CONTROL OF SCALING AND FOULING IN FOOD AND BEVERAGE PROCESS EVAPORATORS

Dr. Paul Day European Technology Manager Industrial Process Peter Stokes European Corporate Account Manager BetzDearborn Europe condensate may be reused after appropriate pretreatment for cooling system makeup or general washing. The function of a multiple effect evaporator system is that of a heat exchanger in which heat from the condensing steam or vapor is transferred across the heating surface to the boiling process liquor. The driving force of the heat exchange is the temperature difference between the heating medium and the liquor, and the heat flow rate is determined by three factors : The temperature difference which essentially is process dependent The heating surface area which is a property of the evaporator structure The heat transfer coefficient, which depends on the process and characteristics of the evaporator structure.
Qualitative Temperature Profile
Temperature Steam temp

INTRODUCTION
The concentration of process streams and waste liquors by thermal evaporation of water is often an integral operation in food, beverage and fermentation processes. Such unit operations can be found in industries as wide ranging as wet corn milling, wheat processing, sugar production, potato processing, dairy products and grain fermentation for spirits. There are many types of evaporation equipment, but for the large sizes required in primary food processes the most successful have been those with vertical tubular heating surfaces. Usually, several discreet evaporators (or '"effects") are arranged in series and often employ vapor compression to minimize energy input while maximizing performance ratios. Such equipment requires substantial capital investment and is designed to operate to high performance standards based on flow rates, evaporation efficiency, energy costs and maintenance costs. A critical parameter is the efficiency of heat-flux transfer across the evaporative metal surface. This is characterized by an overall heat transfer coefficient which is maximized by optimal design, regular plant maintenance and clean heat transfer surfaces. The buildup of scale and other foulants during normal operation progressively degrades efficient heat transfer with economic penalties in increased energy use and production breaks for cleaning. BetzDearborn has developed chemical technologies to retard the deposition of these foulants, and other technologies to improve the quality of subsequent off-line cleaning.

Process stream temp

Tube Wall Condensate Film Fouling

Process Stream

Distance

Figure 1.

Figure 1 depicts a qualitative temperature profile and shows the mechanism of heat transfer from the vapor space in an evaporator effect to the process liquor in the tubes. Various resistances to the heat transfer process are characterized by individual heat transfer coefficients. The interfacial coefficient between steam and condensate which results from molecular interchange and is therefore fixed. The liquid condensate film coefficient which is fixed by the mechanics of the condensation process. The tube coefficient which is a function of the thermal conductivity of the metal and is therefore also fixed. The coefficient of the scale or foulant layer.

HEAT TRANSFER AND FOULING

The objective of the multiple effect evaporator is to raise the dry substance level in the liquid by the removal of water. The condensed water can be used, if of acceptable quality (usually first effect only), for boiler makeup. Condensate from subsequent effects usually has traces of organic material, which if sent to drain will lead to unacceptably high levels of oxygen demand in receiving watercourses. Alternatively, the

 The coefficient of the process liquor which is a function of the fluid properties and its flow through the tubes and which is normally fixed. These separate coefficients are additive and all generally fixed except that of the foulant layer, which therefore tends to progressively dictate the efficiency and economics of the system during operation. Thus, effective heat transfer in several consecutive evaporation stages requires certain minimum temperature differences between heating temperature and process liquor in each effect, and these temperature differences are kept to a minimum to conserve energy by the manipulation of the prevailing pressure. Moreover, it is also arranged that the liquor boiling temperature decreases by only a few degrees between successive effects and this requirement becomes even more important as the number of evaporator effects is increased to achieve better energy efficiency. The onset of fouling and its subsequent buildup serve to progressively insulate the heat transfer surface and despite the counteractive expedient of increasing steam input to maintain heat flux, the gradual effect is to increase the difference in liquor temperature from the first to the last effect with a commensurate loss of evaporator efficiency. Indeed, in simple systems, monitoring the temperature difference between effects serves to indicate the extent and growth of fouling, and operators will stop production for system cleaning when the temperature difference between the second and last evaporator effects reaches some predetermined arbitrary value.

Figure 2.

Thus, periodic chemical cleaning of the evaporator train is necessary to remove deposits and restore heat economy and maximum process flow. Since chemical cleaning often entails production stoppages, utilizes energy intensive boil-outs and generally employs materials corrosive to the plant structure, it is desirable to extend the production time between cleans to a maximum. This can be facilitated firstly by ensuring that such periodic cleans are efficient and thorough, and secondly by the addition to the process stream ahead of the evaporator of processing aids which serve to stabilize the fouling components in solution and prevent their deposition on heat surfaces.

BETZDEARBORN FOODPRO TREATMENTS

Off-Line Deposit Cleaning
Optimal chemical cleaning presupposes knowledge of the composition of the fouling deposits as well as the corrosion resistance of the underlying system metallurgy, and this is hardly ever the case. Instead, process operators employ cleaning protocols consisting of mineral alkali/rinse/mineral acid sequential cycles that may cause serious corrosion problems (even if alternative organic acid is used), or sequential circulations of mineral alkali and rinse water, which, while reducing corrosion problems, have little effect on most inorganic scales. Even calcium oxalate removal requires circulation of concentrated caustic soda/soda ash at elevated temperatures for long periods. BetzDearborn markets a range of FoodPro OLC chemical additives designed for addition to normal caustic cleaning solutions to enhance their cleaning power and eliminate the need for subsequent acid cleaning. These products are a judicious blend of spe2

CONTROL OF SCALING AND FOULING

Scaling and fouling, though highly undesirable, are inevitable within normal economic constraints and derive from dissolved or suspended material in the process liquor and usually consist of organic/proteinbased material or of inorganic/mineral scales and usually a mixture of the two. Fouling deposits occur as the combination of high temperature and high concentration of mineral salts and organic matter results in precipitation of scales and proteinaceous deposits, which adhere directly to the skin of the high temperature heat transfer surfaces. Their composition varies from effect to effect due to the combined influence of the progressive depletion of preferentially precipitated components and increasing concentration of the process stream. In time, fouling deposits can completely block preheater and evaporator tubes, calandria and other voids with concomitant restriction of process flow (Figure 2).

cialty ingredients that promote complete removal of a wide variety of organic deposits and inorganic scales to restore the evaporator system surfaces to optimum efficiency.

Evaporator Operating Data

100

On-line Deposit Control

While a more effective cleaning protocol will itself promote extended process run times, much greater run times between cleans can be achieved by combining efficient off-line cleaning with an on-line deposit control regime. This entails the continuous addition of low concentrations of one or more approved additives into the process stream feed lines to selected evaporator effects. There are several FoodPro DCF deposit control products which can be used in combination, each designed to combat a particular spectrum of foulant or deposit. Thus, after analyses of deposits from all effects, one or more FoodPro DCF products are chosen and applied to provide the optimum control of scaling and fouling.
%/ C 50
Dry Substance Operating Temperature

0 1 2 3 4 Effects 5 Dry Substance 6

Figure 4.

T( C)
20

Temperature Change Between 2nd and 3rd Effect

15

Case History #1 - An evaporator fouling with inorganic deposit

A plant in northern Italy processes wheat to obtain a number of products including gluten and starch and also, via a fermentation process, alcohol. The process begins with milled wheat which is mixed with water (1:10) and left to soak for up to 2 hours. This allows the heavier starch to separate from the gluten. Both products are sent for dewatering and drying, and the remaining water (containing fibers, starch and protein) is sent for evaporation to concentrate the C grade starch prior to discharge of the water. The six-effect evaporator (see Figures 3 and 4) had suffered from progressive fouling so that process run
Evaporator - Shematic Configuration

10

0 1 2 3 4 5 6 7 8 9 10 11 12

Days since last clean Figure 5.

Product in DCF 9839

time was limited to 10 to 14 days before system cleaning to remove deposits became necessary. As noted above, monitoring the temperature difference between effects serves to indicate the extent and growth of fouling, and at this plant operators stopped production for system cleaning when the temperature difference between the second and last evaporator effects reached 16C (Figure 5). At this point a boilout would be performed using caustic (10%) at 70C before returning the evaporator on-line.

1st Effect 2% DS 90 C

2nd Effect 7% DS 80 C

3rd Effect 25% DS 70 C

4th Effect 21 x DS 60 C P

DCF 9839

5th Effect 12% DS 50 C

6th Effect 17% 40 C

Product Out

The six-effect evaporator (see Figures 3 and 4) had suffered from progressive fouling so that process run time was limited to 10 to 14 days before system cleaning to remove deposits became necessary. As noted above, monitoring the temperature difference between effects serves to indicate the extent and growth of fouling, and at this plant operators stopped production for system cleaning when the temperature difference between the second and last evaporator effects reached 16C (Figure 5). At this point a boilout would

Figure 3.

be performed using caustic (10%) at 70C before returning the evaporator on-line. As production at the plant increased, the cleaning requirement became a production bottleneck and BetzDearborn was asked for help in reducing the cleaning frequency. Deposit samples from each effect were analyzed by BetzDearborn, and it was confirmed that the deposit was predominantly inorganic mineral scale (calcium oxalate) throughout the evaporator. At the next scheduled system stoppage, the evaporators were cleaned using a 5% solution of FoodPro OLC9860 in a 7% caustic solution. Subsequent visual inspection confirmed acceptably clean tube surfaces and the on-line treatment commenced at production start-up. This comprised dosing 120 ppm (based upon dry substance) of FoodPro DCF9839. The product was dosed at 2 points with 60 ppm being dosed into the evaporator feed line prior to effect 1 and 60 ppm being dosed into the line prior to effect #4. The temperature difference was again continuously monitored and plotted. As the difference in temperature between the second and last effect rises this indicates reduced evaporation efficiency and hence increased fouling. This is a very good indicator of overall performance. It was found that by dosing the FoodPro DCF 9839, a 42-day period of constant production was achieved before the delta temperatures between effects #2 and #3 rose above 16C (Figure 6). On completion of the 42 days the evaporator was again cleaned and returned on-line and the treatment with dosing FoodPro DCF9839 into the #1 and #4 effects resumed.
Temperature Change Between 2nd and 3rd Effect

A subsequent test showed that although with an untreated process stream the evaporator had on occasion been operated for an average of 25 days before complete fouling and restricted process flow forced closedown, with the process stream treated with FoodPro DCF9839, this period could be lengthened to more than 60 days. This plant has now adopted the cleaning protocol and on-line deposit control program outlined above and has accrued financial benefits from increased production, reduced steam consumption and less downtime due to a reduced cleaning schedule.

Case History #2 - An evaporator fouling with organic (or mixed) deposit

A grain distillery in Scotland takes spent grain from its highland whisky distilleries and processes it to obtain 96 alcohol for use in industrial/beverage applications and, as a by-product, animal feed cake. The process begins fermenting the grain (with added sugar) in large (100m3) vessels. The resulting CO2 generated is collected and liquefied using compressors and then sold to other users. The alcohol is distilled and sold as 96 spirit. The waste grain is washed and dried in a screwpress to approximately 75% dissolved solids. The waste liquor is sent for concentration in large multistage evaporators to approximately 45% dry substance. The liquor thus concentrated is added back to the dried grain which is then sent for final drying in a steam tube drier and then for palletizing and packing. The result is dark colored pellets of high protein animal feed. The four-effect evaporator had suffered for many years from organic fouling, particularly in the #1 effect.

T( C)
20

T( C)
37 40

Grain Distillery Evaporator Treatment Trial (untreated)

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15 10 10 9 8 5 7 6 1 4 7 10 13 16 19 22 25 28 31 34 1 5 11 16 20 25

Days since last clean Figure 6. Figure 7.

Time (days)

This effect is a horizontal shell and tube heat exchanger and serves as a preheater for the remaining vertical effects. As can be seen from the graph below (Figure 7), the temperature of the product was measured at effect #1 and on exit from #4, and the difference tracked as a function of time. As noted above, monitoring the temperature difference between effects serves to indicate the extent and growth of fouling and at this installation, operators arbitrarily stopped production for system caustic cleaning when the temperature difference rose above 10C. Unfettered production in the whiskey distillery is usually contingent on efficient removal of its waste grains and liquors to the animal feed plant. By virtue of the manifold operations required therein, the feed plant is often a bottleneck in the fermentation/whiskey production processes and serious production under-capacity problems can result from inefficient evaporators and evaporator cleaning stoppages in the feed plant. Deposit samples were taken from different areas of the evaporator and found to be over 90% organic based, indicating protein fouling. An on-line treatment using FoodPro DCF9834 was proposed and begun following a complete evaporator clean. The FoodPro DCF9834 was dosed into the inlet of the #1 effect at the level of 300 ppm and the resultant temperature difference between the #1 and #4 effects remained lower for a longer period of time, as depicted in the graph below (Figure 8.) The results show that by using FoodPro DCF 9834, the rate of fouling is reduced and the evaporator could be run for almost seven days longer than previously, allowing increased efficiency (lower steam/energy usage) and an overall higher production volume in any given month.
T( C) Grain Distillery Evaporator Treatment Trial (DCF9834)

Antifoams for Carryover

A perennial problem with any process involving the evaporation of liquors containing organic materials or suspended solids is the formation of foams. Foam can be swept and carried with vapors out of the concentrate side and contaminate the condensate, reducing its purity below acceptable limits for subsequent uses. Even during evaporator cleaning processes involving the removal of insoluble scales and foulants, the formation of foam extends the cleaning cycle, increases the volume of rinse water and requires constant operator involvement. Thus, foam formation in the evaporator during processing and during off-line cleaning is detrimental to the efficiency and economic returns of the operation. BetzDearborn markets a range of liquid FoodPro FAF antifoams to combat these difficulties. They provide safe and effective foam control over a wide range of pH and operating temperatures to minimize process dead space and so improve production throughput and condensate purity. They also significantly improve the facility and economics of the evaporator cleaning operations. The products carry relevant approvals for use in such processes and may be applied to most food processing segments either neat or diluted. The required dose depends upon the application and the severity of the foam.

CONCLUSIONS
The cost of a food and beverage thermal evaporative process can be minimized by maintaining the optimum efficiency of the evaporators and reducing the amount of downtime necessary for cleaning. The efficiency depends largely on the maintenance of clean heat transfer surfaces and efficient separation of liquor and condensate. BetzDearborn markets a range of chemical additives that are designed to maximize evaporator efficiency in those respects. The range of FoodPro OLC products has been developed as additives to enhance the clean cycle by efficiently removing a wide spectrum of difficult deposits and foulants. The range of FoodPro DCF products was developed for feeding in low doses directly into the process stream to help maintain clean heat transfer surfaces by inhibiting the rate of scale and foulant deposition. FoodPro FAF products are designed to control foam in the evaporator during processing (to maintain condensate purity), and for addition to cleaning solutions. FoodPro is a trademark of BetzDearborn Inc. and is registered in one or more countries.

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Time (days) Figure 8.