Körting ICE Condensation Vacuum System · steam jet ejector vacuum unit combined with a liquid...

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1 booster (stage 1)

2 booster (stage 2)

3 mixing (direct contact) condenser

4 ejector (stage 3)

5 intercondenser

6 ejector (stage 4)

7 seal tank

8 cooling water pump I

9 cooling tower

10 cooling water pump II

11 motive steam

12 fresh water cooling tower

13 bleed

14overflowoffattywater

15 draining

16 gas outlet

17 sparging steam from deodoriser

The conventional multi-stage ejector system consists of:Two serial-connected boosters (1 and 2), a main mixing (direct contact) condenser (3) and a downstream 2-stage air evacuation group consisting of a steam jet ejector (4), an interconnected mixing condenser (5)andasteamjetejector(6)asfinalstage.Togetherwiththerequiredmotivesteamfromtheboosters/steamjetejectors,theexhaustwatervapourandfattyacidcomponentsarecondensedinsideofthemixingcondensers.Thepollutedcoolingwaterforcondensationpurposesinthemixingcondenserscir-culatesviathecoolingtower(9)usingcentrifugalpumps(8and10).Furthermore,asealtank(7)hasalsobeen included in the water circuit which, in addition, serves to separatefattycomponentsfromthecirculatingwater.

Advantages• lowinvestmentcosts

• lowmaintenancecosts

• simpleandreliableoperation

• noriskofcondensersfoulingbyfatcarry-over

Conventional multi-stage ejector system greasy cooling tower

Conventionalmulti-stagesteamjetejectorsystemsarestillbeingusedintheedibleoilindustryworldwide.

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Körting ICE Condensation Vacuum System

Comparison with conventional vacuum systems

sunderdiek.de

221-

222-

ICE

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vent

-com

paris

on-E

N-1

5030

4

Körting Hannover AG Badenstedter Straße 56

30453 Hannover

Germany

Tel.:+495112129-253

Fax:+495112129-223

st@koerting.de

www.koerting.de

Disadvantages• highwatertemperature,equivalenttothehighpressureinthemaincondenserrequiresrelativelyhighmotivesteamconsumption(twoboosterstagesupstreamofthemaincondenser).

•pollutedcoolingwater

• odourcan´tbeavoided

• thecoolingtowermustbecleanedfromtimetotime(becauseofthehighpollutionwithfat)

Körting ICE Condensation Vacuum Systems

Theinstallationinthefigureontheleftillustratesthaticecondenser (1) is in use (being charged), where as ice con-denser(2)isinthemeltingcycle.Thespargingsteam(17)fromthedeodoriser,pollutedbyfattyacids,isalternatelysuppliedtotheseicecondensers.Isolationofprocessandcondensersisdonebyhigh-performancebutterflyvalves.The condenser being charged is kept at low temperature bycirculatingarefrigerantatatemperatureofaround -28 °C using a refrigeration unit comprising compressor (11).Arefrigerantcondenser(13A)or(13B)isusedto condensethecompressedrefrigerant.-28 °C is below the condensation temperature of the spar-gingsteamusedinthedeodoriseratapprox.1-2mbaroperatingpressure.Sothesteamiscondensedtogetherwith most of its impurities on the cooling elements as a

coatingoficemixedwithfattycrystals.Theicecondenserundermeltingisentirelyseparatedfromthedeodoriserandheatedtoapprox.60°Cto80°Cwithvapour originating from the polluted condensate in the indirectlyheatedmeltingvessel(3).Thesurplusliquidisdischargedbyacondensatepump(4).Toevacuateonlythenon-condensablegasesasmallsteamjetejectorvacuumunitcombinedwithaliquidringvacuumpumpunitisused.Requiredcoolingwaterfortheinterconnected shell and tube condenser (8) as well as for there-cooler(11)attheliquidringvacuumpump(7)iskeptclean.Onlythesmallamountofcondensateleavingthecondenser(8)canbeslightlypollutedandisdrainedattheliquidseparator(9).

Körting ICE Condensation Vacuum System (clean cooling tower)

How the Körting ICE Condensation works

1 ice condenser I

2 ice condenser II

3 melting vessel

4 condensate pump

5 ejector stage 1

6 ejector stage 2

7 liquidringvacuumpump

8 air evacuation condenser

9 separator(liquidringvacuumpump)

10 re-cooler(liquidringvacuumpump)

11 refrigerant compressor

12 expansion valve

13Awater-cooledplateheatexchangeroralternative

13B air-cooled evaporative condenser

14 refrigerant separator

15 cooling water

16 motive steam

17processflow

18gasoutlet(liquidringvacuumpump)

19overflow(liquidringvacuumpump)

20 freshwater(liquidringvacuumpump)

21overflow(meltingvessel)

22 heating steam (melting vessel)

23 condensate (melting vessel)

24 condensate (heating jacket ejector stage 1)

25 bleed air-cooled evaporative condenser

26 fresh water air-cooled evaporative condenser

Conventional multi-stage steam jet ejector vacuum system

Körting ICE Condensation VacuumSystemoperatingwith water-cooledrefrigerant condenser

Körting ICE Condensation VacuumSystemoperatingwith evaporative air-cooled refrigerant condenser

Design Parameters

suctionflow(kg/h)H2O+8air+5kg/hFFA 300 300 300

suction pressure (mbar) 2.0 2.0 2.0

suction temperature (°C) 80 80 80

Consumption

total motive steam (kg/h) 2 280 180 180

heatingsteam(kg/h) 110 110

coolingtowerwater(m³/h)

vacuumcondensersandliquidring vacuum pump

333 24 24

refrigeration unit ---- 130 2

total water (m³/h) 333 154 26

electrical power (kW)

refrigeration compressor 190 205

liquidringvacuumpump 5 5

condensate pump 1 1

total electrical power (kW) 196 211

Waste water (m³/h) 2.585 0.485 0.485

operatinghoursperyear 8 250 8 250 8 250

steamcosts(Europeryear) 564 300 71 775 71 775

wastewatercosts(Europeryear) 85 305 16 005 16 005

recooling costs for the cooling water (Europeryear) 137 363 63 525 10 725

electrical power costs (Europeryear) 161 700 174 075

Operationcosts(Europeryear) 786 968 313 005 272 580

savingafter1year(inEuro) 473 963 514 388

savingafter2years(inEuro) 947 926 1 028 776

savingafter3years(inEuro) 1 421 889 1 543 164

savingafter4years(inEuro) 1 895 852 2 057 552

Comparison figures of the conventional multi-stage steam jet ejector vacuum system and Körting ICE Condensation Vacuum Systems

Utilities

cooling water temperature 33 °C

wet-bulb temperature 26 °C

motive steam pressure 9 bar (abs)

Utilityprice

cost for motive steam 30.0Euro/ton

cost for electrical power 0.10Euro/kWh

cost for re-cooling the cooling water

0.05Euro/m³

cost for waste water 4.0Euro/m³

The advantages of Körting ICE Condensation Vacuum Systems are:•significantenergysaving

•steamgeneratorcanbesmallersized (investment costs for the steam boiler are much lower)

•virtuallyzeroenvironmentalemissionbyseparatingofrefrigerant and polluted sparging steam

•simpleandreliableoperation

Thedecisionforthesuitablevacuumsystemisaquestionof economicviability.Apartfromtheplant’ssizeanditseffectiveness,theoperatingandinvestmentcostsalsoplayanimportantrole.Risingcostsforutilitiessuchassteam,waterandelectricityallformthebasisforassessingasystem.

On the following pages you will find a comparison between a conventional multi-stage ejector vacuum system and a Körting ICE Condensation Vacuum System.

refrigerant compressor

vacuum unit

evaporative condenser for the refrigerant

melting vesselsight glass on melting vessel

ice formation on the tubes

ice condenser

refrigerant separator