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    Bulletin 16 - Conversion of Triple Effect Evaporator With Five Effect Evaporator

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    Sivaram Krishnamoorthy
    The document describes how Asian Paints Limited in Cuddalore, India converted their triple effect evaporator system to a five effect evaporator system by utilizing idle components from a standby evaporator, reducing their annual steam consumption by 33% and saving over Rs. 3.3 million with a payback period of only 3 months for the Rs. 0.8 million investment. The conversion increased evaporator efficiency and plant capacity while minimizing additional costs.

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    Bulletin 16 - Conversion of Triple Effect Evaporator With Five Effect Evaporator

    Uploaded by

    Sivaram Krishnamoorthy
    114 views2 pages
    The document describes how Asian Paints Limited in Cuddalore, India converted their triple effect evaporator system to a five effect evaporator system by utilizing idle components from a standby evaporator, reducing their annual steam consumption by 33% and saving over Rs. 3.3 million with a payback period of only 3 months for the Rs. 0.8 million investment. The conversion increased evaporator efficiency and plant capacity while minimizing additional costs.

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    The document describes how Asian Paints Limited in Cuddalore, India converted their triple effect evaporator system to a five effect evaporator system by utilizing idle components from a standby evaporator, reducing their annual steam consumption by 33% and saving over Rs. 3.3 million with a payback period of only 3 months for the Rs. 0.8 million investment. The conversion increased evaporator efficiency and plant capacity while minimizing additional costs.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    114 views2 pages

    Bulletin 16 - Conversion of Triple Effect Evaporator With Five Effect Evaporator

    Uploaded by

    Sivaram Krishnamoorthy
    The document describes how Asian Paints Limited in Cuddalore, India converted their triple effect evaporator system to a five effect evaporator system by utilizing idle components from a standby evaporator, reducing their annual steam consumption by 33% and saving over Rs. 3.3 million with a payback period of only 3 months for the Rs. 0.8 million investment. The conversion increased evaporator efficiency and plant capacity while minimizing additional costs.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 2

    Energy Efficiency Bulletin

    Case Study Bulletins from CII-Sohrabji Godrej Green Business Centre


    Bulletin No. 16

    Conversion of Triple Effect Evaporator to Five Effect Evaporator Making Use of Idle Standby

    October 2007

    Company details Asian Paints Limited is one of the leading manufacturers of paint in India. It is a multi-national company of Indian origin having manufacturing facilities across the globe. Asian Paints Limited has its chemical division at Cuddalore, Tamilnadu, manufacturing various grades of Pentaerythritol, sodium format and formaldehyde. Asian Paints Limited, Cuddalore is an ISO 14001 certified company. Project details Original system A multiple-effect evaporator is an apparatus for efficiently using the heat from steam to evaporate water. In a multipleeffect evaporator, water is boiled in a sequence of vessels, each held at a lower pressure than the last. Because the boiling point of water decreases as pressure decreases, the vapor boiled off in one vessel can be used to heat the next, and only the first vessel (at the highest pressure) requires an external source of heat. Putting together evaporators saves heat and thus requires less energy. Theoretically, adding one evaporator to the original decreases the energy consumption to 50% of the original amount. Adding another effect reduces it to 33% and so on. The maximum number of effects in a multiple-effect evaporator is usually restricted to seven because after that, the equipment cost starts escalating to uneconomic levels. There are two types of feeding that can be used when dealing with multiple-effect evaporators. Forward feeding takes place when the product enters the system through the first effect, which is at the highest temperature. The product is then partially concentrated as some of the water is transformed into vapor and carried away. It is then fed into the second effect which is a little lower in temperature. The second effect uses the heated vapor created in the first stage as its heating source (hence the saving in energy expenditure). The combination of lower temperatures and higher viscosities in subsequent effects provides good conditions for treating heat-sensitive products like enzymes and proteins. In using this system, an increase in the heating surface area of subsequent effects is required. Another way to proceed is by using backward feeding. In this process, the dilute products is fed into the last effect with has the lowest temperature and is transferred from effect to effect

    with the temperature increasing. The final concentrate is collected in the hottest effect which provides an advantage in that the product is highly viscous in the last stages so the heat transfer is considerably better. This was followed in the plant. Triple Effect Evaporator (TEE) was used for concentrating the process stream from 14% TS to 55% TS.The steam economy rate of the evaporator was 2.50. The plant had installed a standby evaporator to ensure continuous running of the plant. The steam flow requirement of the process was 3 TPH and the maximum feed flow rate was 145 LPM. Conversion of Triple Effect Evaporator to Five Effect Evaporator
    l l

    In view of the improved maintenance techniques, the need for the stand by evaporator almost got eliminated The idea of Five Effect Evaporator (FEE) conversion was proposed by the plant energy audit team. An external consultant hired by the plant confirmed the feasibility of conversion and energy saving The idling standby evaporator components are used along with the newly designed vacuum system to convert the Triple Effect Evaporator into Five Effect Evaporator which helped to keep the cost of conversion to a bare minimum level

    Original system

    STEAM

    CW IN

    III

    II III II

    I I

    CW OUT

    STEAM HOT COND

    SEAL POT FEED

    PRODUCT

    DISTILLATE STORAGE

    System layout - Triple Effect Evaporator

    Modified system
    STEAM CW IN

    Cost benefit analysis


    l Investment Rs 0.80 million ( USD 0.02

    million)
    V

    CW OUT

    I V

    I V

    II I

    II II I II

    I I

    STEAM HOT COND

    l Annual savings Rs 3.30 million (USD

    0.083 million)
    l Payback 3 months

    SEAL POT FEED

    PRODUCT DISTILLATE STORAGE

    About CII & CII-Godrej GBC CII is a non-government, not-for-profit, industry led and industry managed organisation, playing a proactive role in India's development process. Founded over 112 years ago, it is India's premier business association, with a direct membership of over 6500 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 350 national and regional sectoral associations. Cll-Godrej GBC is a Centre of Excellence in Energy Efficiency, Green Buildings, Renewable Energy, Water, Environment & Recycling and Climate Change activities in India. About 3 Country Energy Efficiency The Project "Developing Financial Intermediation Mechanisms for Energy Efficiency Projects in Brazil, China and India" aimed to substantially increase investments in energy efficiency by the domestic financial sectors in Brazil, China and India. The project was a partnership between the World Bank, the United Nations Environment Programme (UNEP) through the UNEP Risoe Centre on Energy, Climate and Sustainable Development (URC), and institutions in Brazil, China and India. Additional information is available at www.3countryee.org This Energy Efficiency Bulletin comprises of a series of case studies on successful energy efficiency projects implemented by Indian industry. The bulletin is supported under the "3 Country EE" initiative and by USAID.

    System layout - Five Effect Evaporator Issues faced during implementation There were no major issues faced during the implementation of the project. The implementation of this project was scheduled during the annual shut down maintenance. Comments from the plant team The project was implemented by Asian Paints Ltd. Cuddalore, Tamilnadu in the year 2003.Fruitful utilisation of stand by equipment can provide oppor tunities for energy conservation. Financing of the project The plant has invested about Rs 0.80 million ( USD 0.02 million) for implementation of the project.The investment was taken up fully with internal funds. Results of the project l The steam economy for FEE : Increased from 2.4 to 3.4 l Steam consumption: Reduced from 3000 kg/hr to 2000 kg/hr. i.e. 33% reduction in steam consumption l Feed flow: Increased from 145 Liters Per Minute (LPM) to 180 LPM i.e. 25% increase in the plant capacity Energy and cost savings l Reduction in Sp. Steam consumption: 2.24 MT l Fuel saving per annum: 1306 MT of 6000 Gross Calorific Value (GCV) coal Benefits of the project
    l Effective utilization of Idle stand by l Reduction in Specific Steam Consumption

    For further details contact


    Mr T Rajasekar Factory Manager Asian Paints India Ltd. B5-B10 Sipcot Industrial complex Cuddallore - 607005 Ph: 04142- 239247, 239248 Email: [email protected]

    Mr K S Venkatagiri / Mr K Sivaram
    Survey No 64, Kothaguda, Near Hitech City Hyderabad - 500 032 Tel: 040-23112971 73, Fax: 040-23112837 Email : [email protected] / [email protected] www.greenbusinesscentre.com

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