Energy Sustainability for Drying & Evaporation Plants

How does energy sustainability look for the drying and evaporation industry?

There has been a higher demand in the drying and evaporation marketplace due to regulations coming in for Dedert’s customers to change their energy sources to more renewable energy sources. This demand comes from customers wanting to be more ecofriendly within their business practices and with their technologies and systems. Dedert is a supplier of dryers and evaporators that use a lot of energy, and we must consider utilizing alternative energy sources for our processes.

This poses some significant challenges, especially for systems which require high inlet temperatures (150oC to 600oC). These systems are currently heated by burning fossil fuels which costs much less than using electrical power to generate high temperatures. 

Most renewable energy systems are based on producing electricity even if they use thermal energy to generate electricity. This has an efficiency loss which means that turning the electricity back into heat has both a negative effect on efficiency and consequently an economic impact.

The use of renewable electricity is growing significantly, and it is paving the way for sustainability in various industries. The main source of renewable energy that Dedert would use is generated electricity. This energy is often converted to either chemical energy or stored electricity. In some special cases, it could be possible to reuse heat and generate electricity from sources like geothermal or nuclear energy.

How do Dedert’s dryers use energy now?

Most dryers that Dedert provide are convective. Convective dryers use heat from high temperature air to dry the product. The water in the feed evaporates which cools down the incoming hot air. Dedert’s dryers typically use inlet air temperatures between the range of 150°C to 600°C.

High inlet temperatures (above 200oC) are generated by burning some type of fuel. Below 200oC dryers can be heated using steam. Even so, today, most commercial steam boilers use some form of fossil fuel as the heat source.

To date, industry has focused on the reduction and conservation of these conventional energy sources because this offers the lowest operating cost. Consequently, the reduction of CO2 footprint of dryer installations is concentrated on heat recovery systems, or the re-use of heat designed to make the overall plant operation more efficient. Dedert offers state-of-the-art designs of this type which are well established in the marketplace. These include:

Direct Fired Ring Dryer

Direct Fired Ring Dryer

Direct Fired Spray Dryer

Direct Fired Spray Dryer

Steam Heated Fluid Bed Dryer

Steam Heated Fluid Bed Dryer

How do Dedert’s evaporators use energy now?

Dedert’s evaporation systems currently use three main sources of energy for heating and evaporation. These are steam, electricity, or waste heat usually in the form of high humidity air.

These evaporators operate under vacuum so that water boils at temperatures lower than 100 oC. This has the advantage of reducing thermal degradation of the product and reducing fouling.

Several evaporator bodies (effects) can be connected and run at progressively lower pressure such that the steam generated in one body can be used to heat the next effect. In this way the heat can be reused several times. This technique is most used with steam heated evaporators and waste heat evaporators.

The efficiency of evaporators can be improved by recompressing the evaporated steam to raise its temperature and reusing it. Two technologies which are commonly used are Thermo-recompression (TVR) and Mechanical Vapor Recompression (MVR).

The MVR system is effectively a heat pump which uses an electrically driven fan to raise the temperature of the evaporated steam so it can be reused to heat the evaporator. The electrical power required to drive the fan is about one-third of the energy required to evaporate the water in the system. Dedert is a prime supplier of this state-of-the-art technology.

Dedert has increased its efforts in finding ways to reuse energy from other parts of a processing plant. The use of waste heat recovery is one way in which Dedert is contributing to energy sustainability in the evaporation industry. Integrating evaporators to take advantage of the free energy from dryers or distillation columns reduces the plant’s overall energy consumption and impact on the environment. This also leads to a reduction in energy requirements for the downstream emissions handling equipment. An evaporator can use alternative energy sources in lieu of steam, and Dedert has considerable expertise in using otherwise wasted energy sources:

Steam Heated Triple Effect Evaporator

Steam-Heated Triple Effect Evaporator

Waste Heat Evaporator Using Dryer

Waste Heat Evaporator Using Dryer Exhaust

Mechanical Vapor Recompression Evaporator

Mechanical Vapor Recompression Evaporator

How can energy sustainability principles be implemented in dryers?

Once it is not possible to use fossil fuels, then electricity, hydrogen, or biogas would be the energy sources most likely used to generate heat in the future.

Dedert is now preparing designs for its systems to use energy from new emerging technology which uses renewable resources as they are adopted by industry. This will include but is not limited to the processes listed below:

Some of Dedert’s fluidized bed dryer systems already have heat exchangers inside the bed instead of using an air heater on the outside. Most of the heat is provided by heating tubes immersed in the fluidized material with steam. The inlet temperatures are relatively low, ranging from 120°C to 150°C. A heat pump could be used to transfer heat from the dryer exhaust to the tubes using a high temperature refrigerant. Conversely, an MVR (mechanical vapor recompression) system like that used in Dedert’s evaporator systems could be used by compressing the exhaust steam and feeding it back into the heating tubes. This would reduce the energy input by approximately 60%, which would come from electricity.

Fluid bed dryer with internal heating tubes

Fluid bed dryer with internal heating tubes

com heat pump
Superheated Steam Dryer

Today’s best Technology: Superheated Steam Dryer heated by natural gas with waste heat evaporator recovering energy from the dryer

superheated steam drying heated

Future application of superheated steam drying heated by burning green hydrogen and oxygen generated by electrolysis

How Does a Heat Pump Work?

Purpose of Heat Pumps

The purpose of a heat pump is to upgrade low temperature energy by inputting electrical energy. A heat pump takes energy from a cold source and drives the temperature upwards to transfer that energy to a hotter temperature. Generally, the work put into the heat pump compressor is about one third of the heat which is transferred to the heated element.

Working Principles

A heat pump system is essentially the opposite of a refrigerator in your home. The system takes energy from a cold source and converts it to a higher temperature using a compressor. There is always one side that is heating up and one side that is cooling down. The lower temperature source is used to evaporate liquid refrigerant in a heat exchanger, transferring heat into it at the lower temperature end of the heat pump. If this were to be a dryer exhaust, it would be in the range of 60oC to 100oC. The now gaseous refrigerant passes through a compressor which increases its temperature and pressure. This high temperature gas then passes into a second heat exchanger where it is condensed at a higher temperature (for modern refrigerants this can be 120oC to 150oC) heating the incoming cold dryer inlet air. The condensing heat exchanger discharges hot liquid refrigerant at high pressure through an expansion valve which reduces the pressure of the liquid, cooling it down so it can pick up heat in the evaporating heat exchanger at the cooler end of the heat pump.

how heat pump

Challenges with Implementation

Industrial heat pumps are supplied as packaged systems with the evaporator and condenser included on the same skid as the compressor. To use the heat pump with a dryer, two heat exchangers must be added to the inlet and outlet of the dryer. A heat recovery exchanger is installed at the dryer outlet and connected to the refrigerant evaporator on the skid via a glycol loop. A preheater is installed at the dryer inlet and connected to the refrigerant condenser via a second glycol loop. Every time a heat exchanger is used, a bit of temperature difference is lost. It would be more helpful to install the evaporator and condenser in the dryer inlet and outlet so we can eliminate the additional heat exchangers and maximize the temperature difference. However, heat pump systems are not yet used in large scales for heating process plants and are not currently available for commercial purchasing. They are relatively expensive but are becoming more of an economical solution for the future because the cost of current energy sources has risen drastically over the years.

Generating Steam with Fans

As a response to rising energy costs, generating steam using a heat pump is a viable and attractive option. Suppliers of MVR fans have created steam recovery systems that work as an industrial heat pump. A heat pump chain is a series of several MVR fans that would normally be used individually in an evaporator system. The basic principle of an industrial heat pump is to recover waste heat and provide it at a usable temperature level. The maximum temperature that one MVR fan can raise is around 20°C. This is not particularly useful for achieving high temperatures, so this heat pump chain is beneficial because it works by connecting each fan together to gain higher temperatures. As you start with inputting low temperature steam, you then get higher temperature steam as an output.

Steam generation using fans in series Picture courtesy of Piller GmbH

Steam generation using fans in series (Picture courtesy of Piller GmbH)

The main advantages of the heat pump chain include:

What are some examples of renewable sources of energy?

Most sources of renewable energy are used to generate electricity which cannot be stored; therefore, to fully utilize these sources, the electricity can be used to store the energy in different forms:

Green, Blue and White Hydrogen

Presently the principal method of producing hydrogen is by reacting natural gas with steam using a catalyst. This reaction produces hydrogen and CO2. The CO2 is then captured usually in underground containment. This is a transitional production of hydrogen and currently the only method of production at gigawatt scale.

Green hydrogen can be produced by electrolyzing water, also known as electrolysis. A hydrogen electrolyzer is used to create ionization on an industrial scale. There are already pilot hydrogen electrolyzer systems being used today, and they are typically connected to wind turbines, hydroelectric powerplants, or a set of solar panels to generate electricity, and in turn, generate hydrogen. The hydrogen will be collected from the wind turbine or solar panels and then it will be stored as hydrogen gas. Once the hydrogen is burned, you will get the energy back in return. One issue with the hydrogen electrolyzer system is that it generates hydrogen and oxygen together. In most cases, the oxygen is not being used for anything and is exhausted into the atmosphere. This is wasteful dumping of a vital resource. The oxygen makes burning of hydrogen far more efficient, and therefore they should be burnt together. But this can be dangerous because mixing hydrogen and oxygen is potentially explosive. However, a well-designed system should be able to overcome this issue.

Recently there has been interest in exploring the use of hydrogen which is naturally occurring and can be collected from wells in much the same manner as natural gas. This is termed “white hydrogen” and because there is no carbon content it will not produce any CO2 when burnt. This may become a low-cost energy source in the future.

If green hydrogen is to become a significant source of energy for industrial purposes, then it is quite possible that wind power and solar systems in remote locations will be dedicated to electrolyzing systems producing hydrogen which can then be shipped or piped to industrial users. Some of the infrastructure for transferring the hydrogen could be repurposed from that which is currently moving natural gas.

green hydrogen

Using hydrogen as a fuel in dryers

Many existing designs of drying systems which use fossil fuels can be adapted to burn hydrogen as a direct replacement for natural gas or other fossil fuels. For open cycle dryers, the use of hydrogen with preheating from waste heat and heat pump systems could be a way of eliminating CO2 emissions.

For process gas recycle dryers and superheated steam dryers which can operate with recycled exhaust gas, the use of burners fired by hydrogen and oxygen would offer the opportunity to produce steam in the dryer exhaust and recover the energy by condensing the steam in other processes.

Dedert presently uses superheated steam dryers fueled by natural gas. A future possibility for Dedert is to heat our steam dryers directly with oxygen and hydrogen to reduce our carbon footprint. Hydrogen could also replace natural gas in convective drying systems.

SSD Dryer using Natural gas

SSD Dryer using Natural gas

SSD dryer heated by burning Hydrogen

SSD dryer heated by burning Hydrogen & Oxygen

Thermal Batteries

A thermal battery is something that can be heated up to a high temperature and will stay hot for a long period of time. A few different types of thermal batteries are currently being proposed. A Finnish company has created hot batteries made of sand, where the energy will be stored. Essentially, holes are made in the sand and are then filled with tubes. Surplus electrical energy is used to heat up the sand to 600°C by blowing hot air into the tubes. If insulated well enough, this bed of sand can stay heated for months. Recovery of the heat is achieved by drawing air through the tubes to heat whatever system is desired.

An alternate system for storing energy is the use of a nest concrete thermal battery. In this type of thermal battery, energy is stored in tubes filled with concrete that have pipes running through them. Heat passes down through the pipes and heats up the concrete. The fluid passes through the pipes, and you can then recover energy from the heat battery. These systems can store a lot of energy, as they are usually stacked very tall and wide.

thermal batteries

All in all, the future is bright for energy sustainability within drying and evaporation technologies. As the demand increases for renewable energy sources amongst the food, chemical, and pharmaceutical industries, so does the need for more efficient and sustainable technologies for Dedert’s customers around the world. Whether it is an industrial heat pump chain, the use of green hydrogen or heat batteries, there are numerous ways in which the process equipment industry is working to meet the demands of our everchanging world. Dedert plays a principal role in applying the latest economically sustainable energy sources within our technologies. Though Dedert has incorporated some of these practices into our systems already, implementing more energy-efficient options is crucial in transitioning to a cleaner and greener future.

Evaporators: Revolutionizing Industrial Processes

Evaporators are devices that are used to remove liquid from a solution or a suspension, by heating the mixture to promote evaporation. They are an essential component of many industrial processes, including chemical, pharmaceutical, food, beverage production, and wastewater treatment industries.

There are different types of industrial evaporators available in the form of shell and tube, plate and frame and thin film. Typically shell and tube evaporator types include falling film, rising film evaporators, and forced circulation. Typically plate and frame evaporator types include rising film and forced circulation. Each type has its unique features and advantages depending on the specific application and process requirements.

In this article, we will discuss:

Working Principle of Evaporators

Engineers design evaporators based on the physical phenomenon of evaporation, concentrating a solution by converting the volatile liquid into the vapor phase by adding heat energy to the system. The heat source is normally either from condensing or cooling a liquid at a higher temperature and pressure than the solution which is being concentrated.

The basic components of an evaporator are:

Energy Sources of Evaporators

The energy sources of evaporators are listed below:

1. STEAM HEATED

Steam Heated Evaporators are preferred when low pressure steam is available and inexpensive. The steam is condensed on the shell side of the evaporator, which operates at a higher pressure than on the tube side and drives evaporation. The evaporation from the first effect is used as the heating source for the subsequent effect. The vapors produced in the last effect are condensed in a condenser. Steam cost, overall available temperature differential, space requirements and product characteristics are considered to optimize the number of effects.

2. MECHANICAL VAPOR RECOMPRESSION

Dedert originally introduced Mechanical Vapor Recompression (MVR) to the corn wet milling industry over 40 years ago. The evaporator components are like steam driven systems, but with the addition of a mechanical compressor or fan. Mechanical energy compresses evaporated process vapor to a higher pressure and condensing temperature, and returns it to the process, minimizing steam consumption.

With increased gas prices, MVR has become the popular option for reducing operating costs, especially at higher evaporation rates. Fewer vessels are required than in steam powered multiple effect systems, resulting in lower installation costs.

3. THERMAL VAPOR RECOMPRESSION

Thermal Vapor Recompression (TVR) system is more energy efficient than a steam heated system when medium to high pressure steam is available. The motive steam enters through the nozzles and draws in recycled suction vapor. The vapor mixes in the converging section, and the recycled vapor is boosted to an intermediate pressure. Recycling the suction vapor allows for a lower steam consumption. Thermocompressors are more efficient when they are recycling more vapour, producing a lower boost and therefore requiring less steam.

thermocompressor evaporator
Dedert's Thermocompressor Evaporator

4. WASTE ENERGY

As part of the movement for sustainable future, increased efforts have been made in finding ways to reuse energy from other parts of the plants. Dedert has long been a pioneer in waste heat recovery and was granted the US patent for an evaporator chest with built-in scrubber for the corn wet milling industry.

Integrating evaporators to take advantage of the free energy from dryers or distillation columns reduces the plant overall energy consumption and impact on the environment. There is also a reduction in energy requirements for the downstream emissions handling equipment.

An evaporator can use many different energy sources in lieu of steam and Dedert has considerable expertise in making use of otherwise wasted energy sources:

Integration can also reduce capital expenditures:

Typical Operational Process of Evaporators

If we separate the working process of an evaporator into stages, they will typically look as the following:

  1. The process liquid and the heat source are introduced into the heat exchanger heat exchanger.
  2. As the process liquid is heated, it begins to boil. At this point, the more volatile liquid starts to evaporate and turns into a vapor.
  3. The vapor generated during the evaporation process proceeds to the separator, and the entrained droplets are separated from the vapor. 
  4. The vapor then proceeds to a second heat exchanger called a condenser. A colder liquid, like cooling water, is heated by the vapor. This heat transfer causes the vapor to condense back into a liquid.
  5. The condensate is then collected separately from the process liquid and can be used as process water.

The type of evaporation as well as the design and operation of an evaporator depend on various factors, such as:

Each type of evaporator, e.g., falling film or forced circulation has its unique design and operating principles. We will discuss the types of evaporators a bit later. Let’s look at their design considerations first.

Design Considerations of Evaporators

When Dedert designs an evaporator for an industrial application, we must consider a few key factors, including:

1. The Driving Force or the Delta T

Delta T is the temperature difference between the heating source and the liquid to be evaporated. This is the driving force for evaporation.

2. Heat Transfer Area

The evaporator must provide sufficient heat transfer area to enable efficient heat transfer for a given delta T between the heating medium and the liquid to be evaporated.

3. Evaporation Rate

The evaporation is the capacity of the evaporator. This is he amount of vapor produced at a given process liquid feed rate and concentration profile.

4. Liquid Feed Rate

To maintain the desired concentration in the evaporator, the process feed rate is controlled in order to provide a stable steady state operation. 

5. Energy Efficiency

Sustainability is a key factor in today’s industrial designs. The Dedert evaporator design focuses on achieving the best possible energy efficiency and Total Cost of Ownership for the client by optimizing the heat transfer area verses the various available energy sources.

6. Separation Efficiency

The separation efficiency is the degree of separation between the vapor and the liquid. The type of separation medium and the design of the separator is determined by the separation efficiency required and the physical properties of the process liquid, such as density and viscosity.

7. Material of Construction

Our selection of the material of construction for the evaporator is based on the chemical and physical properties of the process liquid being evaporated. Resistance to corrosion and erosion resulting from the liquid, heat, and other environmental factors are important.

8. Maintenance and Cleaning

To ensure optimal performance and longevity of the equipment, the functionality of the Dedert evaporator design strongly considers ease of maintenance and cleaning.

Types of Evaporators

There are several types of evaporators used in industrial settings, each with its own advantages and disadvantages. The choice of evaporator depends on the specific application and the properties of the liquid mixture being concentrated.

Some of the most common types of evaporators are:

1. Falling Film Evaporators

It is by far the most widely used type of evaporator.

falling film evaporator is one of the evaporators
One of Dedert's Falling Film Evaporators

In falling film evaporators, the liquid to be evaporated is fed onto a vertical tube or plate. The liquid forms a thin film on the surface of the tube or plate, and the heat is applied to the outer surface. The vapor generated from the liquid flows downward or upward and is condensed in a separate vessel or condenser.

The following are some advantages of falling film evaporators:

Typical industries that use Falling film evaporators are the food, pharmaceutical, and chemical industries.

2. Forced Circulation Evaporators

When there is a risk of fouling or at high temperatures or scaling with salts that are likely to precipitate, the forced circulation type of evaporator maintains a full tube, which mitigates this risk.

forced circulation evaporators
One of Dedert's Forced Circulation Evaporators

In Forced Circulation Evaporators, the liquid is pumped through a heat exchanger, where it is heated. The liquid then continues to a flash vessel, where it is depressurized, causing the volatile liquid to vaporize.

The following are some advantages of forced circulation evaporators:

Typical industries that use forced circulation evaporators are the distillery, pulp and paper, chemical, and pharmaceutical industries.

3. Rising Film Evaporators

Another type of evaporator that we use for low to medium-viscosity liquids is the Rising film type.

In Rising Film Evaporators, the liquid is fed into a vertical tube, and heat is applied to the outer surface of the tube. The liquid forms a thin film on the surface of the tube, and the vapor generated flows upward and is condensed in a separate vessel or condenser.

The following are some advantages of falling film evaporators:

The food and dairy industries are the most common users of Rising film evaporators.

4. Shell & Tube vs. Plate & Frame Evaporators

Tubular and Plate evaporators both have their own advantages and disadvantages. The choice of a hybrid system depends on the specific application and the properties of the process liquid.

plate evaporators
One of Dedert's Plate Evaporators

A forced circulation plate develops higher shear rates which reduce viscosity and power consumption. It is economical for smaller applications. Tubular forced circulation is economical for larger capacities, take up less floor space and are easier to maintain and clean.

A rising film plate is a perfect solution for small capacities and clean process liquors. Like the forced circulation, the falling film or rising film tubular evaporators, are economical for larger capacities, take up less floor space and are easier to maintain and clean.

What Makes Evaporators Essential for Modern Industries?

If you haven’t guessed already, evaporators are essential equipment for many industries, including food and beverage, chemical, pharmaceutical, and environmental. They are highly useful in industrial settings as they offer several benefits, including:

Improved efficiency

Improving the efficiency of production processes by concentrating liquids, reducing the volume of materials to be handled, and decreasing the energy required for drying, transportation and storage.

Enhanced product quality

Improving product quality by removing impurities, reducing microbial growth, and preserving the flavor and nutritional value of the product.

Reduced costs

Significant cost savings by reducing the volume of liquid to be transported and stored, and reducing energy consumption and operational costs, especially if the product needs to be dried.

Environmental Benefits

Reducing water consumption, decreasing wastewater discharge, and reducing environmental impact.

Dedert’s Innovation in Evaporation Technology and their Contribution to the Industry as a Whole

Dedert's Evaporation Technology is a game-changer in the industry due to its energy efficiency, robust construction, low maintenance, and flexibility to meet specific client requirements. The company has been offering process optimization solutions for over 55 years to reduce waste, increase efficiency, reclaim by-products, and save energy, all while reducing operating costs.

One of Dedert's specialties is process optimization. We offer different types of heat transfer surfaces and energy sources to provide customers with energy-efficient, robust, low-maintenance, and flexible evaporator systems. When configuring each system, we consider various factors such as:

Dedert has also been at the forefront of waste heat recovery for quite some time, and as a result, we were awarded a US patent for our innovative evaporator chest with a built-in scrubber that caters to the needs of the corn wet milling industry. Our expertise in waste heat recovery and our ability to integrate evaporators with other plant equipment reduces overall energy consumption and impact on the environment.

This is why Dedert is now a household name to many industries and has made it a go-to solution provider in the market.

Conclusion

Evaporators have become increasingly valuable equipment in industrial settings due to their many benefits. While they have long been a necessary component for many industries, the growing demand for sustainability has made them even more essential. Choosing the right type and design of the evaporator depends on the specific application and properties of the liquid being concentrated. With the help of a reliable solution provider like Dedert, proper design, and implementation of standard operating procedures, the chosen system can lead to improved efficiency, reduced operating costs, and consistent product quality.

1. What material is used for evaporators in food processing?

In the food processing industry, evaporators are typically made entirely of stainless steel. This material is preferred because it is resistant to corrosion, easy to clean, and does not react with food products. The use of stainless steel in evaporators ensures that food products are not contaminated, and that the equipment can withstand the harsh conditions of food processing environments. Additionally, stainless steel evaporators provide excellent heat transfer properties, allowing for energy efficient concentration of food products.

2. Is evaporator a heat exchanger?

Yes, an evaporator is a heat exchanger used in heat exchange processes to transfer the heat of one fluid into the latent heat of vaporization of another fluid. Typically, if an evaporator is employed to convert water or an aqueous solution from liquid to vapor state, it is called an evaporator. The evaporator's design, type, and size depend on the properties of the fluids involved in the heat exchange process, as well as the intended application.

1. What are the applications of a Dedert Evaporator?

  • Amino Acids
  • Ammonium Sulphate
  • Barley Stillage
  • Beet Stillage
  • Betaine Caustic Stillages
  • Calcium Carbonate
  • Cane Stillage
  • Citric Acid and Salts
  • Corn Steep Liquor
  • Corn Stillage
  • Corn Syrup
  • Dextrose
  • Erythritol
  • Fructose
  • Glucose
  • Gulonic Acid
  • Glycerin
  • Itaconic Acid
  • Kaolin Clay
  • Lactic Acid
  • Lysine
  • Maltodextrin
  • Maltose
  • Molasses
  • MSG
  • Pea Solubles
  • Potassium Carbonate
  • Potato Juice
  • Rendering Waste Sodium Chloride
  • Sodium Sulphate
  • Sodium Thiocyanate
  • Sorbitol
  • Steepwater
  • Succinic Acid
  • Sucrose
  • Sugar Betane
  • Sugar Raffinate
  • Sugar Vinasse
  • Tomato Sauce
  • Theonine
  • Vitamin C
  • Wheat "C" Starch Effluent
  • Wheat Stillage
  • Yeast