17,207
Brix Out 15.6 19.7 25.6 36.1 60.8

Evaporation Rate 15,988 13,884 12,311 11,868 11,741

V a p o r Temp. OF

Preheaters

J u i c e Temp. I n O F
J u i c e Temp. O u t OF
e f f e c t s of a TASTE e v a p o r a t o r w h e r e the f i n a l c o n c e n t r a t i o n of
t h e juice t o 60° B r i x t a k e s place. Once t h e c o n c e n t r a t i o n of t h e
p r o d u c t leaving t h e MVR s y s t e m w a s s e l e c t e d , t h e v a p o r p r e s s u r e
a n d t e m p e r a t u r e r e p r e s e n t a t i v e of the conditions a t t h a t c o n c e n t r a t i o n
in a TASTE e v a p o r a t o r b e c o m e the r e q u i r e m e n t s f o r the c o m p r e s s o r .
The MVR p r e c o n c e n t r a t o r s w e r e c a l c u l a t e d to a c h i e v e a p p r o x i m a t e l y
20° B r i x o r 35O B r i x .

A s c h e m a t i c of a n MVR s y s t e m t h a t p r o d u c e s a 20° B r i x
p r o d u c t i s shown in F i g u r e 6. The o p e r a t i n g conditions a n d
m a t e r i a l b a l a n c e f o r the 20° B r i x unit i s shown in Table 3 f o r a
40, 000 l b s / h r unit. Under t h e s e conditions, t h e s u c t i o n p r e s s u r e
t o the c o m p r e s s o r i s held a t 7 p s i a while the d i s c h a r g e p r e s s u r e i s
10. 5 psia. T h e f i n a l c o n c e n t r a t i o n f o r p r o d u c t is c o m p l e t e d using a
t h r e e - e f f e c t , TASTE e v a p o r a t o r . The m a k e - u p s t e a m r e q u i r e d t o
i n c r e a s e t h e f e e d t e m p e r a t u r e to 195O F i s 360 l b s / h r . The s t e a m
r e q u i r e d t o a c h i e v e a c o n c e n t r a t e of 60° B r i x i s 7, 030 l b / h r .

T h e MVR s y s t e m d e s i g n e d t o c o n c e n t r a t e the f e e d to 35O

B r i x i s shown in F i g u r e 7. T h i s MVR s y s t e m includes two,
possibly t h r e e , s t a g e s . When m u l t i p l e s t a g e s a r e employed, the
f e e d flows in s e r i e s . T h e vapor f r o m e a c h s t a g e e n t e r s t h e s u c t i o n
of t h e c o m p r e s s o r s o t h a t the o p e r a t i n g p r e s s u r e f o r e a c h s t a g e i s
the s a m e . The s u c t i o n p r e s s u r e t o t h e c o m p r e , s s o r i s a p p r o x i m a t e l y
3 p s i a while the d i s c h a r g e p r e s s u r e i s 4. 5 p s i a . As indicated in
Table 4, the s t e a m r a t e r e q u i r e d t o p r e h e a t the f e e d to l 9 5 O ~i s
3,600 l b / h r . The f i n a l c o n c e n t r a t i o n of the p r o d u c t i s a c c o m p l i s h e d
with a s i n g l e - e f f e c t , t h r e e - s t a g e e v a p o r a t o r t h a t r e q u i r e s 9900 l b s / h r
of s t e a m .

A s u m m a r y of the s p e c i f i c a t i o n s a n d utility r e q u i r e m e n t s
for the MVR p r e c o n c e n t r a t o r i s shown in T a b l e 5. T h e s t e a m r e -
q u i r e m e n t s f o r p r e h e a t i n g the feed to 1 9 5 O ~a n d f o r final c o n c e n t r a t i o n
of the juice t o 60° B r i x a l s o a r e shown. T h e s e v a l u e s w e r e u s e d to
c o m p a r e the e c o n o m i c s of f o u r - a n d five-effect TASTE e v a p o r a t o r s
with the MVR s y s t e m s .

The a n n u a l utility c o s t s f o r MVR p r e c o n c e n t r a t o r s a r e

shown in F i g u r e 8. B e c a u s e s e v e r a l of the p r e h e a t e r s a r e e l i m i n a t e d
with the MVR p r e c o n c e n t r a t o r , the s t e a m r a t e s f o r p r e h e a t i n g the
feed a r e m u c h h i g h e r than f o r m u l t i p l e - e f f e c t s y s t e m s . If a s o u r c e
of waste heat capable of p r e h e a t i n g t h e f e e d to 180°F c a n b e found,
the utility c o s t s f o r the MVR s y s t e m p r e c o n c e n t r a t o r c a n b e improved.
F o r e x a m p l e , the a n n u a l utility c o s t s f o r a n MVR s y s t e m r a t e d a t
60, 000 l b s / h r i s a p p r o x i m a t e l y $205, 000. With a w a s t e h e a t s o u r c e ,
the utility c o s t r e d u c e s t o $180, 000.
 Compressor

Barometric

---Vapor
H Preheater
Product

E Effect+
S Stage +
F Flash Chamber

Figure 6. Flow Diagram For System With MVR Reconcentrator to 20° Brix

L i & d t
aJ
u
cn I 0
cool
C l m *
0
N
4

::a I a
'a
m
-
w
0
3
C ~ W
-1
z
N W
in
44
m
 Water to Desuperheater - 1,550 lb/hr
4
C"
V a p o r f r o m F l a s h Chamber - 1 1 , 8 7 0 l b / h r a t 134OF ( s a t u r a t e d )
 Table 5
S u m m a r y of MVR P r e c o n c e n t r a t o r Requirements

AS sume Feed B r i x = 1 2
P r o d u c t B r i x = 60
Compression R a t i o = 1 . 5 (Discharge P r e s s u r e + I n l e t P r e s s u r e )

I Total Evaporator Capacity

Mlbs/hr 20 40 60 80

20' Brix Preconcentrator

Suction Pressure psia 7 7 7 7

Discharge Pressure p s i a 10.5 10.5 10.5 10.5
Vapor R a t e Mlbs/hr 10 20 30 40
C o m p r e s s o r E l e c t r i c i t y kWh/hr 116 23 3 349 46 5
Steam Requirements
Preheat lbs/hr 4 20 840 1,260 1,680
Final Concentration lbs/hr 3,750 7,500 11,250 15,000
Compressor Hardware C o s t $ 125,000 140,000 150,000 175,000
Total I n s t a l l e d Investment $ 187,500 210,000 225,000 262,000
Economy ( t o t a l l b s e v a p / t o t a l l b steam) 4.8 4.8 4.8 4.8

35' Brix Preconcentrator

Suction Pressure psia 3 3 3 3

1
Discharge Pressure psia 4.5 4.5 4.5 4.5
Vapor R a t e Mlbs/hr 16.4 32.9 49.3 65.7
C o m p r e s s o r E l e c t r i c i t y kWh/hr 183 367 550 733
Steam Requirements
Final Concentration lbs/hr 3,020 6,040 9,060 12,080
P r e h e a t 145°-1900F l b / h r 1,060 2,120 3,180 4,240
or
P r e h e a t w i t h w a s t e h e a t to 180°F 4 30 860 1,290 1,720

C o m p r e s s o r H a r d w a r e Cost 175,000 250,000 300,000 350,000

Total I n s t a l l e d Investment
- 262,500 375,000 450,000 525,000
Note: I
F o r 35O B r i x P r e c o n c e n t r a t o r w i t h l i v e steam p r e h e a t , e c o n o m y = 4 . 9 t o t a l l b s water evap.
p e r l b steam. I f w a s t e h e a t from t h e p l a n t is used f o r p r e h e a t i n g , t h e economy becomes
5 . 8 t o t a l l b s w a t e r e v a p . p e r lb s t e a m .
 1

preconcentrata T o
-
3 5 O Brix -
Use Live
Steam For
Preheating Feed

3 5 O Brix US; -
Waste Heat For
Preheating Feed

d
b

71

Basis: S t e a m - $ 4 . 0 0 per 1,000 l b s

Electricity - 3 . 5 ~p e r kwh
Operating h o u r s - 3,000 p e r y e a r

I I 1 I 1 I 1

T O T A L EVAPORATION RATE (1,000 Ibs/hr)

F i g u r e 8. Utility C o s t s For M V R Systems

77.
,
 With t h e s e a s s u m p t i o n s , t h e a n n u a l o p e r a t i n g c o s t s of
the c o m p r e s s o r c a n b e d e t e r m i n e d f r o m i t s t o t a l i n s t a l l e d c o s t .
T h e a n n u a l s a v i n g s f o r MVR when c o m p a r e d t o t h e m u l t i p l e - e f f e c t
e v a p o r a t o r i s t h e n c a l c u l a t e d in the following m a n n e r :

Annual Annual S t e a m Annual o p e r a t i n g

operating - cost for multiple- - costs for
costs savings effect e v a p o r a t i o n compressor

Once t h e a n n u a l o p e r a t i n g c o s t s a v i n g s a r e d e t e r m i n e d , t h e p a y b a c k
p e r i o d a n d D i s c o u n t e d C a s h F l o w ( D C F ) r a t e of r e t u r n c a n b e c a l c u l a t e d .

T h e p a y b a c k a n a l y s i s of t h e c o m p a r i s o n b e t w e e n MVR p r e -
concentrator and multiple-effect e v a p o r a t o r s i s shown in F i g u r e 9 f o r
the 20° B r i x c a s e s . T h e e c o n o m y r a t i o s f o r t h e m u l t i p l e - e f f e c t
e v a p o r a t o r s s i g n i f i c a n t l y affect t h e payback. When t h e e c o n o m y r a t i o
i s 2. 5 f o r the m u l t i p l e - e f f e c t e v a p o r a t o r , t h e o p e r a t i n g c o s t s a v i n g s
f o r t h e MVR p r e c o n c e n t r a t o r would yield a p a y b a c k on t h e t o t a l i n s t a l l e d
i n v e s t m e n t of 2. 4 y e a r s f o r a n 80, 0 0 0 - l b / h r e v a p o r a t o r a n d 4. 9 y e a r s f o r
a 20, 0 0 0 - l b / h r e v a p o r a t o r . Since t h e f i v e - e f f e c t T A S T E e v a p o r a t o r s
a c h i e v e e c o n o m i e s of 3. 0 o r h i g h e r , t h e payback f o r t h e M V R p r e c o n c e n -
t r a t o r would b e a t l e a s t 4 t o 7 y e a r s f o r t h e s a m e r a n g e of c a p a c i t i e s .

T h e e f f e c t s of c a p a c i t y , e c o n o m y r a t i o s of m u l t i p l e - e f f e c t
e v a p o r a t o r s , a n d e n e r g y p r i c e s a r e f u r t h e r d e t a i l e d in T a b l e 6. If t h e
b a s i s f o r e n e r g y s a v i n g s b e c o m e s $5 p e r 1000 l b s of s t e a m , t h e i m -
p r o v e m e n t in the p a y b a c k i s l e s s than 1 y e a r . Again, t h e MVR p r e -
c o n c e n t r a t o r d o e s not c o m p a r e f a v o r a b l y with a f i v e - e f f e c t e v a p o r a t o r .

T h e e c o n o m i c s f o r t h e 35 0 B r i x p r e c o n c e n t r a t o r a r e p o o r e r
than the 20° B r i x p r e c o n c e n t r a t o r , b e c a u s e of h i g h e r i n v e s t m e n t c o s t s
for the c o m p r e s s o r s a n d a n i n c r e a s e in s t e a m r a t e s f o r feed preheating.
In f a c t , t h e s t e a m d e m a n d f o r t h e f i n a l c o n c e n t r a t i o n of t h e juice l e a v i n g
the MVR s y s t e m i s a p p r o x i m a t e l y e q u a l i n both c a s e s . T h e f i n a l c o n -
c e n t r a t i o n i n t h e 35O B r i x c a s e would b e a c h i e v e d using a s i n g l e - s t a g e
e v a p o r a t o r , while t h e 20° B r i x p r e c o n c e n t r a t o r would r e q u i r e a m u l t i p l e -
e f f e c t unit.
0
T h e e c o n o m i c s f o r t h e 35 B r i x , MVR p r e c o n c e n t r a t o r
( F i g u r e 10 a n d T a b l e 7 ) a r e b a s e d on u t ~ l i z a t ~ oofn a w a s t e - h e a t s o u r c e
for p r e h e a t i n g t h e f e e d to 1 8 0 ' ~ . T h e f e e d t e m p e r a t u r e i s t h e n i n c r e a s e d
to 195O F u s i n g live s t e a m . The p a y b a c k f o r t h i s s y s t e m e x c e e d s 5 y e a r s ,
c o m p a r e d t o a m u l t i p l e - e f f e c t e v a p o r a t o r wlth a 3. 0 e c o n o m y r a t i o .
Economy R a t i o o f
Current E v a p o r a t o r
 . r-w. .
Cd LC Ir- L-1- d m

.I. .
lo 0- e a r - ~ n r -

* . ,

.
Vr-r\i

4 N 3
. . . . . . . ,
m
)rnrn~*Yg:
m n

N 4 I P C 1

0 0 0
0 0 0
U3
"2 01
m
N r' 0
-a' r-

'".'l
0 0 0 0 C ) O O C
0 0 0 ~ 0 0 0 0 C
...
0m-T
m m m , " W 7 * C E
47
w u N l r n m o - a
1 N 4

m
.
m r-
m
I .....,
\7mNr.c
.arnemcc

0
. .
r- m
4
- I .)i we. m~. ~.mn.mm, -w
4 4 P I 4

0 0
0
0 0 0
N m r-
m m I-
4 m m

O O C >oooog
0 0 0
0- ". . !I-
-ommu
- .mu
-.
) O O O O -

7 0 3 " rt-r-moc
LnmN > r - u w d t -
I 4 4

0 0 0
C 0 0
m
O
. ?
N m 0
a
N r-
n cn
u

.
m 0. r-
Nmc-
, .....
>or-~nor-
~ n m ~ m v

0
N
0
7 "
0
Figure 10. Economics o f Installing an M V R
Preconcentrator t o 3 5 O Brix
Using Waste H e a t t o Preheat F e e d
 Table 6
Economics of I n s t a l l i n g a n MVR P r e c o n c e n t r a t o r t o 2 0 ' Brix

Steam S a v i n g s Steam Savings

Total E v a w r a t o r Econaw KVR ' l b t a l . -
S/yr with E l e c t r i c i t y Cost JXF S/yr w i t h E l e c t r i c i t y Cost JXF
capacitq of C u r r e n t Installed Steam @ $/yr with E l e c . ROR Payback steam @ $/year w i t h E l e c . F8R Payback
Mlbs,"hr Multi-Effect Investment 4.00 $/)*llbs @ .035 $,'kwh % Years 5.00 $/Mlbs @ .040 $;kwh % Years
 Table 8

MVR P r e c o n c e n t r a t o r to 35' R r i x

Assume Waste Heat S o u r c e A v a i l a b l e for P r e h e a t and S u f f i c i e n t

High P r e s s u r e Steam A v a i l a b l e to Run Compressor w i t h Steam Turhilie

Total Annual $ Discounted

Installed Saved w i t h Cash F l w
Investmnt Steam @ Rate of Pay back
Multi-Effect $ -- 4.00 $/Mlbs Return $ Years-
2.5 54,600 22.6 4.8
3.0 262,500 38,600 15.7 6.0
3.7 -- 23,500 7.5 -- --
7.7
2.5 109,200 30.4 3.9
3.0 375,000 77,200 22.3 4.9
3.7 47,000 1.2.9-. - -
..
6.5
2.5 163,900 36.4 3.3
3.0 450,000 115,900 27.4 4.2
3.7 70,500 16.9 .---
5 . 7--
2.5 218,500 40.5 3.0
525,000 154,500 30.7 3.9
3.7 94,000 - 19.4 5.3 P

83.
 F u r t h e r i m p r o v e m e n t s i n t h e o p e r a t i n g c o s t s of t h e MVR
s y s t e m s c o u l d b e a c h i e v e d b y r e d u c i n g t h e c o s t s of e l e c t r i c i t y .
T h e r e f o r e , a n e c o n o m i c a n a l y s i s w a s c o m p l e t e d f o r t h e 35O B r i x
MVR s y s t e m s a s s u m i n g t h a t t h e c o m p r e s s o r w a s d r i v e n w i t h a
s t e a m t u r b i n e . A s i n d i c a t e d i n T a b l e 8, t h e p a y b a c k would b e
a p p r o x i m a t e l y 4 y e a r s u n d e r t h e b e s t situation when c o m p a r e d t o
a m u l t i p l e - e f f e c t e v a p o r a t o r w i t h a 3. 0 e c o n o m y r a t i o .