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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.Thepollutedcoolingwaterforcondensationpurposesinthemixingcondenserscirculatesviathecoolingtower(9)usingcentrifugalpumps(8and10).Furthermore,asealtank(7)hasalsobeenincludedinthewatercircuitwhich,inaddition,servestoseparatefattycomponentsfromthecirculatingwater.
Advantages• low investment costs
• low maintenance costs
• simple and reliable operation
• noriskofcondensersfoulingbyfatcarry-over
Conventional multi-stage ejector system greasy cooling tower
Conventionalmulti-stagesteamjetejectorsystemsarestillbeingusedintheedibleoilindustryworldwide.
p H11m
5
61
23
4
17
16
8
14
12
10
13
9
15
16
7
11
sunderdiek.de
Körting Hannover AG Badenstedter Straße 56
30453 Hannover
Germany
Tel.:+495112129-253
Fax:+495112129-223
www.koerting.de
Disadvantages• highwatertemperature,equivalenttothehighpressureinthemaincondenserrequiresrelativelyhighmotivesteamconsumption(twoboosterstagesupstreamofthemaincondenser).
• polluted cooling water
• odour can´t be avoided
• the cooling tower must be cleaned from time to time (because of the high pollution with fat)
221-
222-
Com
paris
on-I
CE
-con
vent
-EN
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424
Körting ICE Condensation Vacuum SystemComparison with conventional vacuum systems
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
• steam generator can be smaller sized (investment costs for the steam boiler are much lower)
•virtuallyzeroenvironmentalemissionbyseparatingofrefrigerant and polluted sparging steam
• simple and reliable operation
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
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.Thepollutedcoolingwaterforcondensationpurposesinthemixingcondenserscirculatesviathecoolingtower(9)usingcentrifugalpumps(8and10).Furthermore,asealtank(7)hasalsobeenincludedinthewatercircuitwhich,inaddition,servestoseparatefattycomponentsfromthecirculatingwater.
Advantages• low investment costs
• low maintenance costs
• simple and reliable operation
• noriskofcondensersfoulingbyfatcarry-over
Conventional multi-stage ejector system greasy cooling tower
Conventionalmulti-stagesteamjetejectorsystemsarestillbeingusedintheedibleoilindustryworldwide.
p H11m
5
61
23
4
17
16
8
14
12
10
13
9
15
16
7
11
sunderdiek.de
Körting Hannover AG Badenstedter Straße 56
30453 Hannover
Germany
Tel.:+495112129-253
Fax:+495112129-223
www.koerting.de
Disadvantages• highwatertemperature,equivalenttothehighpressureinthemaincondenserrequiresrelativelyhighmotivesteamconsumption(twoboosterstagesupstreamofthemaincondenser).
• polluted cooling water
• odour can´t be avoided
• the cooling tower must be cleaned from time to time (because of the high pollution with fat)
221-
222-
Com
paris
on-I
CE
-con
vent
-EN
-150
424
Körting ICE Condensation Vacuum SystemComparison with conventional vacuum systems
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
• steam generator can be smaller sized (investment costs for the steam boiler are much lower)
•virtuallyzeroenvironmentalemissionbyseparatingofrefrigerant and polluted sparging steam
• simple and reliable operation
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
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
• steam generator can be smaller sized (investment costs for the steam boiler are much lower)
•virtuallyzeroenvironmentalemissionbyseparatingofrefrigerant and polluted sparging steam
• simple and reliable operation
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
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.Thepollutedcoolingwaterforcondensationpurposesinthemixingcondenserscirculatesviathecoolingtower(9)usingcentrifugalpumps(8and10).Furthermore,asealtank(7)hasalsobeenincludedinthewatercircuitwhich,inaddition,servestoseparatefattycomponentsfromthecirculatingwater.
Advantages• low investment costs
• low maintenance costs
• simple and reliable operation
• noriskofcondensersfoulingbyfatcarry-over
Conventional multi-stage ejector system greasy cooling tower
Conventionalmulti-stagesteamjetejectorsystemsarestillbeingusedintheedibleoilindustryworldwide.
p H11m
5
61
23
4
17
16
8
14
12
10
13
9
15
16
7
11
sunderdiek.de
Körting Hannover AG Badenstedter Straße 56
30453 Hannover
Germany
Tel.:+495112129-253
Fax:+495112129-223
www.koerting.de
Disadvantages• highwatertemperature,equivalenttothehighpressureinthemaincondenserrequiresrelativelyhighmotivesteamconsumption(twoboosterstagesupstreamofthemaincondenser).
• polluted cooling water
• odour can´t be avoided
• the cooling tower must be cleaned from time to time (because of the high pollution with fat)
221-
222-
Com
paris
on-I
CE
-con
vent
-EN
-150
424
Körting ICE Condensation Vacuum SystemComparison with conventional vacuum systems