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In this study, a numerical model is used to investigate the evaporation and flow characteristics of heated liquid sheets and films. The liquid is modeled as water and as black liquor, a byproduct produced by paper mills. In the pulping process, black liquor is concentrated in an evaporator as a falling film. The effectiveness of the evaporator is reduced due to fouling on heat transfer surfaces. Two flow arrangements are studied: falling films, where the liquor and steam are separated by a heat transfer surface; and liquid curtains, which is a thin sheet of liquid falling due to gravity surrounded by steam. For the liquid curtain, the liquid and gas come into direct contact, therefore there is no place for fouling to occur allowing for a more consistent operation of the evaporator. This type of arrangement is not currently used in paper mills but is being investigated in this work to determine its feasibility. The fluid system is simulated using the finite volume method with a single-fluid field to capture the liquid-gas interface. This study investigates how the breakup of a liquid curtain is affected by flow parameters and how the breakup into droplets influences the evaporation characteristics of the liquid curtain. It is found that the falling film evaporator has a much higher liquid evaporation rate than evaporating as a liquid curtain. However the falling film evaporator has an entrance length with no evaporation, and liquid curtains allow for evaporation to start occurring very near the inlet. If reducing length of the evaporator is a priority, liquid curtain evaporators can obtain a higher evaporation rate than falling films within the same distance. Falling film evaporation has a higher steam efficiency than a liquid curtain evaporator. However, for short evaporator lengths the rate at which water is removed from a liquid curtain evaporator is much greater, but at the cost of a higher steam consumption rate.

Neste trabalho é apresentada a avaliação da inversão da sacarose em um sistema constituído de um Evaporador de filme descendente com promotor de película. Foi feita a modelagem da inversão considerando-se os balanços de massa e de entalpia e a cinética de inversão no tubo de evaporação. Os principais parâmetros considerados foram: constante cinética (k), taxa de evaporação(mv), concentração de açúcares totais (C), vazão do líquido no tubo de evaporação (q), pH, temperatura (T) e tempo de residência no tubo de evaporação (T). Usaram-se dois métodos para a resolução do modelo, a primeira através da integração numérica do modelo (Runge Kutta de 4ta ordem) e a outra através de equacionamento simplificado a partir valores médios das propriedades, pH, e calculando as constantes cinéticas nas temperaturas efetivas em cada zona do tubo de evaporação, Tefa (zona de aquecimento) e Tefe (zona de evaporação), possibilitando assim, a integração analítica do modelo. Foram calculados os valores do volume do líquido (V) através dos dois métodos. Os resultados foram expressos em função da vazão do líquido (q). Verificou-se que os resultados calculados pelos dois métodos foram muito próximos. Os modelos desenvolvidos podem ser aplicados para a otimização do processo de evaporação visando à minimização da inversão da sacarose. O método desenvolvido possibilita a determinação do tempo de residência no tubo de evaporação. / In this work the evaluation of sucrose inversion in a system formed by falling film Evaporator with Promoter of film is presented. The modeling was made considering: mass and enthalpy balances and the kinetic of inversion in the evaporation tube. The mean parameters investigated were: kinetic constant (k), evaporation rate (mv), concentration of total sugars (C), volumetric velocity of the liquid in the evaporation tube (q), pH, temperature (T) and residence time in the evaporation tube (T). Two methods was used to solve the model, the first by numeric integration (Runge Kutta 4th Order) and the other by analytic integration of simplified model considering mean values of properties and pH, and the kinetic constant calculates at effective temperatures in each zone of the evaporation tube, Tefa and Tefe, allowed the analytic integration of the model. The volume of liquid in the evaporation tube (V) was calculated by the two methods (numeric integration and simplified methods). The results were expressed as a function of liquid flow rate (q). It was verified that the values obtained by the two methods were very closed. These models can be used for the optimization of the evaporation process emphasizing the minimization of the sucrose inversion. The methodology could be used for the determination of the residence time in the evaporation tube.

An experimental investigation of heat and mass transfer in a horizontal tube falling-film ammonia-water absorber was conducted. A tube bank consisting of four columns of six 9.5 mm (3/8 ) nominal OD, 0.292 m (11.5 ) long tubes was installed in an absorber shell that allowed heat and mass transfer measurements and optical access. A test facility consisting of all the components of a functional absorption chiller was fabricated specifically for this investigation. Several variations of the basic system set up were fabricated to enable testing over the wide range of conditions (nominally, desorber solution outlet concentrations of 5 - 40% for three nominal absorber pressures of 150, 345 and 500 kPa, over solution flow rates of 0.019 0.034 kg/s.) Measurements at the absorber were used to determine heat transfer rates, overall thermal conductances, solution-side heat and vapor-side mass transfer coefficients for each test condition. For the range of experiments conducted, the solution heat transfer coefficient varied from 923 to 2857 W/m2-K while the vapor mass transfer coefficient varied from 0.0026 to 0.25 m/s and the liquid mass transfer coefficient varied from 5.51×10-6 to 3.31×10-5 m/s depending on the test condition. The solution heat transfer coefficient increased with increasing solution flow rate; however, the vapor and liquid mass transfer coefficients seem to remain unaffected with the variations in solution flow rate and were found to be primarily determined by the vapor and solution properties. The experimental heat and mass transfer coefficients were compared with the relevant studies from the literature. Based on the observed trends, heat transfer correlations and mass transfer correlations in the vapor and liquid phases were developed to predict heat and mass transfer coefficients for the range of experimental conditions tested. These correlations can be used to design horizontal tube falling-film absorbers for ammonia-water absorption systems.

Evaporation is used in the dairy industry to reduce the production costs of powder production (including milk powder) as it is more energy efficient to remove water by evaporation than by drying. There are significant economic reasons why gaining a greater understanding of the complex interactions occurring between the liquid and vapour phases in evaporators is advantageous. The multiphase flows in industrial dairy falling film evaporators were studied. Several computational fluid dynamic (CFD) models were created using Ansys CFX 10. Two case studies were chosen. The first case involved modelling the dispersed droplets that require separation from the water vapour evaporated from the feed of the evaporator. The CFD results were able to show that fouling was not caused by a lack of separation. The predicted separation agreed with experimental measurements. The atomisation process was found to be critical in the prediction of the separation. The atomisation process is not well understood and introduced the greatest error to the model. A plug flow assumption is currently used as a basis for the design the separators. The CFD solutions found no validity to this assumption. The second case study aimed to model and solve the distribution of the feed into the heat transfer tubes at the top of the falling film evaporators. The goal of this study was to be able to accurately predict wetting of the tubes. The volume of fluid (VOF) method using the continuum surface force method (CSF) to account for surface tension was chosen to model the system. The poor curvature estimate of the CSF method was found to produce parasitic currents that limited the stability of the solutions. Small VOF timesteps prevented the solver from diverging and the parasitic currents would oscillate the interface around the correct location. The small timesteps required significantly more computational power than was available and the model for the distribution process could not be solved. The CSF VOF method showed considerable promise, particularly because it can predict free surface topography without user input. There are still questions about numerical creeping of films, but the method was able to correctly predict several different surface tension and contact angle dominated film flows expected to be needed to accurately model the distribution of the falling film evaporator. Validated solutions of jet, meniscus, sessile, "overfall" and 3-D weir models were obtained and these agreed with published results in literature. A 2-D weir solution showed qualitative agreement with the expected form of the film. A 2-D hydraulic jump model without surface tension was created and agreed with experimental work in the literature to within 22%. The 3-D hydraulic jump solution only showed partial agreement with published experimental, the solutions were not mesh independent and not well converged so few conclusions can be drawn. The solutions of a rivulet model showed qualitative similarities with experimental work. The predicted wetting rate did not agree with values in the published literature because the spatial domain modelled was believed to be too narrow. An extended model of rivulet flow agreed with the idealised rivulet profile in literature and the predicted wetting rate agreed with some of the published literature. Again the solutions were not mesh independent so few conclusions can be confirmed.

The present study is the first investigation of falling-film evaporation over horizontal rectangular tubes. This geometry is representative of the external profile of microchannel tubes. Incorporating these designs into shell-and-tube heat exchangers has the potential to provide compact, high-performance components for a wide range of applications. This fluid flow was investigated experimentally, targeting three areas: measurements of heat transfer coefficients, quantification of flow characteristics, and the performance of flow distributors. Falling-film evaporation experiments were conducted using water on a rectangular test section with dimensions of 203 × 1.42 × 27.4 mm (length × width × height), measuring heat transfer coefficients over a range of saturation temperatures, test section spacings, heat fluxes, and film Reynolds numbers. This was supported by a flow visualization study that quantified droplet and wave parameters using image analysis of high speed videos. Finally, the performance of eight liquid distributors, which are used to establish falling-film flows, was quantified and the size of the generated droplets and jets was measured. Three models were developed to predict the flow regime, wetted tube area, and heat transfer coefficient. The flow regime model is based on a thermodynamic analysis, while the wetted tube area is found with a hydrodynamic model based on idealized flow assumptions. Finally, the heat transfer model relies on a relationship with the classic Nusselt (1916) film theory. Each of these models demonstrated good agreement with the experimental data, as well as trends in the literature. The increased understanding of falling-film evaporation gained in this study will enable the accurate design of shell-and-tube heat exchangers with microchannel tubes.

Thesis (MSc)--Stellenbosch University, 2013. / ENGLISH ABSTRACT: This work focussed on a local multiple chamber falling film evaporator (FFE). The FFE is currently under operator control and experiencing large amounts of lost production time due to excessive fouling. Furthermore, the product milk dry mass fraction (WP) is constantly off specification, negatively influencing product quality, while the first effect temperature (TE1) runs higher than the recommended 70°C (this is a main cause of fouling). A two month period of historical data were received with the aim to develop a controller that could outperform the operators by keeping both control variables, WP and TE1, at desired set points while also increasing throughput and maintaining product quality. Access to the local plant was not possible and as such available process data were cleaned and used to identify two data based models, transfer function and autoregressive with exogenous inputs (ARX) models, as well as a semi-empirical-model. The ARX model proved inadequate to predict TE1 trends, with an average TE1 correlation to historical data of 0.36, compared to 0.59 and 0.74 for the transfer function and semi-empirical-models respectively. Product dry mass correlations were similar between the models with the average correlations of 0.47, 0.53 and 0.51 for the semi-empirical, transfer function and ARX models respectively. Although the semi-empirical showed the lowest WP correlation, it was offset by the TE1 prediction advantage. Therefore, the semi-empirical model was selected for controller development and comparisons. The success of the semi-empirical model was in accordance with previous research [1] [2] [3], yet other studies have concluded that ARX modelling was more suited to FFE modelling [4]. Three controllers were developed, namely: a proportional and integral (PI) controller as base case, a linear quadratic regulator (LQR) as an optimal state space alternative and finally, to make full use of process knowledge, a predictive fuzzy logic controller (PFC). The PI controller was able to offer zero offset set point tracking, but could not adequately reject a feed dry mass (WF) disturbance (as proposed and reported by Winchester [5]). The LQR was combined with a Kalman estimator and used pre-delay states. In order to offer increased disturbance rejection, the feedback gains of the disturbance states were tuned individually. The altered LQR and PFC solutions proved to adequately reject all modelled disturbances and outperform a cascade controller designed by Bakker [6]. The maximum deviation in WP was a fractional increase of 0.007 for LQR and 0.005 for FPC, compared to 0.012 for PI and 0.0075 for the cascade controller [6] (WF disturbance fractional increase of 0.01). All the designed controllers managed to reduce the standard deviation of operator controlled WP and TE1 by at least 700% and 450%, respectively. The same level of reduction was seen for maximum control variable deviations (370%), the integral of the absolute error (300%) and the mean squared error (900%). All these performance metrics point to the controllers performing better than the operator based control. In order to prevent manipulated variable saturation and optimise the feed flow rate (F1), a fuzzy feed optimiser (FFO) was developed. The FFO focussed on maximising the available evaporative capacity of the FFE by optimising the motive steam pressure (PS), which supplied heat to the effects. By using the FFO for each controller the average feed flow rate was increased by 4.8% (±500kg/h) compared to the operator control. In addition to flow rate gain, the controllers kept TE1 below 70°C and WP on specification. As such, the overall product quality also increased as well as decreasing the down time due to less fouling. / AFRIKAANSE OPSOMMING: Hierdie projek het op ‘n vallende film verdamper (VFV) gefokus. Die VFV word tans beheer deur operateurs en ondervind groot hoeveelhede verlore produksie tyd a.g.v oormatige aangroeisels. Die vorming van aangroeisels is grootliks te danke aan die eerste effek temperatuur (TE1) wat gereeld 70°C oorskrei. Die produk droë massa fraksie (WP) is ook telkens nie op die gewenste vlak nie, wat produk kwaliteit negatief beinvloed. Data, wat oor ‘n twee maand periode strek, was verkry met die doelstelling om ‘n beheerder te ontwerp wat beter sou vaar as die operateurs, deur beide WP en TE2 om ‘n nou stelpunt te beheer. Ter selfde tyd moet die ontwerpte beheerder die produksie tempo en produk kwaliteit verhoog. Geen toegang tot die plaaslikke VFV was moontlik nie, dus was die data skoongemaak en gebruik om twee data gebasseerde modelle te identifiseer, nl. oordragsfunksie en outoregressiwe met eksogene insette (ORX) modelle, asook ‘n semi-empiriese model. Die ORX model kon nie TE1 goed voorspel nie, met ‘n korrelasie faktor (tot die historiese data) van 0.36, vergeleke met die 0.59 en 0.74 van die oordragsfunksie en semi-empiriese modelle onderskeidelik. WP korrelasie faktore was meer konstant tussen die modelle, met waardes van 0.47, 0.53 en 0.51 vir die semi-empiriese, oordragsfunskie en ORX modelle onderskeidelik. Alhoewel die semi-empiriese model die laagste WP korrelasie vertoon het, was die tekortkoming vergoed deur die beter TE1 voorspelling. Gevolglik was die semi-empiriese model gebruik vir beheerder ontwerp en vergelyking. Die sukses van die semiempiriese model stem ooreen met vorige studies [1] [2] [3], tog het ander studies al bevind dat die ORX model beter gepas is vir die VFV proses [4]. Drie beheerders was ontwikkel, nl. ‘n proporsionele en integreerder (PI) beheerder as basis geval, ‘n liniêre kwadratiese reguleerder (LKR) as optimale toestands beheer alternatief en laastens ‘n voorspellende wasige logika beheerder (VWB) om volle gebruik van proseskennis te maak. Die PI beheerder kon foutlose volging van die stelpunte lewer, maar kon nie ‘n inset voer droë massa fraksie (WF) versteuring (soos voorgestel en weergegee deur Winchester [5]) na wense verwerp nie. Die LKR was saamgevoeg met ‘n Kalman afskatter en het gebruik gemaak van onvertraagde toestande. Die versteuringstoestande was individueel verstel om beter versteurings verweping te weeg te bring. Die aangepaste LKR en VWB kon beide die WF versteuring verwerp en het beter gevaar as ‘n kaskade beheer oplossing wat deur Bakker [6] ontwerp was. Die WP afwyking is beperk tot ‘n fraksie droë masse verandering van 0.007 vir LKR en 0.005 vir VWB, vergeleke met die afwykings van 0.012 vir die PI beheerder asook die 0.0075 van die kaskade beheerder [6]. Die ontwerpte beheerder kon ook die standaard afwyking van beide WP en TE1 met ten minste 700% en 450% onderskeidelik verminder. Soortgelyke verbeterings was gesien vir die maksimum beheer veranderlikke afwyking (370%), die integraal van die absolute fout (300%) en die gemiddelde fout (900%). Dus het die ontwerpte beheerders wesenlik verbeter op die operateur beheer. Ten einde om gemanipuleerde veranderlikke versadiging te voorkom, asook die voer vloei (V1) te optimiseer, was ‘n wasige logika optimiseerder (WVO) ontwerp. Die WVO het die beskikbare verdampingskapasiteit ten volle benut deur te sorg dat die stoom druk (PS), wat energie verskaf vir verdamping, ge-optimiseerd bly. ‘n Gemiddelde V1 stygging van 4.8% (±500kg/uur), vergeleke met operateur beheer, is waargeneem. Al die beheerders kon steeds die WP en TE1 stelpunte volg en dus TE1 onder 70°C hou (wat verminderde vormasie van aangroeisels tot gevolg gehad het). Daarom het die produk kwailiteit verhoog en die verlore produksie tyd verminder.

Neste trabalho é apresentada a avaliação da inversão da sacarose em um sistema constituído de um Evaporador de filme descendente com promotor de película. Foi feita a modelagem da inversão considerando-se os balanços de massa e de entalpia e a cinética de inversão no tubo de evaporação. Os principais parâmetros considerados foram: constante cinética (k), taxa de evaporação(mv), concentração de açúcares totais (C), vazão do líquido no tubo de evaporação (q), pH, temperatura (T) e tempo de residência no tubo de evaporação (T). Usaram-se dois métodos para a resolução do modelo, a primeira através da integração numérica do modelo (Runge Kutta de 4ta ordem) e a outra através de equacionamento simplificado a partir valores médios das propriedades, pH, e calculando as constantes cinéticas nas temperaturas efetivas em cada zona do tubo de evaporação, Tefa (zona de aquecimento) e Tefe (zona de evaporação), possibilitando assim, a integração analítica do modelo. Foram calculados os valores do volume do líquido (V) através dos dois métodos. Os resultados foram expressos em função da vazão do líquido (q). Verificou-se que os resultados calculados pelos dois métodos foram muito próximos. Os modelos desenvolvidos podem ser aplicados para a otimização do processo de evaporação visando à minimização da inversão da sacarose. O método desenvolvido possibilita a determinação do tempo de residência no tubo de evaporação. / In this work the evaluation of sucrose inversion in a system formed by falling film Evaporator with Promoter of film is presented. The modeling was made considering: mass and enthalpy balances and the kinetic of inversion in the evaporation tube. The mean parameters investigated were: kinetic constant (k), evaporation rate (mv), concentration of total sugars (C), volumetric velocity of the liquid in the evaporation tube (q), pH, temperature (T) and residence time in the evaporation tube (T). Two methods was used to solve the model, the first by numeric integration (Runge Kutta 4th Order) and the other by analytic integration of simplified model considering mean values of properties and pH, and the kinetic constant calculates at effective temperatures in each zone of the evaporation tube, Tefa and Tefe, allowed the analytic integration of the model. The volume of liquid in the evaporation tube (V) was calculated by the two methods (numeric integration and simplified methods). The results were expressed as a function of liquid flow rate (q). It was verified that the values obtained by the two methods were very closed. These models can be used for the optimization of the evaporation process emphasizing the minimization of the sucrose inversion. The methodology could be used for the determination of the residence time in the evaporation tube.

Yes / The content and concentration of beta-carotene, tocopherol and free fatty acid is one of the important parameters that affect the quality of edible oil. In simulation based studies for refined palm oil process, three variables are usually used as input parameters which are feed flow rate (F), column temperature (T) and pressure (P). These parameters influence the output concentration of beta-carotene, tocopherol and free fatty acid. In this work, we develop 2 different ANN models; the first ANN model based on 3 inputs (F, T, P) and the second model based on 2 inputs (T and P). Artificial neural network (ANN) models are set up to describe the simulation. Feed forward back propagation neural networks are designed using different architecture in MATLAB toolbox. The effects of numbers for neurons and layers are examined. The correlation coefficient for this study is greater than 0.99; it is in good agreement during training and testing the models. Moreover, it is found that ANN can model the process accurately, and is able to predict the model outputs very close to those predicted by ASPEN HYSYS simulator for refined palm oil process. Optimization of the refined palm oil process is performed using ANN based model to maximize the concentration of beta-carotene and tocopherol at residue and free fatty acid at distillate.

Il est démontré que dans de nombreux procédés de transformation de la matière, les dégradations entropiques (et les consommations énergétiques qui en découlent) peuvent être minimisées en répartissant les flux d’énergies dans le volume plutôt qu’aux bornes du système (exemple de la distillation diabatique). Cependant la réalisation et la gestion de profils thermiques contrôlés (tels que des gradients thermiques et des étagements de température maîtrisés) dans les appareils compactes ne sont pas très souvent réalisées parce que souvent complexes et coûteuses (batterie d’échangeurs, gestion des fluides). Cette difficulté technologique affecte non seulement les performances énergétiques et les efficacités de transformation des appareils classiques de grandes tailles, mais aussi les réacteurs microstructurés dont les faibles dimensions internes associées à la grande conductivité thermique du matériau constituant les parois du contacteur entraînent souvent l’homogénéité thermique de l’appareil au détriment de la gestion des gradients thermiques. Par ailleurs, les garnissages utilisés dans les séparateurs sont de formes très complexes dans lesquels il est difficile de faire à la fois de la structuration thermique et hydrodynamique. Les systèmes microstructurés basés sur des géométries à plaques semblent offrir une possibilité intéressante de structuration thermique (contrôle et modulation de flux énergétiques pour l’obtention d’un profil thermique spécifique) et hydrodynamique (contrôle des transferts de matière, des temps de séjour, des pertes de charges etc.). Dans cette thèse, les réflexions menées sur ces verrous technologiques ont conduit à la conception d’un microcontacteur à film tombant. Ce microprocédé a été caractérisé d’un point de vue thermique et hydrodynamique. Une étude de faisabilité sur le potentiel de ce microcontacteur à séparer un mélange binaire d’alcools (ethanol/n-propanol) a été menée, ses performances ont été expérimentalement évaluées d’un point de vue qualitatif (pureté du distillat et du soutirat) et quantitatif (rapports des débits entrant et sortant), mais aussi en intégrant la notion d’exergie compositionnelle, également appelée puissance de séparation / In many processes of mass transformation, entropic degradations (and energy consumptions which results from) can be minimized by distributing heat flows in all process volume rather than boundaries (example: diabatic distillation). However it is difficult to control and impose thermal gradients on small scales because of their complexity and high costs (exchangers, fluids). This technological difficulty affects not only the performances and energy efficiencies of conventional devices (macro scales) but also small devices (e.g. microstructured reactors). Indeed, compact equipments with small dimensions generate some difficulties. First, the driving force inducing liquid flow by gravity is very small. Second, small size and high thermal conductivity of the material induce thermal homogeneity instead of managing temperature gradients in the system. In many separators, the used packing material has complex forms that make difficult thermal and hydrodynamic structurations. Microstructured devices, based on microchannel plate technologies, offer an interesting possibility of thermal structuration (control and modulation of energy fluxes) and hydrodynamics control (e.g. mass transfer, residence times, pressure drop etc). In this thesis, many discussions on these technological barriers led to the design of a new microstructured falling film contactor. The aim of the present work is to study heat transfer phenomena and liquid hydrodynamics in this device and, investigates the separation feasibility of a binary mixture of ethanol and n-propanol. Microcontactor performances were experimentally evaluated in terms of quality (bottom and top concentrations) and quantity (bottom and top flow rate ratios). To fully characterize contactor performances, the separation power concept (also called compositional exergy) was integrated