CHE EL2

EVAPORATION
by: Da-anoy, Gedoria, and Mandadero
TOPIC OVERVIEW:
PURPOSE OF TYPES OF

01 02 03
EVAPORATION
EVAPORATION EVAPORATORS
PROCESS
IN SUGAR USED IN SUGAR
OVERVIEW
REFINING REFINING

CONTROL OF THE

04 05 06
HEAT AND SCALING AND
EVAPORATION FOULING IN
ENERGY
PROCESS EVAPORATORS
EFFICIENCY

COMMON

07 FINAL SYRUP
CONCENTRATION 08 ENVIRONMENTAL
CONSIDERATIONS 09 CHALLENGES IN
EVAPORATION
01 PURPOSE OF EVAPORATION
IN SUGAR REFINING
In sugar manufacturing, evaporation is a critical
process step as it creates conditions where
crystallization can occur in the next processing
phase. Evaporation is a process of concentrating
the liquor to a desired brix. Water is evaporated
from thin syrup containing about 10-15 Brix
dissolved solids to thick syrup of about 50-70 Brix.
During evaporation, the clarified sugar cane juice is
boiled in evaporators which remove most of the
water leaving a thick syrup before sending to pan
boiling.
 EVAPORATION
02 PROCESS OVERVIEW

PROCESS OF EVAPORATING WATER FROM

DECOLORIZED LIQUOR.

STAGES OF CONCENTRATION.
DIFFERENCE BETWEEN EVAPORATION AND

DRYING.
PROCESS OF EVAPORATING WATER
FROM DECOLORIZED LIQUOR

Evaporation is a key step in sugar

processing where the primary objective is
to concentrate the sugar solution, known
as the decolorized liquor, by removing as
much water as possible. This process
helps to increase the concentration of
sugar, measured in Brix, which is a unit
that indicates the percentage of sugar in
the solution.
PROCESS OF EVAPORATING WATER
FROM DECOLORIZED LIQUOR

The decolorized liquor, which has been

purified to remove color impurities, still
contains a significant amount of water.
During evaporation, this water is
gradually removed by heating the liquor,
leading to the formation of a
concentrated sugar syrup. The final Brix
level of this syrup must meet specific
standards to ensure that the syrup is
ready for the crystallization stage, where
sugar crystals are formed.
IMPORTANCE OF EVAPORATION
Evaporation of refinery Shorter residence
liquors in a multiple time in vacuum pans
effect is not only more minimizes color
economical, but it formation and
reduces the boiling and reduces inversion of
crystallization period in sucrose due to
the vacuum pans, prolonged heating or
thereby increasing their high temperature of
capacity. calandria.
 EVAPORATION DRYING

Primarily used to concentrate a Aimed at removing moisture from

liquid solution by removing water solid or semi-solid materials to
or another solvent. It’s often used reduce water content, making the
to increase the concentration of a product easier to handle, store, or
product (e.g., in food processing or use.Heat is applied to a solid material
chemical manufacturing). Involves (or sometimes liquid in the case of
heating a liquid to its boiling point spray drying) to vaporize moisture,
so that the solvent (usually water) which is then carried away by air or
evaporates. The vapor is then another gas stream. The process can
condensed and removed, while the occur through convection,
concentrated solution remains. conduction, or radiation.
 EQUIPMENT
20K+
Decolorized refinery liquors should be

AND evaporated in at least double effect in

which the first body is operating under
INSTRUMEN 14" to 16" of vacuum and therefore the

TATION liquor at 60° Brix will boil at about 185°F

(85°C).

It is possible to use also a quadruple or triple effect for evaporation of sugar

liquors, but since in a quad or triple effect, the first body does not evaporate
under vacuum, sugar liquor of about 60° Brix will boil at atmospheric pressure
or higher and at a minimum temperature of 217°F (103°C) because of boiling
point rise. This temperature is too high for water-white liquors of high purity,
and certain color formation occurs even during the short time the liquor
remains in the first body of the quad or triple effect.
 EQUIPMENT
20K+
If the refinery is operated in conjunction
AND with a raw sugar house, the vapor bled
from the first or second cell of the
INSTRUMEN quadruple or quintuple effect of the raw

TATION sugar house can be used in the calandria

of the first body of the refinery double
effect to minimize steam usage.

The first body of a double effect operates under vacuum and the feed liquor
is sucked in. If the evaporator has more than two effects, the first body will
have atmospheric pressure or higher inside and therefore it will be necessary
to pump the feed liquor into it.
The equipment used is similar to that for
raw sugar mills. However, the liquor was
already been filtered and is cleaner and
purer, with a much-reduced tendency to
scale. Low residence time evaporators are
desirable to minimize sucrose losses and
color formation, particularly as
temperatures tend to be somewhat higher
than in raw mills. Thus, the double effect
can be of conventional design, or it can be
a film evaporator. Falling film evaporators
are also usually used because of the lower
temperature differences possible with
th,is type of evaporator. In general, a small
color increase across evaporation is
experienced.
Heat transfer coefficients are higher
because of the cleaner liquid and reduced
scale, but lower because of the high sucrose
concentrations. Typical values vary to 1.3 to
1.4 kW/m2-K for first effects running on
exhaust steam to 0.6 to 0.8 kW/m2- K for
vessels operating vacuum.
OPERATION
20K+
AND
CONTROL
PARAMATERS

1.Check evaporators and pan entrainments.

2.Check vacuum lines to avoid changes of vacuum.
3.Minimize recycling of liquors.
4.Check all lines to prevent leaks.
5.Operate within quality parameters range.
RILLIEUX
20K+

PRINCIPLES

Norbert Rillieux is famous for his invention of the multiple effect pan
evaporator for sugar refining process in 1881. Rillieux was born in New
Orleans, Louisiana in 1806. He used the steam generated from one pan to
heat the sugar juice in the next pan for energy efficient means of water
evaporation.
RILLIEUX
20K+

PRINCIPLES Rillieux principle states that “In a multiple

effect evaporator of “ N “ effects, one kg
of steam will evaporate N kg of water.”

This is also applicable in refineries as the same in raw sugar houses. However,
it must be remembered that filtrates which enter the multiple effect in a
refinery are much heavier than juices in a raw sugar house and therefore
much less water needs to be evaporated. Hence, much smaller heating
surface of evaporators is needed.
03 TYPES OF EVAPORATORS

Single-effect Evaporator Multiple-effect Evaporator

 Description:
It has a basic design and it is
used in smaller operations.

The liquid enters the bottom of the tubes and

rises.
Steam enters from the side and it goes down
in tubes and makes indirect contact with the
liquid to give up its heat.
Steam condenses and leaves as condensate.
Liquid heats rising to the top, vapors form,
and both the heated liquid and vapors, enter a

SINGLE-EFFECT chamber on the side called the separator.

The liquid leaves from the top and again enter
the bottom of the evaporator section and

EVAPORATOR after it condenses it is be removed from the

section from the side as a concentrated liquid.
 Description:
More efficient systems that use steam in several
stages to improve energy efficiency.

Steam enters the first effect and condensate leaves

at the bottom.
The liquid enters and rises in tubes as it heats to
the top.
Some of the liquid turns into vapor and the rest is
concentrated liquid which moves down the vapors
where they leave.
Rather than discharging them into the
atmosphere, vapor will enter the second effect.

MULTIPLE-EFFECT Steam enters only in the first effect, the rest of the
heating in the second, third effect, and so on is
done by the vapors that are been discharged from

EVAPORATOR the previous effect.

Steam is the focus point as it needs to procure
vapor in every effect.
 Characteristics:
Number of stages: 1 (one stage).
Energy efficiency: Low, as only the heat used in the
SINGLE-EFFECT single stage is utilized for evaporation. Steam is

EVAPORATOR needed for each kilogram of solvent evaporated.

Steam economy: Poor; typically, 1 kg of steam
evaporates around 1 kg of water.
In a single-effect evaporator, there is Equipment cost: Lower initial investment, as only one
only one stage of evaporation. The feed vessel is involved.
solution is heated, and the solvent Complexity: Simple design and easier to operate.
(water) is evaporated in a single step,
with the vapor typically being Effect on Concentration Process:
condensed and removed. Suitable for smaller operations or when energy costs
are not a major concern.
Higher operating costs due to the need for fresh
steam for each cycle.
The concentration process is straightforward but less
energy-efficient.
 Characteristics:
Number of stages: 2 or more stages (can range
from 2 to 7 or more effects).
MULTIPLE-EFFECT Energy efficiency: High, as the vapor from one

EVAPORATOR effect is reused to heat the next. This reduces the

overall steam requirement.

In a multiple-effect evaporator, there are Steam economy: Excellent; typically, 1 kg of

two or more stages (effects) arranged in steam can evaporate 2 to 6 kg of water

series, with the vapor produced in the depending on the number of stages.

first stage used as the heating medium Equipment cost: Higher initial investment, as

for the next stage. This system multiple evaporator stages are needed, but this is

maximizes the use of energy. offset by lower energy costs.

Complexity: More complex design, requiring
careful control of temperature, pressure, and flow
between stages.
 Effect on Concentration Process:
Energy saving: Each additional stage reduces
the amount of steam needed per kilogram of
MULTIPLE-EFFECT solvent evaporated, making the process more
EVAPORATOR economical.
Temperature gradient: The temperature
In a multiple-effect evaporator, there are decreases across stages. The first effect
two or more stages (effects) arranged in operates at the highest temperature and
series, with the vapor produced in the pressure, while subsequent effects operate at
first stage used as the heating medium lower temperatures and pressures.
for the next stage. This system Higher throughput: Multiple effects allow for
maximizes the use of energy. more efficient evaporation, increasing the
amount of solution that can be concentrated.
Optimization potential: Number of stages can
be optimized based on the balance between
capital cost and energy savings.
 COMPARISON OF EFFECTS ON THE
CONCENTRATION PROCESS

FEATURE SINGLE EFFECT EVAPORATOR MULTIPLE-EFFECT EVAPORATOR

NUMBER OF STAGES 1 2 OR MORE

STEAM ECONOMY ~1 KG STEAM PER 1 2 -6 KG WATER PER

KG WATER 1 KG STEAM

ENERGY LOW ( PER UNIT OF

HIGH
CONSUMPTION EVAPORATED SOLVENT )

HIGHER (DUE TO LOWER ( DUE TO

OPERATING COST
ENERGY USE) STEAM ECONOMY )

INITIAL CAPITAL LOWER HIGHER

COST

COMPLEXITY SIMPLE MORE COMPLEX

SMALL SCALE/LOW LARGE SCALE/ENERGY-

SUITABILITY INTENSIVE OPERATIONS
ENERGY COST
04 HEAT AND ENERGY EFFICIENY
1. Role of Steam in Evaporators 2. Role of Heat Exchange in Evaporators

Steam is the primary source of The process of evaporation relies on

energy used to evaporate the effective heat exchange between the
solvent (usually water) from a steam and the solution to achieve
solution in evaporators. Its role is the desired concentration. The
vital in heating the solution to its design of heat exchangers and the
boiling point and providing the process of heat transfer are crucial
necessary latent heat for phase for the efficiency and performance of
change (evaporation). the evaporator system.
04 HEAT AND ENERGY EFFICIENY
04 HEAT AND ENERGY EFFICIENY
Concepts of energy savings through reuse of steam
1. Cascade Use of Steam (Multistage Heating):

Process: In many industrial systems, steam generated from one stage

(e.g., in a boiler) can be reused in subsequent stages. For example, the
high-pressure steam used in one stage of a process can still have enough
thermal energy to serve as a heat source in a lower-temperature stage.
Application: Common in chemical processing, power generation, food
production, and pulp and paper manufacturing.
Benefits: Reduced fuel consumption, lower emissions, and lower
operating costs by making the most of available thermal energy.
04 HEAT AND ENERGY EFFICIENY
Concepts of energy savings through reuse of steam
2. Thermal Vapor Recompression (TVR):
Process: TVR systems take low-pressure waste steam and compress it
back into higher-pressure steam, allowing it to be reused. This
compression is typically done using a steam ejector or mechanical
compressor, which boosts the steam's pressure and temperature.
Application: Common in evaporation systems, such as in sugar or
desalination plants.
Benefits: Reduced energy consumption as the need for fresh steam
generation is minimized.
04 HEAT AND ENERGY EFFICIENY
Concepts of energy savings through reuse of steam
3. Heat Exchangers:
Process: Heat exchangers allow the heat from steam to be transferred to
other fluids without mixing them. This can enable the transfer of heat
from steam used in one process to heat water, air, or another fluid in
another part of the system.
Application: Used in power plants, HVAC systems, and many industrial
processes to recover waste heat.
Benefits: Efficient use of residual heat, reducing the energy required for
heating in subsequent stages.
04 HEAT AND ENERGY EFFICIENY
Concepts of energy savings through reuse of steam
4. Flash Steam Recovery:
Process: Flash steam is generated when high-pressure condensate from
steam systems is released into a lower-pressure area. This steam can be
captured and reused in other processes, such as pre-heating water or
supplying lower-pressure steam processes.
Application: Widely used in steam trap systems and condensate
recovery units.
Benefits: Reduces steam generation requirements, improving overall
system efficiency.
04 HEAT AND ENERGY EFFICIENY
Concepts of energy savings through reuse of steam
5. Cogeneration (Combined Heat and Power, CHP):
Process: Cogeneration systems generate electricity and capture the
waste heat, often in the form of steam, to be used in industrial heating
processes or space heating.
Application: Common in industrial plants, universities, hospitals, and
other facilities with large energy demands.
Benefits: Higher overall efficiency, reduced fuel consumption, and lower
greenhouse gas emissions compared to separate heat and power
systems.
04 HEAT AND ENERGY EFFICIENY
Concepts of energy savings through reuse of steam
6. Multiple-Effect Evaporation (MEE):
Process: MEE is an energy-efficient evaporation technique where the
vapor produced in one effect (stage) is used to heat the next effect. Each
subsequent stage operates at a lower pressure and temperature.
Application: Widely used in desalination, sugar refining, and
concentration of solutions.
Benefits: Significant energy savings, as the reuse of vapor reduces the
need for additional steam generation.
04 HEAT AND ENERGY EFFICIENY
Concepts of energy savings through reuse of steam
7. Steam Traps and Condensate Recovery:
Process: Steam traps remove condensate and non-condensable gases
from steam systems without releasing live steam. The condensate is
often returned to the boiler feedwater tank, where it can be reheated and
reused.
Application: Used in all steam systems to improve efficiency and prevent
energy loss.
Benefits: Minimizes steam waste and improves boiler efficiency by
recovering heat from the condensate.
04 HEAT AND ENERGY EFFICIENY
Benefits of Steam Reuse:
Energy Efficiency: Reduces the need to generate fresh steam, saving
fuel and energy.
Cost Savings: Lowers operating costs by reducing fuel consumption and
maintenance.
Environmental Impact: Reduces greenhouse gas emissions by
maximizing energy use and reducing waste heat.
Process Improvement: Enhances operational efficiency and increases
system reliability.
04 HEAT AND ENERGY EFFICIENY
Benefits of Vacuum Evaporation:
1. Reduction of Boiling Points

Concept: In vacuum evaporation, the pressure inside the evaporator is lowered, which reduces the
boiling point of the liquid.
Mechanism: Under reduced pressure, liquids boil at lower temperatures than they would at
atmospheric pressure. For example, water normally boils at 100°C (212°F) at sea level, but under
vacuum conditions, it may boil at significantly lower temperatures (e.g., 60°C or less).

Benefits:
Energy Savings: Lowering the boiling point means less energy is needed to bring the liquid to
its boiling point, which reduces overall energy consumption.
Gentler Processing: Lower boiling temperatures allow for gentler processing of heat-sensitive
materials, preventing degradation.
04 HEAT AND ENERGY EFFICIENY
Benefits of Vacuum Evaporation:
2. Preservation of Sugar Quality
Application: In the sugar industry, vacuum evaporation is widely used to concentrate sugar
solutions and crystallize sugar.

Benefits:
Prevention of Caramelization: Since sugars are heat-sensitive, high temperatures can cause
caramelization, which degrades the color and flavor of the final product. Vacuum evaporation
allows concentration at lower temperatures, preserving the sugar’s natural qualities.
Improved Crystal Formation: Lower boiling temperatures reduce the risk of sugar
degradation and allow for better control over crystal formation during the evaporation process.
Retention of Nutrients: In some applications, vacuum evaporation helps preserve nutrients
and natural flavors in the sugar solution, leading to a higher-quality product.
04 HEAT AND ENERGY EFFICIENY
Benefits of Vacuum Evaporation:
3. Energy Savings
Concept: One of the major advantages of vacuum evaporation is the reduced energy requirement
compared to traditional evaporation methods.
Mechanism: Lower boiling points mean less heat energy is required to evaporate the same amount of
liquid. Additionally, vacuum evaporators can be used in multi-effect systems, where vapor from one
stage is reused to heat the next stage (multiple-effect evaporation), further improving energy
efficiency.

Benefits:
Reduced Fuel Consumption: The system requires less fuel to produce the steam needed for
evaporation, resulting in significant fuel savings.
Lower Operational Costs: Reduced energy consumption leads to lower operating costs, making
vacuum evaporation an economically viable option in industrial applications.
Environmental Impact: By consuming less energy, vacuum evaporation helps reduce greenhouse
gas emissions, contributing to more sustainable production processes.
05 CONTROL OF THE
EVAPORATION
PROCESS

Monitoring temperature, Pressure, and sugar

concentration levels

Role of Vacuum Pressure in Optimizing

Evaporation

Importance of Keeping the sugar from

Caramelizing.
 Monitoring temperature, Pressure, and
sugar concentration levels
Monitoring temperature, pressure, and sugar concentration level in the evaporation process
during sugar refining is crucial for ensuring the quality, efficiency, and yield of the final product.
Each parameter affects the overall process and product quality, so careful control is necessary.

1. Temperature Monitoring
Importance
Temperature is a key factor in determining the rate of evaporation and preventing sugar
degradation.

High temperatures can lead to caramelization and inversion of sucrose, negatively affecting the
color, taste, and crystallization of the sugar.

Low temperatures under vacuum are ideal for avoiding these problems while still achieving
effective water removal.
 Monitoring temperature, Pressure, and
sugar concentration levels

Target Range
Under vacuum, the boiling point of the sugar solution is significantly reduced, so temperatures
typically range between 60°C and 85°C (140°F and 185°F), depending on the system design and
vacuum level.

Monitoring Tools
Thermocouples or resistance temperature detectors (RTDs) are commonly used to continuously
monitor and regulate temperature within evaporators.

Adjustments
If the temperature rises too high, operators can adjust the heat input or increase the vacuum to
lower the boiling point and maintain ideal conditions
 Monitoring temperature, Pressure, and
sugar concentration levels
2. Pressure Monitoring

Importance
The pressure inside the evaporator is critical because it directly affects the boiling pointof the juice.
Lower pressures (i.e., a vacuum) reduce the boiling point, allowing evaporation at lower
temperatures.
Maintaining a consistent vacuum ensures a steady and controlled evaporation process, preventing
sudden temperature spikes.

Target Range
Evaporators typically operate under vacuum pressures ranging from 30 to 80 kPa, depending on
the stage of the evaporation and the system used.
 Monitoring temperature, Pressure, and
sugar concentration levels
Monitoring Tools
- Pressure gauges and digital sensors are used to continuously monitor vacuum levels in the evaporator.
- Automated systems often adjust the pressure in real time, responding to fluctuations in temperature and juice
concentration.

Adjustments
- If the vacuum pressure is too low (not enough vacuum), operators may adjust the vacuum pumps or valves to
increase the vacuum level, thus lowering the boiling point and preventing excessive temperatures.

3. Sugar Concentration Monitoring

Importance
- Monitoring sugar concentration is critical for determining the end-point of the evaporation process and
ensuring that the juice is sufficiently thickened before crystallization.
- Consistency in sugar concentration affects the crystallization process, with over-concentration leading to
viscosity issues and under-concentration resulting in inefficient sugar recovery.
 Monitoring temperature, Pressure, and
sugar concentration levels
Target Range
- The concentration of sugar (measured as Brix) in the juice increases from around 10-15% in the initial juice to
about 60-70% in the thickened juice (syrup) after evaporation.

Monitoring Tools
Refractometers or density meters are typically used to monitor the sugar concentration (in terms of Brix).
- Inline refractometers can provide continuous, real-time data on the concentration levels, allowing operators
to make adjustments.

Adjustments
- If the sugar concentration is lower than desired, the evaporation process may be extended or heat input
increased (while maintaining a safe vacuum level).
- If the concentration is too high, it may indicate that the process has gone too far, requiring immediate
adjustments to prevent problems with viscosity or crystallization.
 Role of Vacuum Pressure in Optimizing
Evaporation
Vacuum pressure plays a critical role in optimizing the evaporation process. Evaporation
is used to concentrate the sugar juice by removing water, and operating under vacuum
offers several benefits that improve efficiency, energy usage, and product quality.

1. Lowering the Boiling Point of the Juice

Principle - Under vacuum, the atmospheric pressure inside the evaporator is reduced. This
lowers the boiling point of the sugar juice (or syrup), allowing water to evaporate at much
lower temperatures than it would at atmospheric pressure.

Benefit - By reducing the boiling point, the juice can be concentrated without exposing it
to high temperatures that can cause caramelization or inversion of sucrose. This helps
preserve the quality of the sugar, including its color, taste, and purity.
 Role of Vacuum Pressure in Optimizing
Evaporation
2. Energy Efficiency

Less Heat Required - Since evaporation under vacuum occurs at lower temperatures, less energy is
required to achieve the desired level of evaporation. This reduces the amount of steam or fuel needed
to heat the juice, which lowers operating costs.

Multiple-Effect Evaporation - Vacuum allows the use of multiple-effect evaporators, where vapor
generated in one effect is used to heat the next, further optimizing energy use. The lower boiling
points achieved in successive stages of evaporation increase energy savings.

3. Preventing Sugar Degradation

Minimizing Heat Damage - Vacuum pressure prevents the sugar from being exposed to prolonged or
excessively high temperatures, which can lead to caramelization (burning of sugar) or inversion
(breaking down of sucrose into glucose and fructose). These changes negatively affect the flavor, color,
and crystallization of the sugar.
 Role of Vacuum Pressure in Optimizing
Evaporation

Improved Product Quality - By controlling the heat and evaporation rate under vacuum, the
quality of the final sugar product is maintained, ensuring the desired whiteness, purity, and
consistency.

4. Faster Evaporation

Increased Evaporation Rate - The reduced pressure under vacuum speeds up the rate of
evaporation because water can transition to vapor at lower temperatures. This means more water
can be removed in less time, improving overall productivity and throughput.

More Controlled Process - Vacuum allows for better control over the evaporation process.
Operators can fine-tune the temperature and pressure to achieve the most efficient evaporation
while minimizing negative effects on the juice.
 Role of Vacuum Pressure in Optimizing
Evaporation
5. Maintaining Viscosity for Efficient Crystallization

Optimizing Syrup Consistency - As the juice is thickened in the evaporator, its viscosity increases.
By maintaining a lower temperature under vacuum, the viscosity is kept manageable. This is
crucial for the crystallization process, which follows evaporation. Lower temperatures help ensure
the syrup flows properly, aiding in efficient sugar crystallization.

6. Prevention of Scalling and Fouling

Less Scaling - Operating under vacuum helps reduce the formation of scale and deposits in the
evaporators. High temperatures at atmospheric pressure can cause scaling, which affects heat
transfer efficiency and increases maintenance costs. Lower temperatures under vacuum mitigate
this issue.
 Importance of keeping the sugar from
Caramelizing
During the sugar refining process it is important to prevent the sugar from caramelzing
for several reasons. If the sugar is exposed to excessive heat or unfavorable conditions, it
can undergo chemical changes that negatively affect both the quality and yield of the
final product.

1. Maintaining Sugar Quality

Flavor - Caramelization, which occurs when sugar is heated too much, alters the flavor of
the sugar, giving it a burnt or bitter taste. In sugar refining, maintaining a neutral, clean taste
is essential, especially for food products that require consistent flavor profiles.

Color - When sugar caramelizes or degrades, it turns brown, which can result in undesirable
darkening of the final product. Refined sugar is typically expected to be white or very light in
color, especially for industrial uses (e.g., in baking or confectionery).
 Importance of keeping the sugar from
Caramelizing
2. Preventing Loss of Sugar

Yield Reduction - Degradation of sugar, either by caramelization or other chemical reactions (like
inversion), reduces the amount of recoverable sucrose. This can lower the yield, making the
process less efficient and more costly for sugar manufacturers.

Inversion - At high temperatures or in acidic conditions, sucrose can break down into glucose
and fructose through a process called inversion. Glucose and fructose are more hygroscopic (they
absorb moisture from the air) and can cause the sugar to clump, resulting in a less stable product.
 Importance of keeping the sugar from
Caramelizing

3. Maintaining Process Efficiency

Energy Usage - Preventing caramelization or sugar degradation helps optimize the energy
efficiency of the refining process. Excess heat applied to avoid degradation may require additional
cooling or energy corrections, making the process more energy-intensive and expensive.

Crystallization Issues - Degraded sugar can affect the crystallization process. Caramelized or
inverted sugars crystallize less effectively, which can complicate the separation of sugar crystals
from molasses, leading to lower-quality final products.
 Importance of keeping the sugar from
Caramelizing
4. Product Stability

Shelf Life - Preventing degradation ensures the sugar remains stable for longer periods.
When sugars break down or caramelize, they can become more prone to absorbing
moisture, clumping, and even microbial growth, which can reduce the shelf life of both the
raw and refined sugar products.

Purity - High-quality refined sugar needs to be as pure as possible, and preventing sugar
degradation helps in achieving a high level of purity, which is essential for industries like
pharmaceuticals and food production where sugar consistency is vital.
06 SCALING AND FOULING IN
EVAPORATORS

Scaling and fouling are common issues in evaporators, affecting their

performance, efficiency, and lifespan. Both processes involve the deposition of
unwanted materials on the heat transfer surfaces, but they differ in terms of the
substances involved and the mechanisms by which they occur.
06 SCALING AND FOULING IN
EVAPORATORS

1. Scaling in Evaporators

Scaling refers to the deposition of inorganic, insoluble substances (mostly

minerals) on the surfaces of evaporators. This typically occurs as a result of the
concentration and precipitation of dissolved salts as water or another solvent
evaporates.
06 SCALING AND FOULING IN
EVAPORATORS
Causes of Scaling:

Concentration of dissolved salts: As water evaporates, the concentration of dissolved minerals

like calcium carbonate (CaCO₃), calcium sulfate (CaSO₄), and silica (SiO₂) increases. Once the
solution reaches its saturation point, these minerals precipitate out and form solid deposits on
the evaporator surfaces.
Temperature: High temperatures promote the precipitation of minerals, especially those that
are less soluble at elevated temperatures (e.g., calcium carbonate).
pH Changes: A shift in pH can reduce the solubility of some minerals, leading to the formation
of scale. For example, an increase in pH can promote the formation of calcium carbonate scale.
Feedwater Quality: Hard water or water with high concentrations of dissolved solids increases
the likelihood of scaling. Poor water treatment or inadequate water softening often leads to
severe scaling problems.
06 SCALING AND FOULING IN
EVAPORATORS
Common Types of Scale:

Calcium Carbonate (CaCO₃): One of the most common forms of scale, especially in systems
using hard water. Its solubility decreases with increasing temperature, making it a major issue
in high-temperature evaporators.
Calcium Sulfate (CaSO₄): Also known as gypsum, calcium sulfate forms at high temperatures
and low solubility, creating hard and dense deposits that are difficult to remove.
Silica (SiO₂): Silica scaling is particularly problematic in systems using water with high silica
content. Silica forms hard, glassy deposits that are challenging to clean.
Magnesium Salts: Magnesium hydroxide (Mg(OH)₂) can form scale in high-pH environments.
06 SCALING AND FOULING IN
EVAPORATORS
Effects of Scaling:

Reduced Heat Transfer Efficiency: Scaling forms an insulating layer on heat transfer surfaces,
significantly reducing the rate at which heat is transferred. This means that more energy is
required to maintain the desired level of evaporation, increasing fuel or electricity
consumption.
Increased Energy Costs: With reduced heat transfer, more heat is required to reach target
temperatures, leading to higher operational costs.
Reduced Evaporator Capacity: The buildup of scale can reduce the overall capacity of the
evaporator, limiting the amount of fluid that can be processed. Severe scaling may clog tubes
or reduce fluid flow.
Frequent Maintenance and Downtime: Evaporators need to be taken offline for cleaning,
either through mechanical or chemical means, leading to downtime and lost productivity.
06 SCALING AND FOULING IN
EVAPORATORS
2. Fouling in Evaporators

Fouling refers to the deposition of organic, biological, or particulate matter on the

heat transfer surfaces. It differs from scaling because it involves substances like
oils, fats, biofilms, and suspended solids rather than mineral salts.
06 SCALING AND FOULING IN
EVAPORATORS
Causes of Fouling:

Organic Material: Organic substances such as proteins, fats, and oils can precipitate or
coagulate when heated, forming fouling layers on evaporator surfaces. This is common in food
processing (e.g., dairy, sugar refining, fruit juice concentration).
Suspended Solids: Particulates suspended in the feedwater, such as silt, rust, or organic debris,
can settle on heat transfer surfaces, forming fouling deposits.
Microbial Growth: In some evaporators, especially those operating at lower temperatures,
microbial fouling (biofouling) can occur. Microorganisms, such as bacteria, form biofilms that
adhere to surfaces, creating layers that impede heat transfer.
Chemical Reactions: Some fouling occurs due to chemical reactions between dissolved
substances in the fluid, which form precipitates that attach to the surfaces of the evaporator.
06 SCALING AND FOULING IN
EVAPORATORS
Types of Fouling:

Organic Fouling: Caused by substances like fats, oils, and proteins, commonly seen in
industries like food processing and pharmaceuticals.
Particulate Fouling: Caused by solid particles such as sand, clay, and rust that settle on
surfaces.
Biological Fouling (Biofouling): Caused by microorganisms forming biofilms that adhere to
surfaces.
Chemical Fouling: Occurs when chemical reactions between the fluid components produce
insoluble substances that deposit on heat exchange surfaces.
06 SCALING AND FOULING IN
EVAPORATORS
Effects of Fouling:

Decreased Heat Transfer Efficiency: Similar to scaling, fouling forms a layer of insulating material,
reducing heat transfer efficiency and increasing the energy required for the process.
Increased Pressure Drop: Fouling can obstruct fluid flow through the evaporator, increasing pressure
drop across the system and leading to reduced flow rates and inefficient operation.
Frequent Cleaning and Maintenance: Fouling requires frequent cleaning to prevent severe
performance degradation. Depending on the fouling material, mechanical cleaning, chemical
cleaning, or both may be required.
Product Contamination: In industries like food processing, fouling can lead to product contamination,
where degraded organic materials or microbial growth affect the quality of the final product.
Shortened Equipment Lifespan: Fouling, especially in conjunction with corrosion or chemical
reactions, can cause long-term damage to evaporator components, leading to premature failure or
replacement.
06 SCALING AND FOULING IN
EVAPORATORS
Comparing Scaling and Fouling:
07 FINAL SYRUP
CONCENTRATION

In evaporation systems, achieving the final syrup concentration is critical,

especially in industries like sugar processing, where the syrup must reach a
specific concentration for further crystallization or packaging. The final syrup
concentration refers to the percentage of dissolved solids (primarily sugars)
present in the liquid after the evaporation process is complete. Typically, this
concentration is measured in degrees Brix (°Bx), which indicates the
percentage of sugar by weight in the syrup.
07 FINAL SYRUP
CONCENTRATION
Target Concentration:

In sugar processing, the final syrup concentration typically ranges

between 65–75° Brix, depending on the application. The exact target
depends on the subsequent processing steps, such as crystallization,
packaging, or further concentration.
In some processes, higher concentrations (e.g., above 80° Brix) may be
required for specific purposes, like creating syrup for confectionary or
preserving products.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

1. Raw Material Quality

Sugarcane or Sugar Beet Quality: The quality of the raw materials (sugarcane or sugar
beets) has a significant impact on syrup quality. Factors like maturity, freshness, and
sugar content affect how efficiently sugar is extracted and concentrated into syrup.
Mature cane/beet typically yields a higher percentage of recoverable sugar, resulting in
a purer, higher-quality syrup.
Stale or overripe material can lead to the growth of microorganisms, which degrade
sucrose into reducing sugars, affecting syrup purity.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

2. Juice Purification and Clarification

Before evaporation, raw juice undergoes clarification to remove impurities like fibers,
suspended solids, and colloidal matter. Inefficient clarification can lead to:
High levels of impurities in the syrup, which reduce purity, affect color, and hinder
crystallization.
Undissolved solids, which can increase viscosity and affect the quality of the final
syrup.
Color changes due to impurities or incomplete removal of non-sugar compounds,
leading to a darker, lower-quality syrup.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

3. Boiling Temperature and Time

Excessive heat can degrade sugars through caramelization or inversion, producing

unwanted byproducts such as invert sugars (glucose and fructose), which lower syrup
purity and affect crystallization.
Vacuum evaporation, which lowers the boiling point, is used to concentrate syrup at
lower temperatures to minimize sugar degradation and preserve quality.
Prolonged heating can also lead to non-sugar color formation (e.g., Maillard reactions),
resulting in darker syrups with lower commercial value.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

4. pH Levels

Maintaining proper pH levels during the evaporation process is essential for syrup
quality. The ideal pH for sugar syrup is slightly acidic, around pH 6.0–6.5.
Low pH (too acidic) can lead to sucrose inversion, forming glucose and fructose,
which are more difficult to crystallize and reduce product quality.
High pH (too alkaline) can cause the formation of colorants and alter the flavor of
the syrup.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

5. Impurities and Non-Sugars

The presence of non-sugars, including ash, organic acids, proteins, and other dissolved
solids, negatively impacts syrup purity.
High levels of reducing sugars (glucose, fructose) interfere with the crystallization
process by increasing the viscosity and making it more challenging to form high-
quality sugar crystals.
Organic acids and salts (from raw materials or water) can increase the formation of
scale and fouling during evaporation, affecting heat transfer efficiency and syrup
consistency.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

6. Scaling and Fouling in Evaporators

Scaling and fouling on heat exchanger surfaces in evaporators reduce heat transfer
efficiency, leading to uneven heating and concentration.
This can cause localized overheating, increasing the risk of sugar degradation and
affecting syrup quality.
Scale buildup can also trap impurities, which can affect the color and flavor of the
syrup.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

7. Evaporation Rate

The rate of water removal during evaporation affects syrup quality:

Too fast: Rapid evaporation may cause unstable concentration gradients, leading to
uneven syrup consistency.
Too slow: Prolonged exposure to heat can degrade sugars and reduce syrup purity.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

8. Concentration (Brix) Control

Achieving the correct Brix level is critical for syrup quality. If the syrup is over-
concentrated or under-concentrated, it can affect crystallization efficiency and syrup
handling.
Under-concentration can result in a dilute syrup that may require additional
evaporation, risking further heat-induced degradation.
Over-concentration can make the syrup too viscous, affecting flow rates and
increasing the risk of scaling.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

9. Water Quality

Water quality used in the process can influence syrup purity:

Hard water (containing minerals like calcium and magnesium) can contribute to
scaling in evaporators and heat exchangers, affecting heat transfer and syrup
quality.
Impure water can introduce unwanted ions or compounds that alter syrup color or
taste.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

10. Microbial Contamination

Microbial contamination during the handling or processing of syrup can degrade

sucrose, leading to the formation of reducing sugars, acids, and other byproducts that
impact syrup quality.
Good manufacturing practices (GMP), proper sanitation, and controlled handling
environments help prevent microbial contamination.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

11. Viscosity

The syrup’s viscosity increases as it becomes more concentrated, which can affect its
flow properties and heat transfer.
Highly viscous syrups may experience uneven heating, leading to localized
degradation and lower syrup quality.
Maintaining proper flow rates and temperature control can mitigate the effects of
increased viscosity.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

12. Color and Clarity

Syrup color is an important indicator of quality, especially in sugar and food processing
industries.
Darker syrups may indicate sugar degradation, excessive impurities, or
caramelization, all of which reduce product value.
Clear syrups with minimal suspended solids or particles are generally preferred, as
they indicate better processing and purification.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

13. Invert Sugar Formation

Invert sugar (a mixture of glucose and fructose) forms when sucrose breaks down,
either through acid hydrolysis or heat degradation.
High invert sugar levels can reduce the syrup's crystallization efficiency and increase
its hygroscopicity (tendency to absorb moisture), affecting sugar quality.
Controlling pH, temperature, and exposure to acids can help minimize invert sugar
formation.
07 FINAL SYRUP
CONCENTRATION
Factors Affecting Syrup Quality:

14. Handling and Storage Conditions

Improper storage conditions can lead to microbial growth, sugar degradation, or

moisture loss, all of which affect syrup quality.
Ensure that the syrup is stored in a clean, dry, and temperature-controlled
environment to preserve its quality before further processing or crystallization.
07 FINAL SYRUP
CONCENTRATION
Summary of Factors Affecting Syrup Quality:
07 FINAL SYRUP
CONCENTRATION
Summary of Factors Affecting Syrup Quality:
08 ENVIRONMENTAL
CONSIDERATIONS
In the sugar refining industry, environmental considerations during the
evaporation process are essential to reduce resource consumption,
minimize waste, and mitigate environmental impact.

1. Steam and Energy Management to Minimize Environmental Impact

Efficient steam and energy management are crucial in reducing the

carbon footprint and environmental impact of the sugar refining
evaporation process.
08 ENVIRONMENTAL
CONSIDERATIONS

Several strategies are employed:

Multiple-Effect Evaporators (MEE)

Principle: In a multiple-effect evaporator system, steam generated in the

first evaporator is reused to heat the subsequent evaporators. This
reduces the total energy demand for evaporation.
Environmental Benefit: By using less fresh steam and reusing vapor, the
plant’s energy consumption is reduced, thereby lowering greenhouse gas
emissions associated with energy production.
08 ENVIRONMENTAL
CONSIDERATIONS
Waste Heat Recovery

Strategy: Heat exchangers can be used to recover residual heat from

various stages of the refining process, including evaporation. This heat
can be utilized to preheat juice before entering the evaporators.
Environmental Benefit: This reduces the overall energy consumption of
the plant, minimizing fuel usage and emissions.
08 ENVIRONMENTAL
CONSIDERATIONS
Steam Recycling

Condensate Reuse: Steam used in the evaporation process is often

condensed and collected. This condensate is hot water that can be
reused within the plant for heating purposes, reducing the demand for
fresh steam generation.
Benefits: It cuts down on water use and energy needed for heating,
leading to significant resource savings.
 ENVIRONMENTAL
08 CONSIDERATIONS
2. Water Recovery and Reuse Strategies

Water plays a significant role in the sugar refining process, particularly during evaporation.
Developing strategies for water recovery and reuse can substantially reduce environmental
impact.

Condensate Recovery

Reuse of Water from Evaporation: During the evaporation process, water vapor is separated
from the juice. This vapor is condensed and collected, producing clean water that can be
reused in various parts of the plant (e.g., for boiler feed water, cooling systems, or irrigation
purposes).
Environmental Benefit: Reusing water reduces the need for fresh water intake from natural
sources, conserving water and lowering the plant’s water footprint.
08 ENVIRONMENTAL
CONSIDERATIONS
Condensate Recovery

Reuse of Water from Evaporation: During the evaporation process, water vapor is
separated from the juice. This vapor is condensed and collected, producing clean
water that can be reused in various parts of the plant (e.g., for boiler feed water,
cooling systems, or irrigation purposes).
Environmental Benefit: Reusing water reduces the need for fresh water intake
from natural sources, conserving water and lowering the plant’s water footprint.
08 ENVIRONMENTAL
CONSIDERATIONS
Closed-Loop Water Systems:

Principle: By implementing a closed-loop system, water used in the plant is

continuously recycled. Instead of discharging wastewater, water is treated and
reused within the production cycle.
Environmental Benefit: This reduces water pollution, minimizes water withdrawal
from local resources, and prevents the release of potentially harmful effluents into
the environment.
08 ENVIRONMENTAL
CONSIDERATIONS
Reduction of Water Usage:

Optimization: Careful monitoring and optimization of water use during

evaporation and throughout the refining process help reduce water wastage.
Environmental Benefit: Reducing overall water consumption helps alleviate the
pressure on local water resources, especially in regions prone to water scarcity.
08 ENVIRONMENTAL
CONSIDERATIONS
3. Impact of the Evaporation Process on Effluent and Wastewater

The evaporation process in sugar refining has a direct impact on the quality and
quantity of effluent and wastewater produced. Proper management and
treatment of effluent are essential to minimize pollution.

Effluent Composition:

Concentrated Waste Streams: During evaporation, impurities from the sugar juice
become more concentrated in the remaining liquid. This can result in effluent
containing high levels of organic matter and chemical residues, which, if untreated,
can harm the environment.
08 ENVIRONMENTAL
CONSIDERATIONS
Effluent Treatment:

Treatment Technologies: To mitigate environmental impact, effluents from sugar

refining are typically treated in effluent treatment plants (ETPs). Processes such as
aerobic or anaerobic digestion, filtration, and chemical treatment are used to
remove organic load, dissolved solids, and other impurities before discharge.
Environmental Benefit: Proper treatment prevents the contamination of local
water bodies, reducing the risk of ecosystem damage and ensuring compliance
with environmental regulations.
08 ENVIRONMENTAL
CONSIDERATIONS
Reduction in Pollutant Load:

Minimizing Chemical Use: By optimizing the evaporation process and reducing

the need for chemical additives, the amount of potentially harmful substances in
the effluent can be minimized.
Environmental Benefit: Lower chemical use translates to less environmental risk
in effluent discharges, reducing the potential for soil and water contamination.
09 COMMON CHALLENGES IN
EVAPORATION
09 COMMON CHALLENGES IN
EVAPORATION
09 COMMON CHALLENGES IN
EVAPORATION

Controlling the concentration process in evaporation systems is

crucial to avoid over-concentration (which can lead to product
degradation, crystallization, or viscosity issues) and under-
concentration (resulting in incomplete processing, increased water
content, and reduced product quality). Proper control ensures that
the desired level of concentration is achieved efficiently and
consistently.
09 COMMON CHALLENGES IN
EVAPORATION
09 COMMON CHALLENGES IN
EVAPORATION

In the context of evaporation and other thermal processes, energy

consumption, heat transfer inefficiencies, and mechanical failure
are common operational challenges that can negatively impact
efficiency, increase costs, and cause downtime. Addressing these
issues is key to optimizing process performance, reducing costs, and
improving reliability.
09 COMMON CHALLENGES IN
EVAPORATION
09 COMMON CHALLENGES IN
EVAPORATION

Mitigating sugar degradation and quality loss during evaporation

and related processes is critical for maintaining the desired properties
of sugar, such as its sweetness, color, texture, and shelf life. Sugar
degradation can occur due to excessive heat, prolonged exposure to
high temperatures, and chemical reactions during processing, which
can lead to the formation of undesirable by-products like colorants or
off-flavors.
09 COMMON CHALLENGES IN
EVAPORATION
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