Forced Circulation Evaporators

Working Principle

In forced circulation evaporators, the liquor is pumped through a heat exchanger, where an energy source on the shellside heats the liquor on tubeside. The liquor then continues to a flash vessel, where it is depressurized, causing the volatile liquid to vaporize. Any droplets are removed from the vapor in a de-entrainment device at the top of the separator.

The device can be a centrifugal type or a demister. The droplets are then combined with the concentrated liquor. The clean vapor continues to a subsequent effect, a thermocompressor, a compressor or a fan.

Industries

Dedert Forced Circulation Evaporators are hard at work in the following industries:
• Food Processing
• Chemical Manufacturing
• Distillery Operations
• Biofuel Productions

Experience

1,500+

evaporators and crystallizers worldwide

55+

industry experience since 1968

Innovating Flexible Solutions for Over 55 Years!

Countries

Installations

Satisfied Customers

Years of Experience

Global Offices

Applications

Dedert Forced Circulation Evaporators are typically used for solutions and slurries which present a risk of fouling or scaling. Fouling occurs at high temperatures and high concentrations. Scaling occurs with salts that are likely to precipitate. The forced circulation evaporator maintains a full tube, which mitigates these risks. Forced circulation evaporators have longer product residence time and higher liquid volume in the tube Forced circulation evaporators are used for a variety of applications, including:

Kaolin clay
Ammonium sulfate
Barley stillage
Beet stillage
Betaine caustic stillages
Calcium carbonate
Cane stillage
Theonine
Citric acid and salts
Corn steep liquor
Corn stillage
Pea solubles
Potassium carbonate
Rendering waste
Sodium chloride
Sodium sulfate
Sodium thiocyanate
Steepwater
Sugar Vinasse
Wheat “C” starch effluent
Wheat stillage
Yeast

Key Details About

Dedert’s Air Bearing Atomizer

The atomizer's simple and sanitary design features FDA-compliant stainless-steel construction and a lightweight Titanium disc. It has only one moving part, which eliminates premature wear-and-tear and reduces the need for spare parts and maintenance such as bearing changes. The rotatable maintenance stand makes servicing and cleaning easy, further reducing maintenance requirements.

The air bearing atomizer comes with an integrated control module that includes an HMI, PLC, and instrumentation for utility control. The graphical user interface provides an intuitive and comprehensive interface of the complete system and data recording for all the parameters. The product line is available in three sizes to meet the full range of industrial spray dryer capacities, from laboratory-scale applications to industrial-scale and high-volume production.

Overall, Dedert's air bearing atomizer is a significant innovation in spray drying technology, offering customers a reliable, sustainable, and easy-to-maintain solution that meets the demands of today's market and paves the way for future applications.

The Dedert Advantage

The following are some advantages of Dedert Forced Circulation Evaporators:

✔ Reduce precipitation or scaling
✔ Reduce excessive fouling at high temperatures
✔ Higher shear rates which reduces viscosity and allows higher concentrations
✔ Higher viscous solutions which exceed the capabilities of the falling film

Pilot Evaporator

The Dedert research facility has a pilot evaporator to test products on a pilot scale and establish correct parameters and material characteristics needed for optimal design and scale-up. Dedert rental pilot evaporators are:
• Skid mounted and preassembled
• Equipped with vacuum system, pumps and motors
• Easily reconfigured for forced circulation and falling film
• Single effect steam heated
• Robust, with an evaporation capacity of 110-150 lb/h (50-70 kg/h)
• Industrial stainless-steel grade Type 316

Energy Integration

Mechanical Vapor Recompression (MVR)

The vapor is recompressed in the evaporator by a fan, blower, or high-speed compressor that increases both the vapor pressure and temperature before returning the recompressed vapor to the shell side of the heat exchanger where it is condensed, driving evaporation on the tube side. Capacity is controlled by modulating the fan speed with a Variable Frequency Drive, or the flow by inlet guide vanes.

As of 2024, Dedert has provided over 250 MVR systems across 25 countries.

Falling Film Evaporator with Mechanical Vapor Recompression (MVR)

Thermal Vapor Recompressions (TVR)

This process uses waste heat in the form of dryer vapors, ethanol from distillation columns, or even hot process water to recompress the vapor. Dedert was the first to use waste dryer gas as a heating source, receiving a patent in the early 1980s for an all-in-one scrubber and evaporator, which allowed the heat exchanger to accept dryer vapors containing particulates.

Dedert has supplied more than 100 Waste Heat systems across the world, powered entirely by waste heat and fluids.

History of Spray Dryers

Early Days

Modern Spray Dryers

Dedert’s Contribution in Spray Drying Tech

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Early Days

Samuel Percy, an English chemist, filed the first known patent for a spray dryer was in 1872. However, it wasn't until the early 20th century that the spray dryer became more widely used, primarily in the food industry. During World War II, the process was used to create dried milk for the soldiers.

Modern Spray Dryers

The first modern spray dryer was developed in the 1930s, and it used a rotary atomizer to produce droplets of liquid. Still, back then, they were relatively simple machines. The whole system consisted of a nozzle or atomizer to disperse the liquid into droplets, a hot air source to evaporate the liquid, and a collection system to capture the resulting powder. As the process became more popular, improvements were made to increase efficiency. These improvements came in the form of the use of multiple nozzles to increase the production rate or incorporating cyclones to separate the powder from the air stream, etc. However, this design had limitations in terms of the size and consistency of the droplets produced.

In the 1950s and 1960s, the use of spray drying expanded to other industries, such as pharmaceuticals and chemicals. It’s not only that industries favored spray drying because it allowed for the creation of highly concentrated powders that were more easily transported and stored than their liquid counterparts, but also the fact that air bearing atomizers suddenly came into the picture in the 1950s. They improved the atomization process by using high-velocity air to produce fine droplets. They utilized compressed air to produce a thin film of liquid, which is then broken into droplets by the high-velocity air. Thus, their technology allowed for greater control over the size and consistency of the droplets produced, resulting in more uniform and consistent powders.

Over the years, air bearing atomizers have been further developed and refined to improve their efficiency and reliability. Modern air bearing atomizers use advanced materials and design techniques to achieve high performance and durability. They are now widely used in a range of industries, including pharmaceuticals, food, and chemicals, for the production of high-quality powders with specific properties.

Dedert’s Contribution in Spray Drying Tech

As spray dryer technology evolved, they became complicated to maintain and service along with the issue of high power consumption. Fortunately, Dedert's ABA technology provides solutions to these challenges. Our air bearing atomizer is superior to traditional atomizers. It is FDA-compliant and lightweight, with one moving part that requires very low maintenance and spare parts as well as reduced energy consumption. Its rotatable maintenance stand simplifies servicing and cleaning. Dedert's air bearing atomizer thus bring with it sustainability, reliability, easy maintenance and is now the optimal choice for spray drying applications.

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Dedert’s New Innovation: Air Bearing Atomizer (ABA) - An Oil Free Solution for Spray Drying

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The atomizer is also highly energy-efficient, with a permanent magnet motor that can achieve high power levels and disc-tip speeds, low carbon footprint, and reduced overall energy consumption.

Dedert’s New Innovation: Air Bearing Atomizer (ABA) - An Oil Free Solution for Spray Drying

Dedert's air bearing atomizer offers significant advantages over traditional atomizer technologies, particularly in terms of illumination of product contamination sustainability, reliability, and ease of maintenance. Its unique design features an oil-free and contact-free operation, making it suitable for use in food-grade, pharmaceutical, chemical applications without the risk of product contamination.

The atomizer is also highly energy-efficient, with a permanent magnet motor that can achieve high power levels and disc-tip speeds, low carbon footprint, and reduced overall energy consumption.