DOI : 10.
36961/si27422
Piotr Lenard
Operation of a six-effect evaporator station
with a deficit in the vapour balance
Betrieb einer 6-stufigen Verdampfanlage mit einem Defizit in der Dampfbilanz
During the operation of a six-effect evaporator station the
vapour balance is subject of interfering incidents such as
changing technological states of the process or surrounding
conditions (ambient temperature e.g.) This article analyses
and compares possible methods of managing the operation
i.e. reaction to these incidents. In particular, methods of sta-
bilizing the vapour balance by supplying water or thin juice
to individual effects of the evaporator station and bypassing
the vapours between effects are compared.
The best way of reacting to the overload of the evaporator
station seems to be the bypass of vapour from an effect of
higher parameters to an effect of lower parameters. This
method creates a much faster reaction of the evaporator sta-
tion to excessive bleeding of vapour than supply of water or
thin juice, which need to mix with the juice in the vessels.
Feeding water to the thin juice tank or to one of the effects of
the evaporator station to compensate excessive vapour con-
sumption can be an acceptable solution in case of prolonged
increase in vapour consumption from the evaporator station
due to e.g. a significant decrease in ambient temperature.
Key words: evaporator station, vapour balance
1 Introduction
Increasing the number of evaporator effects and supplying
the evaporating crystallizers with vapours of higher effect is
the way to reduce the heating steam demand of sugar facto-
ries. Modern West European sugar factories operating at full
production capacity of the sugar house have operated such
six-effect evaporator stations for a long time. However, there
are numerous sugar factories, especially in Eastern Europe,
that have five-effect evaporator stations or six-effect evapora-
tor stations, which have not been operating for a very long
time. The transition to a six-effect evaporator station requires a
high degree of discipline from the sugar factory in maintaining
stable beet slicing rate and maintaining correct process param-
eters. Possible problems in the proper and smooth manage-
ment of technological processes (especially in crystallization)
may have a negative impact on the operation of the evaporator
station. Problems which increase the steam demand of the
evaporating crystallizers may lower the pressure of the vapours
No. 9 (2021) Sugar Industry 146 | 513–522
Technology/Technologie 513
Während des Betriebs einer sechsstufigen Verdampfan-
lage unterliegt die Dampfbilanz störenden Einflüssen wie
wechselnden technologischen Zuständen des Prozesses oder
Umgebungsbedingungen (z.B. Umgebungstemperatur). Es
werden mögliche Methoden zur Betriebsführung bzw. Reak-
tion auf diese Einflüsse analysiert und verglichen. Insbeson-
dere werden Methoden zur Stabilisierung des Brüdengleich-
gewichts durch Zuführung von Wasser oder Dünnsaft zu
einzelnen Stufen der Verdampfanlage und die Brüdenumlei-
tung zwischen den Stufen verglichen.
Die beste Art, auf eine Überlastung der Verdampfanlage
zu reagieren, scheint die Umleitung des Brüdens von einer
Stufe mit höheren Parametern zu einer Stufe mit geringeren
Parametern zu sein. Diese Methode schafft eine viel schnel-
lere Reaktion der Verdampfanlage auf übermäßige Brü-
denabnahme als die Zuführung von Wasser oder Dünnsaft,
die sich mit dem Saft in den Behältern vermischen müssen.
Die Zufuhr von Wasser in den Dünnsaftbehälter oder in
eine der Stufen der Verdampfanlage zur Kompensation
eines übermäßigen Brüdenverbrauchs kann eine akzepta-
ble Lösung sein, wenn der Brüdenverbrauch der Verdampf-
anlage über einen längeren Zeitraum steigt, z.B. aufgrund
eines deutlichen Rückgangs der Umgebungstemperatur.
Schlagwörter: Verdampfanlage, Dampfbilanz
used to supply these processes, which in turn may increase the
technological problems. Incorrect reactions of the staff that
may occur in such situations may cause a destabilizing feed-
back reaction on the process and it often takes many hours and
great practical skills to bring the process back to normal.
This article attempts to outline methods of stabilizing a six-
effect evaporator station overloaded due to irregularities in
operation of other part of the factory or due to worsening of
operating conditions for example, due to a significant drop in
ambient temperature. The methods of supplying water or thin
juice to individual effects of the evaporator station and bypass-
ing of vapours between effects are considered in this article.
2 Characteristics of performed test calculations
A properly balanced evaporator system should assume the
discharge of the least amount of vapours from the last effect
to the condenser.
514 Technology/Technologie
Balance calculations at the design stage are performed assum-
ing the correct operation of the sugar factory with normal
slicing rate under average conditions. However, during the
sugar campaign there are numerous disruptions that cause
temporary discrepancies between the process parameters and
the assumptions in the design balance. This applies in particu-
lar to the load on individual evaporator effects. In the case of
a six-effect evaporator station, balanced with the minimum
amount of vapours from the last effect sent to the condenser,
even a slight disturbance in the vapour consumption can cause
significant problems. Especially severe are the disruptions
from the sugar house, because the sugar house needs about
half of the vapour of the evaporator station.
The most common causes for a disturbance of the evaporator
load are the following:
– a change in the ambient temperature resulting in a decrease
of the temperature of beet sliced and an increase in heat
losses to the environment;
– large fluctuations in the flow rate in the juice purification;
– unevenness in the work of the evaporating crystallizers can
cause a rapid increase in vapour consumption of the sugar
house;
– addition of too much wash water to the centrifuges due to
the excessive amount of fine crystals in poorly crystallised
massecuites. This causes blocking of the centrifuge screens,
which in turn causes excessive dilution of the runoffs and
increased vapour consumption for sugar crystallization;
– reintroducing C sugar stored from the previous campaign
or sugar from poorly crystallised massecuites back into the
process, which increases the vapour consumption for sugar
crystallization;
– failure of individual devices;
– an error in the operation of technological processes;
– introduction of deteriorated beet or beets of a significantly
reduced processing quality.
Support for the evaporator station in the event of disruption
should be considered at the design stage. However, sometimes
this is overlooked at the design stage and sugar factories must
make changes to the installations themselves, often without
sufficient supporting analysis.
In practice, there are four common methods to stabilize the
vapour balance of an evaporator station:
– water addition to the thin juice tank before the evaporator
station;
– water addition to one of the later effects of the evaporator
station;
– vapour transfer (bypassing) between the effects of the evap-
orator station;
– feeding of thin juice to one of the later effects of the evapo-
rator station.
For the purpose of this analysis, calculations of mass and heat
balances were performed for a six-effect evaporator station
with cocurrent juice flow.
Effects 1 to 5 were chosen as falling film type evaporators,
effect 6 as plate-type evaporator. The technological scheme of
the sugar factory, the amount of beet processed (6000 t/d),
process parameters and laboratory data were assumed to be
the same as described in detail in [1].
All balance calculations assume the same heating vapour con-
DOI : 10.36961/si27422
sumption of the individual effects of the evaporator station by
heaters and other vapour receivers, apart from the evaporat-
ing crystallizers for product A.
It was assumed that massecuite A is crystallised from standard
liquor in five batch evaporating crystallizers with a capacity of
60 t each and in one seed magma crystallizer with a capacity of
50 t. Massecuite B is crystallized from A green runoff syrup, B
white runoff syrup and affination runoff syrup, in three batch
evaporating crystallizers with capacity of 60 t each and one
seed magma crystallizer with a capacity of 50 t. Massecuite C
is crystallised from the B green runoff syrup in three batch
evaporating crystallizers with a capacity of 60 t each. It was
also assumed that all evaporating crystallizers are equipped
with mechanical agitators and their heating chambers are fed
with vapours of the 5th evaporator effect.
The greatest load on the evaporator station is the vapour
demand of the A evaporating crystallizers.
Table 1 presents the estimate of vapour consumption from
5th evaporator effect by all evaporating crystallizers operating
under average and extreme conditions.
For average conditions, it was assumed that one A evaporating
crystallizer works in the thickening phase, one in the steaming
out phase, and all other A, B and C evaporating crystallizers
work in the crystal grow phase. For extreme conditions, it was
assumed that two product A evaporating crystallizers work in
the thickening phase, one in the steaming out phase, and all
the other evaporating crystallizers for product A and products
B and C work in the crystal growth phase.
In the calculations presented in Table 1, it was assumed that
1 kg of vapour is needed to evaporate 1 kg of water.
Nine (9) test calculations were performed. Their definition and
labelling are shown in Table 2, and the graphical designation
of tests T3 to T9 is shown in Figure 1, together with the bal-
ance of the evaporator station for test T2.
The evaporator station balance T1 assumes an average steam
demand for sugar crystallisation, which allows the calculation
of a vapour balance without sending vapour from the last
effect to the condenser and obtaining the thick juice at the
desired concentration of 74% rds.
The T2 balance assumes an increased steam demand for
sugar crystallisation. This may be caused by a disorder of the
sequence of A sugar cycles in time (starting 2 cycles within
a too short time frame) or by an increased water input to
crystallization mainly for the washing of A sugar in the cen-
trifugals. There is no vapour loss to the condenser and the
thick juice d.s. content exceeds 77%. Such a high d.s. content
of the thick juice will cause difficulties at the filter station and
increase the quality problems due to poor crystallisation of A
massecuite. Long-time operation with thick juice d.s contents
of 77% or higher is too challenging for the assumed sugar
factory. A prerequisite for eliminating the disturbances or the
too high use of wash water is returning the desired thick juice
d.s. content of 74%. Tests T3 to T9 compare different ways to
achieve this goal. In the long run the factory aims to return to
the state T1, but for an intermediate period measures against
the troubles in crystallization and evaporation must be taken.
The complete results of the balance calculations for tests T1
and T2, which are the basis for the comparative analysis, are
given in Tables 3 and 4 and in Figure 1.
Sugar Industry 146 (2021) No. 9 | 513–522
DOI : 10.36961/si27422 Technology/Technologie 515

Table 1: Water balance of evaporating crystallizers (beet processing rate: 6000 t/d)
No Name A evap. crystallizer A seeding evap. B evap. crystallizer B seed magma evap. C evap. crystallizer
cryst. cryst.
Thicken- Crystal Thicken- Crystal Thicken- Crystal Thicken- Crystal Thicken- Crystal
ing growth ing growth ing growth ing growth ing growth
1 Massecuite mass in t 60 60 50 50 60 60 50 50 60 60
2 Massecuite density in t/m3 1.46 1.46 1.44 1.44 1.46 1.46 1.45 1.45 1.46 1.46
3 Useful capacity of evap. crystallizer 41.2 41.2 34.7 34.7 41.2 41.2 34.6 34.6 41.0 41.0
in m3
4 Volume used at the end of crystal 40.0 100.0 40.0 100.0 40.0 100.0 40.0 100.0 40.0 100.0
growth phase in %
5 Volume used at the end of crystal 16.5 41.2 13.9 34.7 16.5 41.2 13.8 34.6 16.4 41.0
growth phase in m3
6 Standard liquor and A & B run off 75.00 75.00 75.00 75.00 81.00 81.00 81.00 81.00 83.00 83.00
syrup dry substance content in %
7 Dry substance content at the end of 80.0 92.0 81.0 90.0 81.5 92.5 82.5 91.0 84.5 94.0
thickening phase in %
8 Temperature at the end of thicken- 74.0 81.0 74.0 81.0 74.0 84.0 75.0 84.0 76.0 85.0
ing phase in °C
9 Density at the end of thickening 1.38 1.46 1.39 1.44 1.39 1.46 1.40 1.45 1.41 1.46
phase in t/m3
10 Water evaporation in t 1.52 11.76 1.54 8.22 0.14 8.35 0.36 5.76 0.42 7.47
11 Time in min 20.0 215.0 20.0 160.0 15.0 345.0 15.0 315.0 15.0 705.0
12 Water evaporation rate in t/h 4.56 3.28 4.62 3.08 0.57 1.45 1.43 1.10 1.67 0.64
in t/h 7.36
13 Water evaporation in evap. crystallizers B & C: (crystal growth B: 3 · 60 t & seed magma B: 50 t) + (crystal growth C: 3 · 60 t) in t/h
in % o.b. 2.94
Water evaporation in evap. crystallizers A: (steaming out: 1 · 60 t) + (thickening: 1 · 60 t) + (crystal growth: 3 · 60 t & 50 t - seed in t/h 17.49
14
magma) in % o.b. 7.00
15 Water evaporation in all evap. crystallizers: A(14) + B & C(13) – average in % o.b. 9.94
Water evaporation in evap. crystallizers A: (steaming out: 1 · 60 t) + (thickening: 2 · 60 t) + (crystal growth: 2 · 60 t & 50 t - seed in t/h 18.77
16
magma) in % o.b. 7.51
17 Water evaporation in all evap. crystallizers: A(16) + B & C(13) – extreme in % o.b. 10.45
18 Amount of vapour 5 bled for supplying all evap. crystallizers, assumed for tests performance (average conditions) in % o.b. 9.90
19 Amount of vapour 5 bled for supplying all evap. crystallizers, assumed for tests performance in extreme conditions in % o.b. 10.50
No. 18 is a rounding of no. 15 and no. 19 is a rounding of no. 17.

Table 2: Description of tests 1 to 9 The balance calculations of the six-effect evaporator station for
Test no Description tests T3 to T9 are presented in Tables 6 to 8. Various methods
T1 Thick juice 74% d.s., 9.9% o.b. of vapour 5 to sugar house were used to compensate the excessive load in order to obtain
T2 Thick juice 77% d.s., 10.5% o.b. of vapour 5 to sugar house a thick juice with the desired content of 74% d.s.
T3 3.50% o.b. water (90 °C) to thin juice tank
The balance calculations for the tests T3 to T5, with water sup-
T4 1.75% o.b. water (90 °C) to effect 5
plied to the evaporator station, are presented in Table 6.
T5 1.40% o.b. water (90 °C) to effect 6
T6 1.90% o.b. vapours 3 overflow to vapour 5
The balance calculations for the T6 to T8 tests, with vapour
T7 3.20% o.b. vapours 4 overflow to vapour 5 bypass between the effects, are presented in Table 7.
T8 1.05% o.b. vapours 1 overflow to vapour 6 Table 8 shows the balance calculation for test T9, in which thin
T9 4.50% o.b. thin juice (90 °C) to effect 5 juice was supplied to the 5th effect.
The exhaust steam demand, the water evaporation and the
The calculations of the evaporator balances for tests T3 to T9 evaporation factor of the evaporator station for individual
were made assuming a maximum load from A sugar evaporat- tests T1 to T9 are given in Table 9.
ing crystallizers, as defined above.
In these tests, various methods were used to compensate the
overload of the evaporator station by adding water or thin 3 Discussion and conclusions
juice to different effects, or transfer of vapours between the
effects in the amount needed to obtain desired thick juice d.s. Problems that arise in practice and that are caused by exces-
content of 74%. sive loading of the evaporator station due to increased vapour
Examples of evaporator station mass and heat balances for consumption, often cause long-term difficulties for the staff
two tests using overload compensation of the evaporator sta- in bringing the sugar factory back to the optimal operating
tion by adding water to the 5th effect (Test 4) and by using conditions with optimal beet slicing rate.
the vapour bypass from 4th to 5th effect (Test 7) are shown in Difficulties with balancing the amount of vapour bled in each
Figures 2 and 3. effect result in thick juice with an excessive d.s. content that
The balance calculations for the tests T1 and T2, which are the hinder its filtration and cause the lower vapour availability for
basis for the comparative analysis, are shown in Table 5. other steam users. As a consequence, it is often necessary to

No. 9 (2021) Sugar Industry 146 | 513–522

516 Technology/Technologie DOI : 10.36961/si27422

Table 3: Mass and heat balance of a six-effect evaporator station – Test 1 results (thick juice 74% d.s., 9.9% of 5th effect vapour to sugar house)
Parameter’s name Units Apparatus description
I II III IV VA VB VI
Apparatus type FF FF FF FF FF FF Plate
Heating surface m2 2,500 2,400 2,700 2,500 2,500 2,500 500
Heat exchanged kW 29,915 26,603 26,128 24,001 15,241 5,831 747
Effective temperature diff. °C 3.94 3.56 3.65 5.27 6.65 4.32 2.58
O.H.T.C. W/(m2 · K) 3035 3112 2652 1823 917 540 579
Water evaporation % o.b. 18.18 18.20 17.66 16.18 10.34 3.66 0.68
Vapour to next effect % o.b. 17.70 17.28 15.77 13.71 0.48 0.06
Outside vapour consum. % o.b. 0.60 1.19 2.38 3.49 14.82 1.81
Vapour from flashing % o.b. 0.13 0.28 0.48 1.01 1.30 1.19
Vapour temperature °C 131.59 127.06 122.09 114.61 103.74 94.25
Vapour pressure MPa 0.28 0.25 0.21 0.17 0.12 0.08
Steam/vapour supply % o.b. 20.04 17.70 17.28 15.77 9.92 3.79 0.48
Heating steam temp. °C 136.00 131.29 126.76 121.79 114.31 114.31 103.44
Condensate temperature °C 135.01 130.40 125.85 120.47 112.64 113.23 102.79
Juice quantity – inlet % o.b. 110.58 92.40 74.21 56.55 40.36 30.02 26.36
Juice quantity – outlet % o.b. 92.40 74.21 56.55 40.36 30.02 26.36 25.67
Juice d.s. – inlet % d.s. 17.18 20.56 25.60 33.60 47.07 63.28 72.08
Juice d.s. – outlet % d.s. 20.56 25.60 33.60 47.07 63.28 72.08 74.00
Juice temperature – inlet °C 124.00 132.06 127.72 123.11 116.53 107.66 109.99
Juice temperature – average °C 132.06 127.72 123.11 116.53 107.66 109.99 100.86
Ebuliometric B.P.E. °C 0.47 0.66 1.02 1.92 3.92 6.25 6.61

Table 4: Mass and heat balance of six-effect evaporator station – Test 2 results (thick juice 77% d.s., 10.5% of 5th effect vapour to sugar house)
Parameter’s name Units Apparatus description
I II III IV VA VB VI
Apparatus type FF FF FF FF FF FF Plate
Heating surface m2 2,500 2,400 2,700 2,500 2,500 2,500 500
Heat exchanged kW 30,166 26,866 26,409 24,309 15,948 5,542 689
Effective temperature diff. °C 3.98 3.60 3.72 5.50 8.11 5.07 2.98
O.H.T.C. W/(m2 · K) 3034 3105 2632 1769 786 437 462
Water evaporation % o.b. 18.35 18.37 17.85 16.39 10.86 3.45 0.63
Vapour to next effect % o.b. 17.88 17.47 15.97 13.97 0.44 0.00
Outside vapours consum. % o.b. 0.60 1.19 2.37 3.49 15.41 2.03
Vapour from flashing % o.b. 0.13 0.29 0.49 1.07 1.54 1.39
Vapour temperature °C 131.55 126.98 121.92 114.13 101.33 90.25
Vapour pressure MPa 0.28 0.25 0.21 0.16 0.11 0.07
Steam/vapour supply % on.b 20.21 17.88 17.47 15.97 10.37 3.60 0.44
Heating steam temp. °C 136.00 131.25 126.68 121.62 113.83 113.83 101.03
Condensate temperature °C 135.01 130.35 125.75 120.25 111.80 112.56 100.29
Juice quantity – inlet % o.b. 110.58 92.23 73.86 56.01 39.62 28.76 25.30
Juice quantity – outlet % o.b. 92.23 73.86 56.01 39.62 28.76 25.30 24.67
Juice d.s. – inlet % d.s. 17.18 20.60 25.72 33.92 47.96 66.06 75.08
Juice d.s. – outlet % d.s. 20.60 25.72 33.92 47.96 66.06 75.08 77.00
Juice temperature – inlet °C 124.00 132.02 127.65 122.96 116.13 105.72 108.76
Juice temperature – average °C 132.02 127.65 122.96 116.13 105.72 108.76 98.05
Ebuliometric B.P.E. °C 0.47 0.67 1.04 2.00 4.39 7.43 7.80

support the vapour balance of the evaporator station by add-
ing water to one of its effects or to transfer vapour between
effects.
In this analysis the duration of the disturbance in the load of
the evaporator station was assumed to be longer than the total
juice retention time in the evaporator station and in the thick
juice tanks. After this time, a stabilization of the thick juice
and vapours parameters can be expected. This stabilization
facilitates the use of the results of the balance calculations
presented here.
Analysing the parameters of an evaporator station in non-
equilibrium states is very difficult. Therefore, equilibrium state
balances for each of the tests T1 to T9 were taken into account.
The general assumption was, that the process disturbance
in the test T2 and all operator responses in the tests T3–T9
last long enough to reach an equilibrium state. This assump-
tion reduces all tests to a common denominator and enables
quantitative and qualitative comparison of vapour and juice
parameters in all tests.
If the duration of a disturbance in the operation of the evapo-
rator station, which manifests itself in a sharp increase in
vapour consumption is significantly shorter than the juice
retention time in the evaporator station and thick juice tanks,
the juice and vapour parameters are in an intermediate state.

Sugar Industry 146 (2021) No. 9 | 513–522

DOI : 10.36961/si27422 Technology/Technologie 517

The values of the intermediate param-

110,58 % o.b.
1,32 main lim. 2nd

to condenser

17,18 % d.s.
0,71 press water

0,00 % o.b.

thick juice
eters will depend on the amount of juice

thin juice

90,00 C
in the evaporators and thick juice buffer
tanks.
The short-term disturbance due to a
% on b.

77,00 % d.s.
24,67 % o.b.
462 W/(m2*K)
0,63 % o.b.

0,44 % o.b.
6th effect
momentary increase in vapour uptake

101,03 C
90,25 C

98,05 C
500 m2

Test3
from the evaporator station is usually

Fig. 1: Mass and heat balance of a six-effect evaporator station – Test 2 (thick juice 77% d.s., 10.5% of 5th effect vapour to sugar house). The arrows show the addition points of tests T3 to T9.
flashing 1,39

buffered by the juice in the evaporator

and the thick juice tanks.
The result of this short disturbance is a

Test5
temporary increase in the thick juice d.s.
Test 8

content and a decrease in vapour param-

eters, which usually do not require addi-
25,30 % o.b.
75,08 % d.s.
437 W/(m2*K)
5th B effect
3,45 % o.b.

3,60 % o.b.
101,33 C

113,83 C

108,76 C
tional intervention from the operator.
2500 m2

In order to analyse the methods of

Fig. 1: Mass and heat balance of six effects evaporator station - Test 2 results (thick juice 77 % d.s., 10,5 % o.b. vapours 5 to boiling house).
supporting the evaporation station in
the event of its excessive load, a situa-
v. pans ABC
2nd carb. 1st.
circ row juice
main lim. 3rd
thin juice 1st

tion was selected in which two A prod-

uct evaporating crystallizers are in the
concentration phase, causing a rapid
increase in vapour consumption.
1,35
0,80
1,11
1,64
10,50

10,86 % o.b.

10,37 % o.b.

28,76 % o.b.
66,06 % d.s.
786 W/(m2*K)
5th A effect
101,33 C

113,83 C

105,72 C
2500 m2

In practice, an excessively sharp increase

% on b.

in beet slicing rate, which results in a

Test9
flashing 1,54

sharp increase in the juice flow to the

purification station, frequently occurs
0,30 rem.+run offs
1,22 2nd carb. 2nd.
1,96 thin juice 2nd

after a sugar factory downtime. The

Test7

resulting filling up of the intermediate

tanks (also the tank before the evapora-
tor station) requires an increase in the
Test6

Test4
1769 W/(m2*K)
16,39 % o.b.

15,97 % o.b.

39,62 % o.b.
47,96 % d.s.
4th effect
114,13 C

121,62 C

116,13 C
2500 m2

juice flow rate to the evaporator station

% on b.

and, results in a greater production of

flashing 1,07

thick juice, which consequently leads

to the filling up of the standard liquor
v.p. steaming
thin juice 3rd

sugar drying

5 heaters

tanks in the sugar house. To prevent

standard liquor from spilling onto the
floor, operators will then often turn
on the next A massecuite evaporating
1,57
0,30
0,50

Test6

2632 W/(m2*K)
17,85 % o.b.

17,47 % o.b.

56,01 % o.b.
33,92 % d.s.
3rd effect
121,92 C

126,68 C

122,96 C

124,00 C
2700 m2
% on b.

crystallizer, prior to the completion of

the thickening phase in the previously
flashing 0,49

The graphical designation of tests T3 to T9.

started evaporating crystallizer, caus-

ing excessive vapour bleeding from the
thin juice 4th

evaporator. If this action is repeated two

or three times, the problems are exacer-
bated.
1,19

The size of the excess consumption and

3105 W/(m2*K)
18,37 % o.b.

17,88 % o.b.

73,86 % o.b.
25,72 % d.s.
2nd effect
126,98 C

131,25 C

127,65 C
2400 m2
% on b.

its duration have an impact on the mag-

nitude of the problem arising from the
flashing 0,29

excessive bleeding of vapours from the

thin juice 5th

evaporator.
The reaction time to eliminate the dis-
turbance is important for the selection
Test 8

of the approach to eliminate the effects

% on b.
0,60

of excessive vapour bleeding from the

3034 W/(m2*K)
18,35 % o.b.

20,21 % o.b.

92,23 % o.b.
20,60 % d.s.
1st effect
131,55 C

136,00 C

132,02 C
2500 m2

evaporator.
In all tests analysed the same bled
flashing 0,13

vapour consumption for all effects was

used. Some differences in these values
exhaust
steam

between individual tests result from the

`

mode of action of the test studied.

No. 9 (2021) Sugar Industry 146 | 513–522

518 Technology/Technologie DOI : 10.36961/si27422

1,32 main lim. 2nd Slight differences in the amount of water

to condenser

17,18 % d.s.
110,58 % o.b.
0,71 press water

0,01 % o.b.

thick juice
evaporated in the tests are due to the

thin juice

90,00 C
modified water addition to individual
effects, the vapour transfer between the
effects, and a variable amount of flash
% on b.

25,67 % o.b.
74,00 % d.s.
0,79 % o.b.

0,55 % o.b.
579 W/(m2*K)
6th effect
vapours due to differences in vapour

102,88 C
93,35 C

99,92 C
500 m2
temperatures, which result from the
flashing 1,25

mode of action in a given test.

The steam consumption of the 1st effect
and the vapour equilibrium tempera-
tures of the 5th and 6th effect were used
as evaluation criteria for tests 3 to 9.
A summary of the vapour parameters of

26,46 % o.b.
71,80 % d.s.
5th B effect
3,77 % o.b.

3,91 % o.b.
551 W/(m2*K)
103,18 C

113,67 C

109,30 C
2500 m2

the tests is given in Tables 10 and 11.

In tests 3 to 5 and 9, water or thin juice
is fed to one of the effects. The juice is
diluted in this respective and in the fol-
v. pans ABC
2nd carb. 1st.
circ row juice
main lim. 3rd
thin juice 1st

lowing effects, which slightly reduces

the increase in colour of the juice in

Fig. 2: Mass and heat balance of six effects evaporator station - Test 4 results (1,75 % o.b. water 90 °C to effect 5).
these effects and increases their effi-
ciency.
10,50
1,35
0,81
1,11
1,64

10,89 % o.b.

10,15 % o.b.

30,23 % o.b.
62,83 % d.s.
5th A effect

938 W/(m2*K)
103,18 C

113,67 C

107,01 C
2500 m2
% on b.

In tests 6 to 8, vapours are transferred

between the effects of the evaporation
flashing 1,31

station and the juice is concentrated in

the effect, from which the vapours are
1,22 2nd carb. 2nd.
0,30 rem.+run offs
1,96 thin juice 2nd

transferred, and in the previous effects.

This slightly increases the colour of the
juice in these effects and reduces their
Fig. 2: Mass and heat balance of a six-effect evaporator station – Test 4 (1.75% o.b. of 90 °C water to the 5th effect)

efficiency.
16,46 % o.b.

16,03 % o.b.

39,37 % o.b.
48,25 % d.s.
1751 W/(m2*K)

1,75 % o.b.
4th effect
113,97 C

121,57 C

115,99 C
2500 m2
% on b.

However, the changes described above

Test4

are not very significant.

flashing 1,08

The impact of adding water to the thin

juice tank before the evaporator on
0,50 sugar drying
1,57 thin juice 3rd
0,30 v.p. steaming

5 heaters

the thick juice d.s. content after the

6th effect of the evaporator station is
delayed due to the large buffer capacity
of the tank and the amount of juice in
17,91 % o.b.

17,52 % o.b.

55,84 % o.b.
34,02 % d.s.
2626 W/(m2*K)
3rd effect
121,87 C

126,65 C

122,91 C

124,00 C
2700 m2
% on b.

the individual evaporators.

The delay will be smaller when water is
flashing 0,50

added to one of the effects, the later the

1,19 thin juice 4th

smaller the delay. However, some time

will always be needed for the water to
mix with the juice. The best approach
is to add water before the 5th effect
18,43 % o.b.

17,94 % o.b.

73,74 % o.b.
25,76 % d.s.

because of the favourable steam con-

3103 W/(m2*K)
2nd effect
126,95 C

131,24 C

127,62 C
2400 m2
% on b.

sumption of the 1st evaporator effect

and the high vapour temperatures of the
flashing 0,29

5th and 6th effect – see test T4 in Tables

0,60 thin juice 5th

10 and 11.
Water should not be added to 6th effect
because there is a risk that thick juice
d.s. content surpasses 74% after the 5th
% on b.

18,40 % o.b.

20,26 % o.b.

92,18 % o.b.
20,61 % d.s.
3033 W/(m2*K)

effect – see test T5 in Tables 10 and 11.

1st effect
131,54 C

136,00 C

132,01 C
2500 m2

This situation is difficult to control and,

in extreme cases, the d.s. content in the
flashing 0,13

5th effect may increase so much that

spontaneous crystallization occurs.
exhaust
steam

Transfer of vapours between effects is

`

advantageous because of the fast reac-

Sugar Industry 146 (2021) No. 9 | 513–522

 DOI : 10.36961/si27422 Technology/Technologie 519

1,32 main lim. 2nd tion of the evaporator station, transfer

to condenser

17,18 % d.s.
110,58 % o.b.
0,71 press water

0,00 % o.b.

thick juice

thin juice

90,00 C
from the 3rd or 4th effect to 5th effect
is preferred – see test T6 and test T7 in
Tables 10 and 11.
The transfer of vapour to the 6th effect
% on b.

25,67 % o.b.
74,00 % d.s.
0,80 % o.b.

0,56 % o.b.
579 W/(m2*K)
6th effect

102,71 C
93,14 C

99,70 C
500 m2
is undesirable because there is a risk
that the thick juice d.s. content sur-
flashing 1,23

passes 74% in the 5th effect, even with

the transfer of vapour from 1st effect –
see test T8 in Table 7. In addition, a high
steam consumption in the 1st evapo-
rator effect can be expected. Vapour
transfer from other effects would give

26,47 % o.b.
71,76 % d.s.
5th B effect
3,14 % o.b.

3,26 % o.b.
552 W/(m2*K)
103,01 C

112,75 C

109,12 C
2500 m2

an even worse result. In this case low

vapour temperatures in the 5th and 6th
effect can be expected. The vapour pres-

% o.b. vapours 4 overflow to vapours 5).

sure control system and possibly the
2nd carb. 1st.

v. pans ABC
circ row juice
main lim. 3rd
thin juice 1st

thick juice d.s. content control system,

if present in 6th effect, will also be dis-
turbed. Use of exhaust steam was not
1,35
0,81
1,11
1,64
10,50

considered because of safety reasons

29,62 % o.b.
64,14 % d.s.
5th A effect
8,45 % o.b.

8,08 % o.b.
875 W/(m2*K)
103,01 C

112,75 C

107,06 C
2500 m2
% on b.

and in addition, a highest from other

tests steam consumption in the 1st
flashing 1,18

evaporator effect can be expected.

1,22 2nd carb. 2nd.
0,30 rem.+run offs

The best way to react to the overload of

1,96 thin juice 2nd

3,20 % o.b.
Test7

the evaporator station in an emergency

seems to be the transfer of vapours
according to the tests T6 or T7. Those
vapours)

tests have the favourable values of the

16,83 % o.b.

16,38 % o.b.

38,07 % o.b.
49,90 % d.s.
1652 W/(m2*K)
4th effect

to 5th(3,20
113,05 C

121,27 C

115,23 C
2500 m2
% on b.

parameters adopted here as the criteria

for the evaluation. In these tests, the
results
flashing 1,19

evaporator station reacts much faster to

- Testof7 4th
1,57 thin juice 3rd
0,30 v.p. steaming
0,50 sugar drying

the transfer of vapours than to the sup-

5 heaters

ply of water or thin juice, which requires

o.b. overflow

mixing with the juice present in the

evaporators.
Test 7 (3.20%station

Feeding water to the thin juice tank or

18,23 % o.b.

17,84 % o.b.

54,90 % o.b.
34,60 % d.s.
2591 W/(m2*K)
3rd effect
121,57 C

126,50 C

122,65 C

124,00 C
2700 m2
% on b.

to one of the effects of the evaporator

station –evaporator

station to compensate excessive vapour

flashing 0,52

consumption can be an acceptable solu-

1,19 thin juice 4th

tion in case of prolonged increase in

vapour bleeding from the evaporator
of six effects

station due to e.g. a significant decrease

in ambient temperature. In this case, an
evaporator
18,74 % o.b.

18,24 % o.b.

73,14 % o.b.
25,98 % d.s.

evaporator overload results from exces-

3092 W/(m2*K)
2nd effect
126,80 C

131,17 C

127,48 C
2400 m2
% on b.

sive vapour uptake by juice heaters at

balance

purification station.
flashing 0,30

a six-effect

Introduction of thin juice to one of the

0,60 thin juice 5th

effects is beneficial according to the

of heat

analysis of selected evaluation criteria

used – see test T9 in Tables 10 and 11.
and
balance

However, this method cannot be used

Mass
% on b.

18,70 % o.b.

20,55 % o.b.

91,88 % o.b.
20,68 % d.s.
3030 W/(m2*K)

as an independent and stand-alone

1st effect
131,47 C

136,00 C

131,95 C
2500 m2

method.
and heat
Fig. 3: Mass Fig.3:

The thin juice tank usually has a juice

flashing 0,14

capacity of about 30 min and above all

must ensure the constant juice supply
exhaust
steam

to the 1st effect. It may happen that in

`

an emergency the use of this method

No. 9 (2021) Sugar Industry 146 | 513–522

520 Technology/Technologie DOI : 10.36961/si27422

Table 5: Tests 1 to 2 – calculation results is required, which might

Effect no. / Type / Heating area in m2 coincide with a low thin
1 2 3 4 5A 5B 6 juice level in the tank. The
Test no Parameter’s name Units
FF FF FF FF FF FF Plate simultaneous deliver y
2500 2400 2700 2500 2500 2500 500
of the juice to 1st effect
Outside vapour consumption % o.b. 0.60 1.19 2.38 3.49 14.82 1.81
and to one of the later
Juice quantity – inlet % o.b. 110.58 92.40 74.21 56.55 40.36 30.02 26.36
T1 Juice quantity – outlet % o.b. 92.40 74.21 56.55 40.36 30.02 26.36 25.67
effects will require emer-
Juice d.s. – inlet % d.s. 17.18 20.56 25.60 33.60 47.07 63.28 72.08 gency water to be fed to
Juice d.s. – outlet % d.s. 20.56 25.60 33.60 47.07 63.28 72.08 74.00 the tank, which will spoil
Outside vapour consumption % o.b. 0.60 1.19 2.37 3.49 15.41 2.03 the beneficial effect of
Juice quantity – inlet % o.b. 110.58 92.23 73.86 56.01 39.62 28.76 25.30 the test T9. Therefore, it
T2 Juice quantity – outlet % o.b. 92.23 73.86 56.01 39.62 28.76 25.30 24.67 is recommended to use
Juice d.s. – inlet % d.s. 17.18 20.60 25.72 33.92 47.96 66.06 75.08 the method T9 only for
Juice d.s. – outlet % d.s. 20.60 25.72 33.92 47.96 66.06 75.08 77.00 short periods. As soon as
possible vapour transfer
Table 6: Tests 3 to 5 – calculation results between effects (accord-
Effect no. / Type / Heating area in m2 ing to test T7) should be
1 2 3 4 5A 5B 6 started.
Test no Parameter’s name Units
FF FF FF FF FF FF Plate An example of the use
2500 2400 2700 2500 2500 2500 500 of thin juice to close the
Outside vapour consumption % o.b. 0.63 1.25 2.45 3.55 15.47 2.03 vapour balance is shown
Juice – inlet % o.b. 114.08 95.19 76.27 57.91 41.07 30.26 26.43 in test T9.
Juice – outlet % o.b. 95.19 76.27 57.91 41.07 30.26 26.43 25.67
T3 When water or thin juice
Juice d.s. – inlet % d.s. 16.65 19.96 24.91 32.80 46.26 62.78 71.88
is fed to one of the effects,
Juice d.s. – outlet % d.s. 19.96 24.91 32.80 46.26 62.78 71.88 74.00
the evaporator station’s
Water 90 °C – thin juice tank % o.b. 3.50
Outside vapour consumption % o.b. 0.60 1.19 2.37 3.49 15.42 2.03 reaction is delayed due
Juice – inlet % o.b. 110.58 92.18 73.74 55.84 41.12 30.23 26.46 to the time needed for
Juice – outlet % o.b. 92.18 73.74 55.84 39.37 30.23 26.46 25.67 the following processes:
T4
Juice d.s. – inlet % d.s. 17.18 20.61 25.76 34.02 46.20 62.83 71.80 pumping of water or thin
Juice d.s. – outlet % d.s. 20.61 25.76 34.02 48.25 62.83 71.80 74.00 juice to the vessel, mixing
Water 90 °C – effect 5A % o.b. 1.75 it with the juice present
Outside vapour consumption % o.b. 0.60 1.19 2.37 3.49 15.41 2.03 in the vessel and heat-
Juice – inlet % o.b. 110.58 92.20 73.79 55.90 39.46 28.50 26.49
ing to the boiling point.
Juice – outlet % o.b. 92.20 73.79 55.90 39.46 28.50 25.09 25.67
T5 Less water than thin juice
Juice d.s. – inlet % d.s. 17.18 20.61 25.75 33.98 48.14 66.67 71.73
Juice d.s. – outlet % d.s. 20.61 25.75 33.98 48.14 66.67 75.73 74.00
is needed to bring the
Water 90 °C – effect 6 % o.b. 1.40 vapour balance into equi-
librium (see tests T4 and
T9).
Table 7: Tests 6 to 8 – calculation results Taking into account the
Effect no. / Type / Heating area in m2 above arguments it is
1 2 3 4 5A 5B 6 preferable to add water to
Test no Parameter’s name Units
FF FF FF FF FF FF Plate one of the later effects in
2500 2400 2700 2500 2500 2500 500
order to bring the vapour
Outside vapour consumption % o.b. 0.60 1.19 4.27 3.49 13.52 2.03
balance into equilibrium
Juice – inlet % o.b. 110.58 91.72 72.82 54.41 39.35 29.93 26.49
Juice – outlet % o.b. 91.72 72.82 54.41 39.35 29.93 26.49 25.67
in case of prolonged over-
T6 load of the station.
Juice d.s. – inlet % d.s. 17.18 20.71 26.09 34.91 48.27 63.48 71.73
Juice d.s. – outlet % d.s. 20.71 26.09 34.91 48.27 63.48 71.73 74.00 In order to stabilize the
Overflow vapour 3 to 5 % o.b. 1.90 –1.90 process parameters after
Outside vapour consumption % o.b. 0.60 1.19 2.37 6.68 12.22 2.03 a disturbance from the
Juice – inlet % o.b. 110.58 91.88 73.14 54.90 38.07 29.62 26.47 sugar house, in addition
Juice – outlet % o.b. 91.88 73.14 54.90 38.07 29.62 26.47 25.67 to the methods discussed
T7
Juice d.s. – inlet % d.s. 17.18 20.68 25.98 34.60 49.90 64.14 71.76 in this article (T3–T9),
Juice d.s. – outlet % d.s. 20.68 25.98 34.60 49.90 64.14 71.76 74.00
the following actions are
Overflow vapour 4 to 5 % o.b. 3.20 –3.20
recommended:
Outside vapour consumption % o.b. 1.65 1.19 2.37 3.49 15.42 0.98
Juice – inlet % o.b. 110.58 91.45 73.35 55.78 39.67 29.16 25.67
– gentle, gradual increase
Juice – outlet % o.b. 91.45 73.35 55.78 39.67 29.16 25.67 25.67 of the exhaust steam
T8 pressure with simulta-
Juice d.s. – inlet % d.s. 17.18 20.77 25.90 34.06 47.89 65.16 74.00
Juice d.s. – outlet % d.s. 20.77 25.90 34.06 47.89 65.16 74.00 74.00 neous controlled trans-
Overflow vapour 1 to 6 % o.b. 1.05 –1.05 fer of vapours from

Sugar Industry 146 (2021) No. 9 | 513–522

DOI : 10.36961/si27422 Technology/Technologie 521

Table 8: Tests 9 – calculation results iting the vapour supply

Effect no. / Type / Heating area in m2 to both vessels, which
1 2 3 4 5A 5B 6 will reduce the disrup-
Test no Parameter’s name Units
FF FF FF FF FF FF Plate tion of the evaporator
2500 2400 2700 2500 2500 2500 500
station.
Outside vapour consumption % o.b. 0.58 1.16 2.33 3.41 15.37 2.03
A slow, gradual increase
Juice – inlet % o.b. 106.08 88.12 70.16 52.72 41.21 30.21 26.51
Juice – outlet % o.b. 88.12 70.16 52.72 36.71 30.21 26.51 25.67
in exhaust steam pres-
T9 sure together with a par-
Juice d.s. – inlet % d.s. 17.18 20.68 25.98 34.57 46.10 62.88 71.66
Juice d.s. – outlet % d.s. 20.68 25.98 34.57 49.64 62.88 71.66 74.00 allel vapour overflow may
Thin juice 90 °C – effect 5A % o.b. 4.50 speed up the recovery
from disturbances, at the
expense of increasing the
Table 9: Tests 1 to 9 – exhaust steam consumption, water evaporation and evaporation factor amount of exhaust steam
Exhaust Effect no.
Multi- supplied to the 1st effect.
steam to 1 2 3 4 5A 5B 6 Sum in % The aim of this operation
Test no plicity of
1st effect o.b.
in % o.b. Water evaporation % o.b. evapor. is to achieve the highest
T1 20.04 18.18 18.20 17.66 16.18 10.34 3.66 0.68 84.91 4.24 possible temperature of
T2 20.21 18.35 18.37 17.85 16.39 10.86 3.45 0.63 85.91 4.25 5th effect bleed vapours
T3 20.80 18.89 18.92 18.36 16.84 10.81 3.83 0.76 88.41 4.25 feeding the evaporating
T4 20.26 18.40 18.43 17.91 16.46 10.89 3.77 0.79 86.66 4.28 crystallizers, while main-
T5 20.24 18.38 18.41 17.89 16.44 10.97 3.41 0.81 86.31 4.26 taining the thick juice d.s.
T6 20.71 18.86 18.90 18.40 15.06 9.43 3.44 0.81 84.91 4.10 content below 75%.
T7 20.55 18.70 18.74 18.23 16.83 8.45 3.14 0.80 84.91 4.13
T8 20.97 19.13 18.10 17.57 16.11 10.51 3.48 0.00 84.91 4.05
T9 19.76 17.96 17.96 17.44 16.01 11.00 3.70 0.84 84.91 4.30
4 Comments

Table 10: Tests1 to 9 – OHTC (overall heat transfer coefficient) values and vapour temperatures Intuitively, it might seem
Test no
Effect no. that when the evapora-
1 2 3 4 5A & 5B 6 tor station is overloaded
OHTC in W/(m2 · K) / Vapour temperature in °C due excessive vapour con-
3035 3112 2652 1823 917 540 579
T1 sumption, resulting in an
131.59 127.06 122.09 114.61 103.74 94.25
increase in thick juice
3034 3105 2632 1769 786 437 462
T2
131.55 126.98 121.92 114.13 101.33 90.25
d.s. content, one should
3061 3149 2699 1873 941 548 579 interfere directly with
T3 the parameters of the 6th
131.50 126.91 121.90 114.42 103.51 93.77
3033 3103 2626 1751 938 551 579 effect. This analysis, how-
T4
131.54 126.95 121.87 113.97 103.18 93.35 ever, showed that add-
T5
3033 3104 2628 1758 760 417 579 ing water or thin juice,
131.54 126.96 121.89 114.03 100.75 90.92 or transferring vapours
3028 3085 2572 1750 907 553 579 from any of the earlier
T6
131.44 126.73 121.41 113.98 103.60 93.66
effects directly to 6th
3030 3092 2591 1652 875 552 579
T7 effect is not a good way
131.47 126.80 121.57 113.05 103.01 93.14
3026 3096 2624 1773 828 473 579
to stabilize the vapour
T8 balance of an excessively
131.38 126.85 121.83 114.15 102.16 94.25
3030 3091 2593 1667 936 556 579 overloaded evaporator
T9
131.63 127.11 122.04 113.88 103.26 93.24 station.
The key goal in manag-
ing a six-effect
Table 11: Tests 1 to 9 – steam consumption, vapour temperature of 5th and 6th effect evaporator sta-
Test no tion, if the sugar
T1 T2 T3 T4 T5 T6 T7 T8 T9 house operates at
Exhaust steam to 1st effect in % o.b. 20,04 20,21 20,80 20,26 20,24 20,71 20,55 20,97 19,76 normal through-
Vapour 5 temperature in °C 103,74 101,33 103,51 103,18 100,75 103,60 103,01 102,16 103,26
put, is to keep the
Vapour 6 temperature in °C 94,25 90,25 93,77 93,35 90,92 93,66 93,14 94,25 93,24
vapour consump-
tion of the evapo-
the effect with higher parameters to the effect with lower rating crystallizers as low and as stable as possible.
parameters; It is recommended to measure and accurately monitor the
– extending the thickening time in two evaporating crystalliz- total amount of condensate formed in the evaporating crys-
ers operating simultaneously in the thickening stage by lim- tallizers. The amount of this condensate corresponds to the

No. 9 (2021) Sugar Industry 146 | 513–522

522 Technology/Technologie
amount of vapour taken from the evaporator station by these
vessels. The practical experience of the author shows that sys-
tematic control and analysis of the condensate flow allows for
a significant improvement in the operation of the sugar house
and the evaporator station.
The author witnessed a situation, in which sugar factory staff
tried to increase the pressure of the exhaust steam supplying
the 1st effect to increase the vapour pressure of later evapora-
tor effects.
The approach could be effective in case of scale formed on the
heating surfaces of the evaporators. It is not a good option; if
the station is overloaded by excessive vapour consumption.
Increasing the exhaust steam pressure increases the vapour
parameters of all effects of the evaporation station. Conse-
quently, this results in an increase in vapour uptake by heaters
and evaporating crystallizers supplied by vapour bled from the
late effects, especially of heaters with too large heating surface
and without temperature control system. This will cause an
additional undesirable load on the late effects and increase the
deficit in the vapour balance.
Lowering the exhaust steam pressure has the opposite effect,
i.e. lowering the vapour pressure and lowering the vapour
DOI : 10.36961/si27422
uptake from the late effects, which would favourably affect the
station’s vapour balance.
However, the reduction of the vapour pressure is always disad-
vantageous for the operation of the sugar house, which in the
scheme discussed here is supplied with 5th effect vapour. Thus
lowering the exhaust steam pressure to improve the vapour
balance is disadvantageous and not advisable for the reason
described above.
References
1 Lenard P. (2019): Comparison of evaporator stations with and without pre-
evaporator, Sugar Industry 144, 597–603 DOI: 10.36961/si23680
Paper received on April 7, 2021.
Author’s address: M.Sc.Eng. Piotr Lenard, ul. Sarmacka 22 m.
108, 02-972 Warsaw, Poland; e-mail: piotr.lenard1@gmail.com
Sugar Industry 146 (2021) No. 9 | 513–522