Basic design and operation of vacuum
systems
Karl Tomas Eriksson
• German Technology meets ASAGA World Congress on Oils and Fats and 31st Lecture series
• Rosario – Argentina - Oct. and Nov. 2015
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1871 Ernst and Berthold Körting found GEBRÜDER
KÖRTING.
1872 Steam jet and water jet pumps are produced to
generate vacuums.
1909 The legendary Wright brothers use 40 HP
Körting aircraft engines.
1919 At the end of the 1st World War all foreign
factories and branches was been lost.
1920 First multi-stage steam jet vacuum systems are
fabricated.
1945 The company is completely destroyed. After the
2nd World War it is rebuilt with the help of the
remaining employees.
History – Foundation and development
“Injector“, 1871 drawn by Ernst Körting
Berthold
Körting
ErnstKörting
3
1964 Steam jet vacuum pumps for pressure of 0.01
mbar and steel degassing systems are constructed.
1987 The first ice condensation system is installed for
the edible oil industry.
1991 The first alkaline closed loop system is installed
for the edible oil industry.
2004 The world's largest ice condensation plant was
built by Körting for IOI Corporation - Rotterdam.
2011 Koerting do Brasil, first Koerting subsidiary in the
Americas, founded.
2013 Koerting do Brasil, assume responsibility for
South America.
2013 More than 100 Alkaline Closed Loop vacuum
systems supplied world wide
2014 More than 40 ice condensation plants supplied
world wide
History – Manufacturer leading products
4
• Körting Hannover AG manufactures leading
products in vacuum and environmental
technology
• The focus lies on engineering skills and
core competencies in niche markets
worldwide
• Subsidiaries / agencies worldwide
• Sales: > €60 mn. (Körting Group)
• Employees: > 330 (Körting Group)
• Proportion of products exported: > 80%
Numbers, data & facts
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Subsidiaries and agencies worldwide
BrazilKoerting do Brasil
ChinaKörting Trading (Beijing Ltd.)
GermanyHans Hennig GmbH
IndiaKoerting Engineering Private Ltd.
Malaysia / SingaporeKoerting SEA Sd. Bhd.
PolandKörting Polska Sp. z.o.o.
RussiaKörting Export und Service GmbH
DenmarkAage Christensen A/S
Belgium / LuxembourgL. Tas & Co. bvba
FranceSpirax Sarco SAS
IndonesiaP.T. Egamekinka Pratama
NetherlandsTas Technics B.V.
NorwayChristian Berner A/S
PortugalSpirax Sarco
SwedenChristian Berner AB
SpainSpirax Sarco S. A.U.
TaiwanAllmaster Enterp. Co., Ltd.
HungaryDr.-Ing. Bela Katona
FinlandChristian Berner Oy
ItalyFED srl
AustriaKörting Hannover AG
SwitzerlandKörting Hannover AG
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Product overview
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• Consistent enhancement of products and
services using Körting test rigs
• Innovative applications are based on:
– complex tasks
– the demand for turnkey solutions
– close liaison between customers and experts
from the worlds of science, research and
industry
• Customised analysis of the required tasks
• Development of customised solutions
Application-driven research and development
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• The company’s own manufacturing and
testing departments work hand in hand
• These are the ideal conditions for providing
top quality and customer-driven solutions
• The quality management system
consistently monitors processes
• The quality of the company’s products is
inspected and monitored using special test
rigs
• Certified quality, based on AD2000-HP0
with pressure equipment directive 97/23EC
(Europe), Manufacture Licence ML (China),
TR (Russia) or ASME (USA)
Manufacturing
Footer 9
Ejector function
Footer 10
Direct contact condenser
Kondensatordruckcondenser pressure
DampfeintrittVapour inlet
MischwasserMixing water
KühlwasserCooling water
GasaustrittGas outlet
First point of condensation
appr. 7°C above the cooling
water inlet temperature
Footer 11
Multi-stage Vacuum System with Mixing Type Condenser
11
38 °C
66,5 mbar
ø 61017,5 mbar
energy consumption:
motive steam : 372 kg/h
cooling water : 50,4 m³/h
220 kg/h
draining
DN 250
heating steam
Savety valve
1 bar / 180°C
100 kg/h
3,3 mbar
condensate
185 kg/h H2O 10 kg/h air
DN 300
design
draining
vacuum
32 °C
(atmosphere)
barom.
height > 10,5 m
37 °C
45 °C
ø 168
64,1 °C230 mbar
draining
motive steam
1067 mbar
32 °C
26 kg/h 26 kg/h
cooling water
1.8 m³/h
48,6 m³/h
Footer 12
Comparison of condensers -
Mixing Type vs. Shell and Tube condensers
38 °C
66,5 mbar
ø 61017,5 mbar
energy consumption:
motive steam : 372 kg/h
cooling water : 50,4 m³/h
220 kg/h
draining
DN 250
heating steam
Savety valve
1 bar / 180°C
100 kg/h
3,3 mbar
condensate
185 kg/h H2O 10 kg/h air
DN 300
design
draining
vacuum
32 °C
(atmosphere)
barom.
height > 10,5 m
37 °C
45 °C
ø 168
64,1 °C230 mbar
draining
motive steam
1067 mbar
32 °C
26 kg/h 26 kg/h
cooling water
1.8 m³/h
48,6 m³/h
20 kg/h
condensate
vacuumDN 300
ø 168
ø 600
( F = 42 m² )
91 mbar44 °C
DN 250
25 kg/h
( F = 1,8 m² )65 °C250 mbar
draining Savety valve
23 mbardesign1 bar / 180°C
heating steam
280 kg/h
1067 mbar(atmosphere)
condensate
32 °C
36 °C
56 m³/h
condensate
42 °C
1,8 m³/h32 °C
125 kg/h
draining
185 kg/h H2O 10 kg/h air
3,3 mbar
energy consumption:
motive steam : 450 kg/h
cooling water : 57,8 m³/h
draining
motive steam
Footer 13
Traditional Multistage Ejector System with Cooling Tower
1 Booster (stage 1)
2 Booster (stage 2)
3 Main direct contact
condenser
4 Ejector (stage 3)
5 Inter condenser
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 (cooling
tower)
14 Overflow of fatty water
15 Draining
16 Gas outlet
17 Stripping steam
from deodorizer
Low cost system
but polluted cooling water
Air pollution
Cooling tower must be
cleaned time to time
Maintenance free
(no risk of pollution in
the condensers)
Footer 14
Motive steam consumptions at different motive steam pressure (2-16 bar abs.) and best efficiency
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
3000
0 5 10 15 20
Total
Motive
steam flow
(kg/h)
200 kg/h H2O
+ 10 kg/h air
@ 2 mbar
100 °C
Motive steam2-16 bar abs. Cooling
water
33 °C
Air
evacuation
unit
38 °C
2 4 6 8 10 12 14 16 bar abs.
1930 1470 1345 1285 1250 1220 1205 1195 kg/h
70
mb
ar
39 °
C
Best efficiency
8-12 bar abs.
Over
flow
Motive steam pressure
2-16 bar abs.
Cooling water temp. 33 °C
Footer 15
Traditional Multistage Ejector System with Adjustable SecondStage Booster
Cooling water
intlet temperature
Motive steam flow
for the two boosters
Main Condenser
pressure
cooling water
main condenser
33 °C 1620 kg/h 69.9 mbar = 39 °C 227 m3/h
31 °C 1516 kg/h 63.7 mbar = 37.3 °C 214 m3/h
29 °C 1412 kg/h 57.6 mbar = 35.4 °C 201 m3/h
27 °C 1308 kg/h 51.4 mbar = 33.4 °C 188 m3/h
25 °C 1204 kg/h 45.2 mbar = 31.2 °C 179 m3/h
23 °C 1100 kg/h 39.0 mbar = 28.6 °C 162 m3/h
Footer 16
Alkaline Vacuum System (Normal Cooling Water)
Low cost system
with clean cooling water
Environmentally friendly
No air pollution
Maintenance free
1 Booster (stage 1)
2 Booster (stage 2)
3 Main direct contact condenser
4 Ejector (stage 3)
5 Inter condenser
6 Ejector (stage 4)
7 Fat separator (buffer Tank)
8 Circulation pump
9 pH-control unit
10A Plate heat exchanger (in operation)
10B Plate heat exchanger (in stand by)
11 Cooling tower pump
12 Cooling tower
13 Motive steam
14 Heating steam
15 Stripping steam
from deodorizer
16 Condensate
17 Circulation water
18 Total over flow
19 Caustic soda (NaOH)
20 Gas outlet
21 Fresh water (cooling tower)
22 Bleed (cooling tower)
Footer 17
Alkaline Vacuum System (Chilled Water)
1 Booster (stage 1)
2 Main direct contact condenser
3 Ejector (stage 2)
4 Inter condenser
5 Liquid ring vacuum pump
6 Fat separator (buffer tank)
7 Circulation pump
8 pH-control unit
9A Plate heat exchanger (in operation)
9B Plate heat exchanger (stand by)
10 Brine pump
11 Compensation vessel
12 Coolant compressor (chiller)
13 Cooling tower pump
14 Cooling tower
15 Motive steam
16 Heating steam
17 Stripping steam
from deodorizer
18 Condensate
19 Circulation water
20 Chilled water
21 Total over flow
22 Caustic soda (NaOH)
23 Gas outlet
24 Fresh water (cooling tower)
25 Bleed (cooling tower)
Low energy consumption
Low amount of waste water
No air pollution
Save operation
Footer 18
Main Advantages of an Alkaline System with Chilled Water
Overflow
Gasoutlet
NaOH
Fat separator
8.0
Circulationpump
hotwater
pH-control
Liquid ringvacuum pump
Condensate
Mixingcondenser
Motivesteam
Heatingsteam
Booster
Brinepump
Plate heatexchanger
Chiller
Process Vessel
Coolingwater
Motivesteam
significant saving of motive steam
only one booster is necessary
environmental effects are reduced
minimized air pollution
safe operation
experience by various installation
world wide since 1989
Footer 19
Ice Condensations Vacuum System
1 Ice condenser I
2 Ice condenser II
3 Melting vessel
4 Condensate pump
5 Ejector stage1
6 Ejector stage 2
7 Air evacuation condenser
8 Liquid ring vacuum pump
9 Gas separator (Liquid ring vacuum pump)
10 Re-cooler (Liquid ring vacuum pump)
11 Refrigerant compressor
12 Expansion valve
13 Priority vessel
14 Refrigerant separator
15 Evaporative condenser
16 Cooling water
17 Motive steam
18 Stripping steam from deodorizer
19 Gas outlet (Liquid ring vacuum pump)
20 Over flow (liquid ring vacuum pump)
21 Overflow (melting vessel)
22 Heating steam
23 Condensate
24 Fresh water (soft water)
25 Bleed (evaporative condenser)
Most efficient system for large capacities
Lowest energy consumption
Minimum amount of waste
Footer 20
Main Advantages of an Ice Condensation Vacuum System
CondensatePump
Ref rigerant CondenserRef rigerant
Compressor
Steam Jet EjectorVacuum Group
Liquid RingVacuum Pump Melting Vessel
Process Vessel
Ice Condenser
Ref rigerantSeparator
significant energy saving by
high efficiency
far less waste water will be produced
nearly no air pollution will
be produced
minimum space requirement
(skid mounted units)
non barometric installation
newest technology with
computer controlled operation
experience by various installation
world wide since 1988
Footer 21
Comparison of the Various Systems
ALKALINE
NORMAL WATER
Motive Steam consumption = 2597 kg/h
Cooling Water consumption = 425 m³/h
Electrical Power consumption = 40 kW
Waste Water consumption = 2,854 m³/h
Motive Steam consumption = 678 kg/h
Cooling Water consumption = 185 m³/h
Electrical Power consumption = 210 kW
Waste Water consumption = 0,935 m³/h
ICE
CONDENSATION
ALKALINE
CHILLED
WATER
Motive Steam consumption = 235 kg/h
Cooling Water consumption = 42 m³/h
Electrical Power consumption = 165 kW
Waste Water consumption = 0,489 m³/h
SURFACE
CONDEN-
SATION
Motive Steam consumption = 3000 kg/h
Cooling Water consumption = 450 m³/h
Electrical Power consumption = 13 kW
Waste Water consumption = 3,257 m³/h
Comparison of the Various Systems(approximate daily production 600 t)Design Data: 250 kg/h stripping steam + 10 kg/h air + 4 kg/h FFA, 80°C
1,5 mbar at inlet to the vacuum system;
motive steam pressure 10 bar abs / saturated
cooling water inlet temperature 30 °C;
wet bulb temperature 21 °C
Footer 22
Comparison of the Various Systems
ALKALINE
NORMAL WATER
Motive Steam consumption = 2597 kg/h
Cooling Water consumption = 425 m³/h
Electrical Power consumption = 40 kW
Waste Water consumption = 2,854 m³/h
Motive Steam consumption = 678 kg/h
Cooling Water consumption = 185 m³/h
Electrical Power consumption = 210 kW
Waste Water consumption = 0,935 m³/h
ICE
CONDENSATION
ALKALINE
CHILLED
WATER
Motive Steam consumption = 235 kg/h
Cooling Water consumption = 42 m³/h
Electrical Power consumption = 165 kW
Waste Water consumption = 0,489 m³/h
SURFACE
CONDEN-
SATION
Motive Steam consumption = 3000 kg/h
Cooling Water consumption = 450 m³/h
Electrical Power consumption = 13 kW
Waste Water consumption = 3,257 m³/h
Footer 23
Comparison of the Various SystemsDesign Data : 250 kg/h stripping steam + 10 kg/h air + 4 kg/h FFA, 80 °C
1,5 mbar at inlet to the vacuum system
motive steam pressure 10 bar abs / saturated
cooling water inlet temperature 30 °C
wet bulb temperature 21 °C
ICE ACL (cold) ACL (warm) Surface
condensation
Steam costs (US $/t) / year 25 51.975 138.600 535.631 618.750
Re-cooling costs for the cooling water (Cent/m³) / year 10 33.000 174.900 350.625 378.675
Electrical power cost (Cent/kW) / year 10 134.475 181.500 33.000 8.250
Effluent costs (US $/m³) / year 4 16.698 30.657 94.182 107.481
Caustic soda costs 25% (Cent/kg) / year 8 0 1.980 1.980 1.980
Operation costs / year ( in US $ ) 236.148 527.637 1.015.418 1.115.136
Difference / year ( in US $ ) 878.988 587.499 99.718
Equipment price ( in US $ ) 1.000.000 410.000 360.000 325.000
Difference / year ( in US $ ) 675.000 85.000 35.000
Saving after 1 year 203.988 502.499 64.718
Saving after 2 years 1.082.976 1.089.998 164.436
Saving after 3 years 1.961.964 1.677.497 264.154
Cost Comparison for 8.250 operation hours / year
Footer 24
Vacuum Unit in Drying, Neutralisation and Bleaching
Process
• Clean cooling tower
• Strict separation of cooling water
and process medium
• Easy cleaning during operation
• Simple and reliable operation
• Proven technology
• Maintenance free operation
Footer 25
Vacuum Unit in Drying, Neutralisation and Bleaching Process
• Clean cooling tower
• Non barometric installation
• Strict separation of cooling
water and process medium
• Low air pollution
• Easy cleaning during
operation
• Simple and reliable operation
• Proven technology
Footer 26
Vacuum Systems in the Bio-Diesel Process
edible oilfree fatty
acid
gums
methanol
crude oil
catalyst
oil drying
physical refining
methylester drying
glycerine water
evaporation
glycerine
distillation
transesterfication
methylester/glycerine
separation
methylester washing
methanol rectification
washing
water
biodiesel
glycerine
degumming
Footer 27
Typical Vacuum Units for the production of Bio-Diesel
Fully continuous operation
Clean cooling tower
Non barometric installation
Ex-proof design
Simple and reliable operation
Optimised with low operation cost
Horizontal and vertical installation possible
Ejetores e Equipamentos de Vácuo Ltda.
Rua Adib Auada 35
Bloco B - Sala 110
06710-700 Cotia – SP
Tel.: +55 11 4321-2745
Koerting do Brasil
www.koerting.de
