Effective communication is the backbone of any successful organization. It ensures that information flows seamlessly across all levels – facilitating understanding, decision-making, and collaboration. Clear communication reduces ambiguity, minimizes conflicts, and promotes transparency.

Impact on Team Dynamics and Company Vision

Accountability:

When expectations, goals, and responsibilities are communicated clearly, each team member knows what is expected of them. Regular feedback and updates keep everyone answerable for their roles and actions. As well as clear all the doubts and facilitate fast and correct decision making.

Energy and Motivation:

Open communication boosts morale by giving employees a voice. When people feel heard and informed, they are more engaged, enthusiastic, and willing to contribute. Also, this promotes emotional bonding with the organization which is a very critical attribute for the maximum productivity and quality output.

Alignment with Vision:

Consistent communication about the organization’s mission, goals, and progress ensures that all teams are moving in the same direction. It fosters unity and shared purpose, which is vital for strategic execution. When employees have clear vision of the organization, they can also visualize their growth trajectory. This reduces the employee attrition rate. Apart from above, this help to develop strategic thinking among employees, which expedite the mission to achieve company’s vision.

Strategy to Foster an Effective Communication Environment

Below can be the initiatives we can pursue to build effective communication environment in the organization:

• Establish Clear Communication Channels be it is verbal, written or in presence. Define formal and informal channels for different types of communication.
• Promote a Two-Way Culture, in this encourage listening and feedback at all levels, which is very important. One side communication has no meaning.
• Train Managers and Leaders to equip them with skills like active listening, empathy, and clarity.
• Leverage of the technology that use collaboration tools like Slack, Teams, or Trello. Below is the summary of various tools:

• Ensure transparency by sharing company goals, updates, and challenges regularly.
• Celebrate Success and Acknowledge efforts of the team members. In this initiative we can use communication, rewards or certification to recognize and motivate.

Action Plan

Below is tentative action plan which can be rolled out to meet the objective “to develop the effective communication environment”.

Conclusion

Effective communication is not just a tool but a culture that drives accountability, energizes teams, and ensures alignment with organizational goals. With deliberate strategy and consistent action, organizations can create a communication-rich environment that fuels growth and success.

Thank for reading…

The post Importance of Effective Communication within an Organization appeared first on ChemEnggHelp.

1. Technical Challenges:
   • Equipment failures or breakdowns. This can be due to wrong process design parameters or incompatible material of construction selection.
   • Difficulty in maintaining consistent production quality. Possibly process designer has designed a inefficient unit operation, like smaller surface area of the exchanger, wrong selection of pump, insufficient stages in distillation column or limitation of heat management in reactor for the given reaction.
   • Technological upgrades or integration of new systems. This happens when we have selected a older version of control system while particular equipment local control is advance. In such cases it is very difficult to integrate or upgradation.
2. Supply Chain Issues:
   • Delays in material delivery. If we have selected a vendor who is too much loaded or has poor infrastructure we can face delivery issues and delay in project completion. Apart from this if we don’t have a well thought procurement planning then also we are going to face delivery challenges.
   • Fluctuations in raw material costs. In project we plan everything and try to maintain the cost within capex cost. Sometimes steel, cement or chemical cost escalates which will impact heavily the projected capex cost. This can delay the further investments and impacts plant start up.
   • Supply chain disruptions due to external factors (e.g., weather, political instability). These all factors will affect the delivery of equipment and other items on construction site.
3. Labor and Staffing Issues:
   • Difficulty in hiring skilled labor. To complete a projects we need skilled labour and this comes with a cost. If we try to control the project cost and compromise with the quality of labour this will certainly impact work quality and delay in project work completion.
   • High turnover rates or lack of employee retention. During plant construction we keep on hiring the engineers, technicians, fitters and other staff. But at that time work load is of different in nature, like supervision of plant construction, study and understanding of new processes, training, etc. So keeping employing engaged is a tough challenge, therefore many employees leave in between for some better opportunities in running plant.
   • Safety concerns and ensuring a safe working environment. In a plant under construction maintaining safety is very difficult work, as fabrication, rigging, insulation, instrumentation, electrical work is in process. Hence, there are lots of chances of accidents and to control those is a big task for a safety officer.
4. Financial and Budgeting Problems:
   • Underestimating operational costs. When plant is mechanically completed and commissioning starts our main focus remain to run the plant only. We are least bothered about the production capacity, raw material & utility norms. This loss is the part of plant start up cost or pre-operative cost. If plant commissioning takes more time then envisaged then project completion cost will increase and we need to arrange the funds to meet the requirements.
   • Securing necessary funding or managing cash flow. For the project manager and finance controller it is a very big challenge when project is delayed and performance is not meeting with design parameters. In such situation we need additional funds to pump into the plant till all the issues are resolved and plant is running on its designed parameters (i.e., capacity, RM & Utility norms, effluent norm, product quality).
   • Variations in market demand or product pricing. For a business head it becomes a very disturbing situation, when the plant is successfully commissioned and demand is low or product prise drops. This will impact financial feasibility of the investment and increase the capex pay back period. Some times whole capex expenditure comes under huge loss to the organization if that product is ban or out of use.
5. Regulatory and Compliance Hurdles:
   • Navigating local, state, or federal regulations. For a marketing manager to sell the product across states comes under various rules and regulation. When any rule is unfavourable is affects the product sale negatively and leads to the revenue loss.
   • Meeting environmental standards and obtaining necessary permits. If in original plant design we do not ponder over various effluent generation, their capacity and quality, it can be a big nightmare for a plant manager and site head. Because we can not discharge any effluent be it gas, liquid or solid in to the environment without treatment. Therefore, we need to install the ETP, CETP, Incinerators, Thermal Oxidizers, spray dryers, vent gas scrubbers for the treatment of various effluent streams to meet the environmental standards.
   • Adhering to industry-specific regulations. If we are running a industry then it is mandatory to abide with the rule and regulation of the land.
6. Operational Efficiency:
   • Optimizing production processes for maximum efficiency. After plant commissioning to meet the market challenges and remain in competition we need to keep continue to work upon product cost reduction and productivity enhancement. For this purpose we need to train the employees for TPM (Total Productive Maintenance), Lean & Six Sigma.
   • Managing waste and minimizing resource consumption. Our process excellency or operational excellency team can work upon the processes to reduce, reuse and recycle schemes of the various waste. In absence of this initiative the product cost will increase and it will reduce the company profit margins.
   • Ensuring smooth coordination across departments. Because an organization is the group of various functions like operation, supply chain, Human Resource & training, Design & Projects, Business, Finance, Operational Excellence, Safety & Environment, Quality, R&D, etc. If there is poor coordination among these groups, respective group people have personal ego greater than organization benefit then it is a disaster. Any successful organization keeps growing if there is efficient communication and smooth coordination across the departments.
7. Quality Control and Customer Expectations:
   • Ensuring that products meet quality standards consistently. Any mistake of quality control department during sample testing can create a big problem for business. The customer will reject the material and it return back to the factory. Reprocessing of the off spec or low quality product is a additional cost and simultaneously is a dent to the brand value.
   • Managing customer expectations and complaints. If quality control department is not addressing the customers complaint timely, then it is possible that we can loose the business. Also it will spread bas name for the organization.
   • Implementing feedback loops for continuous improvement. When a complaint is received, it should be logged promptly, and the urgency and impact assessed. From there, a thorough root cause analysis is carried out—often using methods like the 5 Whys or a Fishbone Diagram—to dig beyond surface symptoms and uncover the real issue. Once identified, corrective actions are taken to address the root cause directly.
   • But it doesn’t stop there. Preventive actions are just as critical. These are designed to stop the issue from recurring—not just in the affected product, but across similar systems or operations. Clear, timely communication with the customer is maintained throughout the process, sharing updates and outcomes transparently.
   • Every step is documented and reviewed, and the CAPA is only closed once effectiveness has been verified. Over time, analyzing these cases can reveal patterns that help drive continuous improvement and build stronger, more resilient processes.
   • In short, CAPA isn’t just about fixing what went wrong—it’s about learning from it, so it doesn’t happen again.
8. Environmental Factors:
   • Weather conditions and natural disasters can significantly delay plant start-up by disrupting construction schedules, damaging infrastructure, or hindering the delivery of equipment and materials. Heavy rains, floods, storms, or extreme temperatures can halt on-site activities and pose safety risks to workers. In severe cases, natural disasters like earthquakes or cyclones can cause structural damage, requiring repairs and reassessments before commissioning can proceed. Such delays can impact project timelines, increase costs, and require contingency planning in high-risk areas.
   • Sustainability concerns and environmental impact can pose significant challenges during plant start-up, particularly in industries with high emissions, effluent discharge, or hazardous waste generation. Regulatory compliance has become more stringent, requiring detailed environmental impact assessments, pollution control systems, and waste treatment solutions to be operational from day one. Delays in obtaining environmental clearances or issues with effluent treatment plant (ETP) performance can stall commissioning activities. Additionally, communities near industrial zones are increasingly vocal about ecological risks, prompting greater scrutiny from authorities and stakeholders. Sustainable sourcing of raw materials, energy efficiency, and carbon footprint reduction must also be integrated into process design, often necessitating modifications late in the project cycle. These factors not only affect timelines and budgets but also demand a more proactive approach to environmental management, making it a critical consideration in successful and responsible plant start-up.
9. Navigating local community relations, especially if the plant has environmental concerns
   • Especially when there are environmental concerns involved. Resistance from nearby residents—due to fears of pollution, water usage, or health impacts—can lead to protests, legal actions, or demands for additional safeguards. Gaining community trust often requires extensive engagement, transparency, and sometimes redesigning parts of the project to address public concerns. Without early and consistent communication, local opposition can escalate, prompting regulatory reviews or halts in construction, ultimately delaying commissioning and operations.

Conclusion

Problems rarely end with project initiation—they persist through commissioning and often continue even after start-up. That’s why it’s crucial to anticipate potential challenges early and develop proactive strategies and contingency plans to manage them effectively. By foreseeing issues related to design, regulations, environment, community relations, and operations, we can minimize disruptions and maintain smooth, efficient business operations. Preparedness not only reduces delays and costs but also builds resilience and ensures long-term success.

Thanks for Reading.

The post Challenges after a Plant Commissioning appeared first on ChemEnggHelp.

With over 25 years of experience in chemical plant design, process optimization, and digitalization, I have witnessed firsthand how expert consulting can bridge the gap between technology and profitability. Let’s explore the key responsibilities and value additions that a consultant brings to chemical process industries.

1. Feasibility Studies & Conceptual Design

A successful project begins with a robust feasibility study. This involves:

• Process Selection: Evaluating raw materials, reaction pathways, and technology options. So that capex investment is safe and provide highest possible returns to the investors.
• Techno-Economic Analysis: Assessing CAPEX, OPEX, and ROI to determine economic viability. Selecting best possible technology in terms of initial capital requirement. Choosing contemporary technology which is providing highest product yield, lowest cost of manufacturing and generating low waste which is not toxic and hazardous.
• Process Flow Development: Creating initial Process Flow Diagrams (PFDs) and performing mass & energy balances. This will help to understand the process at macro level to the stockholders and enables to estimate cost of production data for financial feasibility study.
• Risk Analysis: Identifying potential challenges related to safety, sustainability, and regulatory compliance. Assessment of the safety equipment requirement, process controls, material handling, selection of effluent treatment, required provision during plant design & engineering.

2. Process Design & Engineering

Once feasibility is established, the consultant plays a pivotal role in detailed process design:

• PFDs & P&IDs: Developing block flow and process flow diagram, carryout the material and energy balance for the process. Subsequently designing of process control system with process and instrumentation diagrams.
• Equipment Sizing & Selection: Designing and preparation of specification sheets of unit operation such as reactors, distillation columns, heat exchangers, pumps, and separators.
• Process Simulations: Using advanced tools like ChemCad, HYSYS, and other simulators to optimize process conditions. The detailed design of heat exchangers, distillation & absorber columns.
• Safety Considerations: Conducting HAZOP studies, SIL assessments, and relief system design to mitigate risks.

3. Detailed Engineering & Project Support

A chemical process consultant collaborates with multidisciplinary teams to ensure smooth project execution:

• Material & Equipment Specification: Providing detailed guidelines and equipment specification data sheets for procurement and fabrication. This includes all the required details including equipment operating parameters (i.e., flow rate, capacity, pressure, temperature), design parameters and material of construction, applicable codes & standards for equipment design and testing, sketch of the equipment with nozzle schedule, site conditions, etc.
• Process Control & Automation: Defining instrumentation requirements, control schemes, and digital monitoring solutions. After detailed study of the chemical process, we design a control philosophy for the smooth and efficient plant operation. In this course of work we take into consideration emergency plant shutdown requirements to avoid any hazardous conditions.
• Vendor & Licensor Evaluations: Analysing technology proposals for proprietary processes, identify optimal solutions, assess technological options to minimize variable production costs, and study effluent generation, treatment methods, and environmental impact.

4. Process Optimization & Troubleshooting

Even well-designed plants require continuous optimization and this is imperative for businesses to remain competitive. To meet this objective, a consultant applies tools like Six Sigma & Lean and can provide solutions for:

• Energy & Yield Optimization: Applying DMAIC & Lean methodology, Implementing heat integration, advanced process controls, and AI-driven analytics.
• Debottlenecking & Capacity Expansion: By process mapping and using Lean methodology to Identify the constraints or debottleneck stages. This way improving throughput without major capital investment.
• Operational Issues: Analysing process data using six sigma tools and troubleshooting quality, yield, or equipment performance problems.

5. Sustainability & Green Chemistry

With increasing regulatory pressure and environmental concerns, sustainability is at the core of modern plant design. To meet this objective we need to work upon below line items:

• Waste Reduction & Byproduct Recovery: Enhancing material efficiency to minimize waste. Finding the possibilities of recycling & reusing the effluent streams inside the plant. Working upon options to convert the waste into wealth so that final product can more economical and sustainable.
• Carbon Capture & Green Energy Integration: Exploring alternative energy sources and emission control strategies. We can study the process and work upon the methods to recover waste heat available from heat of reaction, distillation column condensers, high temperature streams and flue gases. This way we can reduce the overall energy requirement for the plant and can reduce the carbon foot prints.
• Eco-Friendly Processes: To design a sustainable and green process, evaluation of renewable feedstocks, green solvents, and low-carbon production methods.

6. Commissioning & Startup Support

Consultants play a hands-on role in plant commissioning and startup. Since he or she has complete knowledge of process technology and plant, therefore can anticipate the possible hurdles and problems during commissioning. Also, previous experience gives hands of solutions to resolve the issues which helps to expedite the plant start up:

• Pre-Startup Safety Reviews (PSSR): Ensuring that the plant meets all design and safety criteria. This step help to avoid any unforeseen issues which can lead to accident or equipment breakdown before commissioning. This includes to check the issues like missing of gaskets, bolts, welding joint failure, electric motor direction, any blind availability, NRV fitting, strainer or filter chocking, safety valves, vents & drain provisions, etc.
• Operator Training: Conducting workshops on plant operation, troubleshooting, and digital tools. This is an important step before plant handover to the production team. Also, preparation and review of the plant standard operating procedures before actual plant commissioning is very crucial.
• Performance Validation: Analysing startup data to confirm that the plant is operating as per design expectations. In case there is any gap in plant performance then conducting brainstorming to fix the problems so that design parameters can be achieved.

7. Compliance & Regulatory Support

Navigating the complex landscape of industry regulations is another critical aspect:

• Environmental & Safety Regulations: Ensuring compliance with OSHA, EPA, REACH, and other global standards.
• Documentation & Permitting: Preparing necessary reports and technical documentation for regulatory approvals.
• Risk Management: Conducting safety audits and implementing best practices for chemical handling.

How a Consultant Adds Value

• Independent & Unbiased Perspective: Unlike in-house teams, consultants provide objective insights.
• Cost Savings: Optimizing CAPEX & OPEX through smarter engineering and technology choices.
• Innovation & Digitalization: Leveraging real-time analytics, AI, and machine learning for better plant control.
• Risk Mitigation: Proactively identifying and resolving potential failures.

Conclusion

In an industry where margins are tight and efficiency is key, the right consulting expertise can mean the difference between success and failure. Whether you are planning a new project, troubleshooting an existing plant, or looking for digital transformation solutions, expert consulting can help unlock new levels of productivity and sustainability.

If you are looking for a consultant with deep experience in chemical plant design, process improvement, and digital transformation, feel free to reach out. Let’s work together to build the future of chemical manufacturing!

Thanks for reading,

Kailash Mehra

The post The Role of a Chemical Process and Plant Design Consultant appeared first on ChemEnggHelp.

So, to achieve above objective every chemical process industry must be energy efficient to minimize their carbon foot prints. Moreover, need to reduce the effluent generation during chemical manufacturing. This we can achieve by adopting zero discharge policy, be it for any type of effluent. However, as a chemical manufacturer selection of a technology is very important, where effluent generation is minimum. Also, selection of effluent treatment methodology is equally important to make the manufacturing facility zero effluent discharge. In this article we will discuss various types of common effluents generation during chemical manufacturing and their possible treatment methods.

Various Types of Effluents Generation

We can broadly categorize the effluent or waste generated in chemical manufacturing in four types as below:

1. Liquid Waste – This can be of different type based on chemical compositions present in water. Like Aqueous effluent containing acid impurities like HCl, H2SO4, HNO3, etc. Other can be Aqueous effluent containing organic impurities such as benzene, ethanol, acetic acid, pyridine, etc.  Apart from this Aqueous waste having impurities of various salts like NaCl, Na2SO4, MgCl2, NH4Cl, etc. Other types can be the various combination or mixture of above effluents. The sources of these wastes, can be the processes like extraction, decantation, centrifuge or ANF washing mother liquor, neutralization, etc.
2. Organic Waste – This is also in liquid form but in some cases at lower temperature can be solidified also. An organic residue is mix of high boiling organic compounds or contain tarry material. In chemical industries organic residue mainly generates from the bottom of a distillation column.
3. Solid Waste – It can be semi-solid also like slurry or wet cake containing moisture or other chemical in the range of 5% to 30%. The examples of solid waste are activate carbon, reactor catalyst, inorganic salts (i.e., NaCl, MgCl2, Na2SO4, etc.). The final discharge points for these wastes are solid-liquid filters, sedimentation tanks, centrifuge, ANF, ATFD, etc.
4. Gaseous Effluent – The source of this effluent stream in chemical plant we can see from absorber column top, spray dryers, vents of heat exchangers, vessels and tanks. Many times, this effluent is not harmful for the environment and we can discharge it into the atmosphere without any treatment. But in some cases where it contains chemicals such as ammonia, organic solvent, reactor off gases mixture of various toxic organics, it requires treatment before venting into the atmosphere.

Effluent Treatment Methodologies

We select effluent treatment methodology based on the type and characteristics of the effluent. Below are some common techniques to treat the effluents in our industries:

Liquid Waste Incinerator

This incinerator we use to treat the aqueous waste containing organic impurities, which are not biodegradable and we can not treat this using ETP. As we can not discharge or recycle the waste water due presence of hazardous chemicals in it. Therefore, for treatment of such effluents we use incinerator.

In Liquid waste incinerator there is a combustion chamber which operates around at 800 to 850 ⁰C temperature. In case of the presence of chloride impurities in waste water we need a secondary combustion chamber also. This secondary combustion chamber operates at around 1100 to 1150 ⁰C temperature to incinerate chloride chemicals. The fuel inside the incinerator can be furnace oil or natural gas. Hot flue gases subsequently pass through a waste heat boiler and we can generate waste steam, which we can used inside the plant. After waste heat boiler flue gas passes through economizer where combustion air required for incinerator is preheated and flue gas passes through chemical scrubber to remove the NOx and SOx impurities before discharging into the atmosphere at safe location.

We use liquid waste incinerator for the incineration of Liquid Organic Waste and Vent Gas also. As organic waste and vent gas has good calorific values, therefore it reduces overall fuel consumption for the incinerator. Below is the schematic sketch of a Liquid Waste Incinerator.

Solid Waste Incinerator

It is similar as above shown only difference we require one pyrolizer or Rotary kiln before incinerator combustion chamber. In rotary kiln we charge solid waste through a conveyor, this kiln rotates at very low RPM between 0.5 to 1 rotation per minute. The temperature of kiln or pyrolizer is maintained around 800 to 850 ⁰C by burning fuel through fuel burners. All the organic material present in solid waste burn and remaining non-combustible solid discharge from other end of the kiln. Hot flue gases enter into next combustion chamber where temperature is further increased around 1100 to 1150 ⁰C to incinerate chloride impurities. Subsequently follow the similar path as described in Liquid Waste incinerator.

The solid waste which non-incinerable is send for secured land fill sites, however this not a suitable method of waste disposable. Below is the photo of a solid waste incinerator installation.

Dioxins are not usually present in waste, but they can form when chlorine-containing organic substances are burned. Modern incinerators produce dioxins and furans from three points in the process: stack-gas emissions, bottom ash, and fly ash. Operating Incinerator at higher temperatures above 1100°C is considered the most effective way to destroy dioxins.

Presence of Dioxins in our environment can cause cancer, reproductive and developmental problems, damage to the immune system, and can interfere with hormones.

Spray Dryer for Inorganic Aqueous Waste

In case when inorganic salts are presents in aqueous waste such as NaCl, MgCl2, Na2SO4, we can use spray dryer chamber. In this case we do not produce waste steam and here we use a spray chamber in place of the waste heat boiler. Rest other equipment remain as it is as liquid waste incinerator. Here hot flue gases at 800 to 850 ⁰C coming out from the combustion chamber enters into the spray dryer. Aqueous inorganic waste is sprayed through a nozzle from top, water gets evaporated and comes out with flue gases while dry solid salt is collected from the bottom of spray dryer. Which can be reused or sold depending on the quality otherwise goes for secured land fill sites.

ETP for Waste Water Treatment

We use Effluent treatment plants (ETP) for the removal of high amounts of biodegradable organic compounds, tar, debris, dirt, toxic, non-toxic materials and polymers etc. from the industrial waste water. The typical process steps for a ETP are as below:

• First remove any oil or tar from liquid surface through grease trap,
• Addition of flocculant to enrich organic matter in wastewater,
• Filtration and collection of solids (solid waste)
• Destroy large organic molecules in wastewater using oxidation methods,
• Adjust PH 7-8 with sodium hydroxide and flow into anaerobic process,
• Effluent passes through aerobic tank, converting all organic molecules into carbon dioxide, water and biomass (sludge) which we can be remove from the effluent.

Subsequently mass flows into a sedimentation tank and air flotation machine to remove biomass/sludge.

The waste water which contains non-biodegradable chemicals such as insecticides, pesticides, synthetic fibers, pyridines, cyanopyridines, ammonical impurities, glass objects, mercury, lead, arsenic etc., we use incineration method for treatment.

Conclusion

Effluent treatment technology is a continuously evolving field and require new ecofriendly and energy efficient ways. Because treatment of effluent is a cost and it reduces profit margin. Simultaneously, engineers should keep on working to reduce the effluent generation inside the plant using new technologies. Also, we need to look into the recycling of the effluent so that final effluent quantity is minimum for treatment requirement.

Thanks for reading…

The post Effluent Generation & Its Treatment Methods appeared first on ChemEnggHelp.

A poorly designed feed pipe distributor can cause back flow. This we can see in case of low pressure drop across the distributor holes. While, in case of high pressure across the distributor holes causes jet & mist formation, which may lead to emulsion formation in case of liquid liquid extraction column.

Liquid Pipe Distributor Sizing

Below is the sample calculation to size the pipe distributors for a liquid-liquid extraction column:

Conclusion

Above calculation is helpful to size a pipe distributor for a given liquid feed. A properly designed distributor is very critical for the best performance of the absorber column, extraction column or distillation column.

Thanks.

The post Pipe Distributor for Liquid appeared first on ChemEnggHelp.

There are many advantages in using a liquid jet pump for certain applications, where fluid viscosity is low, fluid is not highly volatile, not very erosive in nature, has no sticky or polymerizing tendency, etc. The benefits of liquid jet pump use in such applications can be like, no moving parts, in line mixing, no or low maintenance and comparatively simple system.  

Principle of Liquid Jet Pump

In operation a high velocity jet of pressurised liquid discharged from the motive nozzle produces a region of low pressure in the suction chamber that entrains the secondary liquid or fluidised solid. The two streams then thoroughly mix in the throat before the resulting mixture flows through the diverging cone to regain some pressure to overcome system discharge heads.

Liquid jet pumps, utilize the pressure energy of a high-pressure fluid stream to boost the pressure and/or flow of a low-pressure fluid stream.

Ejectors are generally inefficient devices. However, their simplicity and lack of moving parts make them worthy of consideration, particularly where a high-pressure fluid stream is already available. This way we can use the available waste energy and can save energy cost for the process.

Performance of the Liquid Jet Pump

Let us refer the below simple liquid-liquid jet pump sketch.

Let us assume at Section-1, two fluids are mixing Stream-1 having mass flow rate W1 (kg/s) and Stream-2 with mass flow rate W2 (kg/s). The flow area for Stream-1, for Stream-2 is S2 (m2) and at Section-2 flow area is S3 (m2).

Mass Balance for the System

Here we can write the mass balance at steady state between Section-1 and Section-2,

W1 + W2 = W3                (here W3 (kg/s) is the mass flow rate at Section-2)

ρ1*V1*S1 + ρ2*V2*S2 = ρ3*V3*S3         -Eq.1     (i.e., rate of mass in at Section-1 = rate of mass out at Section-2)

since this is a liquid and can be assumed as an incompressible fluid hence, ρ1= ρ2= ρ3= ρ

Also, from geometry we can have, S1 + S2 = S3                 -Eq-2

Therefore, we can rewrite above Eq.1 with the help of Eq.2 and above assumptions:

V1*S1 + V2*S2 = V3*(S1 + S2)

(S2/S1) = [(V1 -V3)/(V3 – V2)]              -Eq.3

Momentum Balance for the System

Assuming negligible friction, the momentum balance can be written as below:

Rate of momentum in – Rate of momentum out = 0         (for steady state flow)

W1*V1 + W2*V2 – W3*V3 + P1*S1 + P2*S2 – P3*S3 = 0              

We can solve the above equation for discharge pressure,

P3 = (W1*V1 + W2*V2 – W3*V3 + P1*S1 + P2*S2)/S3                   -Eq.4

Hence, using above equations we can estimate the inlet pressure and flow rates to meet the required discharge flow rate and pressure requirements.

Various Applications of Liquid Jet Pump

We can find various industrial application of Liquid Jet Pumps as below:

• Eductors Inside as Storage Tank for mixing the liquid inside. In many cases such as dilution of incoming feed into the tank or when there are multiple streams are coming into the tank with different composition. In such cases Eductors can be very helpful and below figure shows the typical installation.

Here, the pump provides high pressure liquid stream which passes through the jet pump or eductor nozzle and pumps the tank liquid to make it a homogeneous mixture. This way we can avoid the installation of large size agitators and motor power consumption.

• Second application we can see for inline dilution of some concentrated solution. Many times, we use dilute NaOH solution for our process requirements and available is of 48% concentration. So, in such cases we can use an inline liquid-liquid ejector to get the desired dilute caustic solution. The typical installation in such cases can be as shown in below figure.

So, this way we can avoid a mixing vessel and can get continuous feed of dilute caustic solution.

• Another use we can see to pump the liquid using available high-pressure liquid. This way we can use available waste energy and can save power bill for the process. This type of arrangement we can understand by below figure.

As we can see in above figure, the primary fluid is passed through a nozzle where the pressure energy is converted into kinetic energy. The high-velocity jet entrains the secondary fluid. The two streams mix in the mixing tube, leading to pressure recovery. Further static pressure is recovered in a narrow-angle diffuser downstream of the mixing tube.

• High pressure liquid jet generates a vacuum, which we can use to diffuse the gas into the mixing chamber. As the gas/liquid mixture enters the diffuser, the static pressure begins to recover. This way gas is compressed as it approaches into the discharge. This way, we can see the Liquid Ejector works as an evacuator as well as a compressor also.

Conclusion

Liquid Jet Pumps/Ejectors are available in stainless steel, carbon steel, duplex steel, Hastelloy, titanium, rubber lined, PP, PTFE and PVDF. Liquid jet ejectors are jet pumps, which uses high pressure liquid as motive fluid. They use the kinetic energy of the pressurized liquid to entrain liquid, gases or vapours. Moreover, these can be used for pumping slurries and other liquids or granular solids. These devices discharge the resultant mixture against a higher pressure.

We should look into the plant and should find the applications of liquid jet pumps. As this will save the power bill required for pumping or generating vacuum. Also, this is the idea of creating wealth from waste energy, where we have high pressure liquid stream available.

Thanks for reading..

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Different Types of Structured Packings

For example, Mellapak 250Y is a less denser structured packing and mostly used where we are looking for highest vapour or gas throughput rates and low theoretical plates per meter of packed height. While, Mellapak 750Y or gauge packing like BX & CY are used where we are looking for highest number of theoretical stages in per meter of packed height. Here, we can get around 8-10 stages. But these packing packings are good for low liquid flow rates and gas throughput rates.

Once we get the superficial velocity through column for a given structured packing, using the velocity and volumetric flow rate we can calculate column diameter.

Flow Area (m2) = Volumetric Flow Rate (m3/s)/ Superficial Velocity (m/s)

Diameter (mm) = 1128.4*(Flow Area^0.5)

Superficial Velocities for Different Structured Packings

In below table there are the values of superficial velocities which we can use to estimate the packed column diameter for given vapour load. In my experience I found these values are very close to actual plant operation. These values are good for atmospheric column operation. For vacuum operation we can use higher superficial velocities than this, around 3-4 times of the given values.

Conclusion

Column diameter depends on vapor or gas volumetric flow rate through the column. And, volumetric flow rate is the function of column pressure. At higher pressure, vapour density will be higher and volumetric flow rates will be lesser. On other hand, in vacuum while density is low therefore we can afford higher superficial velocities through the column. In summary, we can say if we operate a column in vacuum, which was designed for atmospheric conditions, the capacity of that column will reduce. As, at higher gas velocities column will lead to flooding conditions.

Thanks,

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Impact of Heat Exchanger Fouling

In chemical plants heat exchanger fouling is a big problem and this causes loss of revenue in terms of equipment replacement cost, maintenance & cleaning expanses. Moreover, fouling is responsible for productivity loss also as fouling of heat exchanger force us to continuously keep on reducing the raw material or input feed rates to the plant. In a shell & tube type heat exchanger fouling can be inside and outside surface of the tubes. Due to increase in fouling thickness, heat transfer resistance increases which continuously bring down the operating heat duty of the heat exchanger. And, finally when this operating heat duty is too low to operate the plant above its minimum turndown capacity, we need to shut down the plant to clean the heat exchanger.

Below is the figure showing shell & tube heat exchanger fouling at outside surface of the tubes:

To understand the heat exchanger fouling at inside surface of the tubes please refer to the below figure:

Most of the time we can clean the fouled surface and restart the plant for normal operation. But, is some cases where this fouling is impossible to remove, we need to replace the fouled heat exchanger with new equipment.

In a heat exchanger, deposition of fouling reduces overall heat transfer coefficient. Because of this heat transfer efficiency of the equipment reduces. According to a study, roughly build-up of a 0.6mm thick layer of fouling & scaling in tubes can reduce chiller efficiency by 20% approximately.

Causes of fouling in Heat Exchangers

We can classify various causes of fouling in heat exchangers in below three broad categories: –

Slurry & tarry material in fluid

There are fluids containing slurry or tar which we handle in our plants. This will settle & deposit on tube surface at low fluid velocity. This is generally a soft scaling or fouling and can be cleaned easily using low pressure water jets. The example of this is reaction product liquid containing catalyst fine particles or slurry of a crystallized material.

Dissolved Solid or Salts

In other cases, we can see some fluid containing dissolved solids like sodium chloride & water. When this fluid is heated in a heat exchanger (i.e., vaporizer) because of boiling at tube surface water evaporates but dissolved salt is non-volatile and remains on tube surface. In due course of time this deposition keeps on building and causes hard fouling of salts. To clean this, we need high pressure jets and wire brush. This fouling we can see in distillation column condensers (i.e., primarily operating at high condensing vapor temperatures around > 120 ⁰C), where we use cooling water as cooling utility. At this temperature dissolved solids present in cooling water retain at inside tube surface because localized boiling phenomena. This fouling we can see mostly at the vapour inlet side of the exchanger.

Miscellaneous Reasons

Many fluids have tendency to polymerize or form tar at high temperature. When we heat or boil this type of fluid using reboilers in distillation column bottom, after a certain operating cycle tubes of reboiler chock and cleaning is required.  

Overcooling of a fluid below its freezing point over a heat transfer surface causes coating of frozen fluid layer. This we type of fouling we know as a freezing fouling.

Other cause of fouling can be wrong selection of metallurgy, in such case due to corrosion metal surface get corroded and creates fouling on heat transfer surface.

Dealing with the Heat Exchanger Fouling

As we discussed above, fouling is heat exchanger is a serious problem for an efficient plant operation. Hence, as a process engineer, we need design the heat exchanger to deliver efficient working time span. So that, this can tackle fouling problem effectively. Below are some practical solutions, which we can consider:

Considerations during Design

One strategy we can opt, during heat exchanger designing is, keeping more fouling fluid inside the tubes. While, less fouling fluid we should keep in shell side. This type of arrangement facilitates us to easy cleaning of tubes from inside using water jet or wire brush to remove deposited fouling. As it is very difficult to clean the shell side fouling comparatively.

However, shell side cleaning, which is the removal of scaling or fouling from outside surface of the tubes. We can use suitable chemicals circulation methods through shell side, which can dissolve of remove deposited scale on the tubes outer surface. Chemical removal of fouling in heat exchanger we can achieve, in some cases by weak acid, special solvents, and so on.

Where, shell side fouling is too much, there we can select U-Tube bundle and shell type arrangement instead of fixed tube sheet type exchanger. After fouling we can open the heat exchanger and pull out the tube bundle to do the cleaning.

Considerations During Operation

Avoid large temperature gradients for heating with steam and thermic fluid. We should keep temperature gradients for heating around 30-35 ⁰C in case of organics and 35-40 ⁰C for the aqueous solution. This will minimize hard scaling on the process side due to over heating of the chemical on the tube surface. Also, we should use saturated steam into the reboilers.

In condensers and coolers tube side velocity (i.e., cooling water side) should be sufficiently high (around 6 – 8 ft/s minimum) to ensure the self-cleaning of the tube surface.

For viscous, sticky & slurry type materials we can use scrap surface heat exchangers. For example, a super saturated fluid is likely to crystallise on cooling & degree of fouling is very high. We can use scraped-surface heat exchangers in which a rotating element has spring-loaded scraper blades which wipe the surface of the tubes for efficient heat transfer.

Where fouling is the part of the process and unavoidable, we can consider a standby equipment in line. So, when one gets fouled take other in line and clean the fouled heat exchanger for next cycle. This way we can achieve uninterrupted plant operation.

Selection of compatible metallurgy will avoid the corrosion fouling of the heat exchanger tubes. We should provide temperature interlocks and controls to eliminate the possibility of freezing fouling, wherever we are dealing with possible below freezing temperatures.  

Cooling Tower Parameters Monitoring

In case of condensers & coolers, where we use cooling water, there we need to monitor and maintain the cooling tower parameters (i.e., TDS & pH) regularly. Cooling tower blowdown, side stream filter and chemical dozing are the measures to control the cooling water quality. These measures help us to control the total dissolved solid, suspended solids, microbiofoulants such as slime and algae and macrobiofoulants such as snails and barnacles in circulation cooling water.

Fouling in tubeside because of untreated cooling water and no side stream filter provision in Cooling Tower.https://www.chemengghelp.com/wp-content/uploads/2026/03/FouledHE.mp4

Conclusion

Finally, we understand that fouling in heat exchanger is the inherent part of the chemical process operation in heat transfer surfaces, especially in heat exchangers. Therefore, as a process engineer and plant operator it is very important to understand the causes and nature of possible fouling. This understanding will enable us to handle the fouling deposition effectively and we can keep our plant running for a longer span of time. In many cases we can avoid the damage of costly equipment altogether.

I assume this article will help you to understand & effective dealing with fouling of heat transfer surfaces.

Thanks for reading..

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Process Description

Let us assume a homogeneous liquid phase non-catalytic reaction. In this reaction two organic raw materials, chemical ‘A’ and chemical ‘B’ reacts to form chemical ‘C’. This is an exothermic reaction and raw material ‘A’ is limiting reactant. Chemical ‘B’ consumption is 1.25 times of reactant ‘A’. Heat of reaction is 150 kcal/kg of reacted ‘A’.

 In this process equilibrium conversion of the reaction is 85% on the mass basis for reactant ‘A’. This reaction takes place at 85 ⁰C and atmospheric conditions. Selectivity of the reaction is 95% on mass basis. And remaining 5% of reacted ‘A’ converts into high boiling tar like material. This residue composition is as below which is sent for incineration. The calorific value for residue is 7500 kcal/kg approximately.

Physical and Chemical Properties

For our batch reactor process calculations, we need physical and chemical properties for the chemicals are in below table.

A (liq.) + B (liq.) —->  C (liq.)      at 85 ⁰C and atmospheric pressure, below is the process flow diagram for our batch reactor system.

Process Flow Diagram (PFD)

Here,

RM – Raw Material

CWS – Cooling Water Supply

CWR – Cooling Water Return

Cond. – Steam Condensate

Material Balance for the Batch Reactor System

This process includes two steps first is reaction and second is batch distillation. The material balance for per batch will be as below.

• Charge of RM – A, 2000 kgs/batch
• Charge of RM – B, 2500 kgs/batch (since B is charged 1.25 times of A)
• Total mass of in reactor (RM – A + RM – B = 4500 kgs/batch)
• Equilibrium conversion is 85% hence unreacted RM – A in crude product = 2000*(100 – 85)/100 = 300 kg.
• Unreacted RM – B in crude will be = 300*1.25 =375 kg.
• Product C in crude will be (2000 + 2500) *0.85*0.95 = 3633 kg (since selectivity is 95% for the product C.)
• Heavies’ generation in reaction will be = (2000 + 2500) *0.85*0.05 = 181.7 kg/batch. Since the composition of heavies in residue is 95% hence residue generation per batch will be = 181.7 *100/95 = 191.3 kg.
  • Loss of RM – A in residue will be 191.3 *1/100 = 1.91 kg/batch
  • Loss of RM – B in residue will be 191.3 *2/100 = 3.83 kg/batch
  • Loss of Product C in residue will be 191.3 *2/100 = 3.82 kg/batch

• The recovered quantities from distillation based on 90% recovery will be as below (given in R&D technology package).
  • RM – A recovered = 300 *90/100 = 270 kg/batch
  • RM – B recovered = 375 *90/100 = 337.5 kg/batch
  • Product – C recovered = 3633 *90/100 = 3269.7 kg/batch
  • Intercut quantity of A & B = 45.5 kg/batch (66% A and 34% B) – from R&D package
  • Intercut quantity of B & C = 44.0 kg/batch (50% B and 50% C) – from R&D package
• Total production of product – C will be = product in crude – loss in intercut – loss in residue = 3633 – 22 – 3.82 = 3607.2 kg/batch.
• Total RM – A consumed = Charged – Recovered = 2000 – 270 = 1730 kg/batch
• Total RM – B consumed = 2500 – 337.5 = 2162.5 kg/batch

Energy Balance for the Batch Reactor System

Heating utility for our process is 3.5 bar steam at saturated conditions. The temperature of the steam is 139 ⁰C and latent heat is 513.5 kcal/kg. 

Steam Requirement

• Heat load for reaction mass heating after charging of RM – B will be Q1 = mass RM-B * Cp * (initial temp – final temp) = 2500*0.35*(80-35) = 39375 kcal/batch. Hence steam requirement will be m1 = Q1/513.5 = 76.7 kg/batch.
• Heat load and steam requirement in distillation will as follows:
  • For recovery of RM – A, heat load will be Q2 = mass recovered * (1 + reflux ratio) * latent heat = 270*(1 + 5) *100 = 162000 kcal/batch. Steam requirement will be m2 = Q2/513.5 = 162000/513.5 = 315.5 kg/batch.
  • Similarly, for RM – B recovery Q3 = 337.5*(1 + 10)*100 = 371250 kcal/batch. Steam requirement will be m3 = Q3/513.5 = 723.0 kg/batch.
  • For product recovery Q4 = 3269.7*(1 + 10)*90 = 3237003 kcal/batch. Steam requirement will be m4 = Q4/513.5 = 3237003/513.5 = 6303.8 kg/batch.
  • For first intercut Q5 = 44.5*(1 + 25)*100 = 115700 kcal/batch. Steam required will be m5 = Q5/513.5 = 225.3 kg/batch.
  • Heat load for second intercut Q6 = 44.0*(1 + 40)*100 = 180400 kcal/batch. Hence steam requirement will be m6 = Q6/513.5 = 351.3 kg/batch.

Therefore, total steam requirement for total batch processing will be Q = Q1 + Q2 + Q3 + Q4 + Q5 + Q6 = 76.7+315.5+723.0+6303.8+225.3+351.3 = 7995.6 kg/batch. Considering 5% steam loss actual steam requirement will be Q’ = 1.05*Q = 8395 kg/batch.

Cooling Water Requirement

Cooling water flow rate requirement will be based on when our reaction is going on and pure product draw is going on. As this will be maximum requirement any point of time during the process.

• Hence, heat load on jacket during reaction q1 = rate of addition A * heat of reaction = 500 * 150 = 7500 kcal/h (for calculation we are considering 100% conversion). Cooling water supply and return temperature are 32 and 40 ⁰C respectively. Hence, cooling water flow will be w1 = q1/(Cpw*(40-32)) = 7500/(1*(40-32)) = 937.5 kg/h.
• Heat load during pure product draw (3269.7/10 = 327 kg/h) will be q2 = 327*(1 + 10) *90 = 323730 kcal/h. Therefore, cooling water requirement at column condenser will be w2 = q2/(Cpw*(40-32)) = 323730/(1*(40-32)) = 40466 kg/h.
• Water circulation in reactor condenser w3 = 5000 kg/h.

Total flow rate for cooling water pump will be W = w1 + w2 + w3= 937.5 + 40466 + 5000 = 46403.5 kg/h or 46.4 m3/h.

Power Requirement

Cooling water pump will be 50 m3/h and 30 m head. Hence power consumption will be P1 = m*9.81*h/(3600*pump efficiency) = 50000*9.81*30/(3600*0.75) = 5450 W = 5.45 kW. Total consumption per batch will be P1’ = P1*Batch Cycle Time = 5.45*27 = 147.15 kW/batch.

Reactor and distillation vessel agitator motor power is 5.5 kW. Hence power consumed by agitator motors will be P2 = Reactor agitator* operating hours + Distillation agitator* operating hours = 5.5*570/60 + 5.5*1050/60 = 148.5 kW/batch.

Other transfer pumps and auxiliary power requirement P3 = 60 kW.

Total power requirement will be P = P1’ + P2 + P3 = 147.15 + 148.5 + 60 = 355.65 kW.

Norms Estimation

RM – A consumption norm = Consumption A/Production of C = 1730/3607.2 = 0.4796 kg/kg

RM – B consumption norm = Consumption B/Production of C = 2162.5/3607.2 = 0.5995 kg/kg

Residue generation norm = Residue generation/Production of C = 191.3/3607.2 = 0.053 kg/kg

Steam consumption norms = Q’/3607.2 = 8395/3607.2 = 2.327 kg/kg

Power requirement will be = P/3607.2 = 355.65/3607.2 = 0.099 kW/kg

Cycle Time Estimation for Batch Reactor System

Listing down unit operation wise all the steps in batch reactor process system and adding the time taken in each process step provides the cycle time for that process step. Below is the table and sample working for your understanding:

In our example there are two process steps, first is reaction and second is distillation. From above table we can see in batch reactor total time cycle is 570 min and in distillation step batch cycle time is 1050 min. Therefore, effective batch cycle time for this process will be whichever is highest and here it is distillation step. So, batch cycle time or BTC of this batch process is 1050 min. While overall batch time cycle is (570+1050= 1620 min).

Conclusion

You can use this procedure to carry out the material and energy balance for the batch reactor plant. For your work you will get a technology package from your R&D department. In this you will get all the information regarding reaction and downstream requirement. After this we do the equipment design for equipment. In our example various equipment are such as reactor, reactor condenser, transfer pump, distillation vessel, distillation column, column condenser, etc.

Next, we design control system requirement for reactor temperature, distillation column temperature, steam flow and reflux flow. Pipe line sizing for process, cooling water, steam and condensate.

P&ID development, equipment layout and elevation drawings are developed subsequently. In my future post we will go through all the steps.

Thanks,

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Steam Economy

The steam economy for a MEE is (kg of steam used/kg of water evaporated from all effects). We can enhance steam economy by increasing number of effects. However, we should evaluate the steam economy v/s fixed cost for the MEE. In our industries most of the effects are 3 or 4 stage only. Using higher number of effects will not increase steam economy substantially, while investment required will be more. Some of the applications where we use MEE are as below:

• Concentration of aqueous feed of Vitamin before feeding into the dryer.
• Raw spent wash concentration before feeding into slop fired boiler.
• Concentration of lean organic effluent stream before feeding into the incinerator and reducing fresh water requirement by recycling evaporated water.
• Waste water concentration, which contain various salts (i.e., NaCl, Na₂SO₄, (NH₄)₂SO₄, etc.) and recycle the evaporated water to reduce the fresh water and final effluent quantities.

Types of MEE Systems

Based on the feeding orientations, we can categorize MEE operation as described below:

Forward Feed Operation

In this operation the feed enters into the first effect via feed pump and then subsequently flow through all the effects in downstream. Similarly, vapour from first effect enters into second and continue till the last effect. In this operation lowest temperature is at the last effect as pressure in effects keep on decreasing. Therefore, this kind of arrangements are good where final concentrated product is heat sensitive. Below is the figure for your reference:

Backward Feed Operation

Here, feed enters into the last effect and the concentrated product we collect from the first effect. To understand this operation, you can refer to below figure. Here, feed flows from low temperature & pressure to higher temperature & pressure. Which is in contrast with feed forward operation. This type of arrangement is advantageous when final product is viscous. As, with decrease in temperature viscosity increases, therefore it is better option to use feed backward MEE system. This way concentrated product after each effect is at higher temperature and at higher temperature viscosity will be lower. 

Other Feed Operations

Apart from above we can use mix feed operation mode also, which is the combination of feed forward and feed backward operations. In mixed feed the dilute liquid enters in between of effects, flows in forward feed to the end of the effect and then pumped back to the first effect for final concentration. Also, MEE can be natural circulation or forced circulation type.

You can see another common evaporator arrangements as shown in below figure, which is more common in crystallizations. This we know as parallel feed operation. In this feed enters individually to all the effects. While, vapour from first effect enters into the second effect and continue to travel till last effect.

To improve steam economy, vapour compression may be applied to the vapour from the first effect of a multiple effect system. Thus, giving increased utilization of the steam for the MEE system. However, such a device is not suitable for use with liquid feeds with a high boiling-point rise. Because in this case, we need to compress the vapors at high pressure to superheat, so that it can provide heat to next calendarial. Finally, this will reduce the energy efficiency.

Simulation Results of a Three Effect MEE

Below is the material & energy balance of a four-effect feed forward evaporator system. In this multiple effect evaporator we are concentrating a NaCl water solution containing from 3.00 to 23.90% by wt. Feed rate in first effect is 15000 kg/h at 40 ⁰C.

First effect is operating at 1.6 bar pressure and last effect which is fourth one is operating at 0.1 bar pressure. These are absolute pressure not gauge, so in gauge pressure 1^st effect is at 0.6 bar positive pressure and 4^th effect is 0.9 bar vacuum. Corresponding temperatures for 1^st & 4^th effects are 113.33 ⁰C and 45.75 ⁰C respectively. Apart from this 2^nd effect is operating at 85.93 ⁰C and 3^rd effect is at 75.84 ⁰C.

In first effect evaporator we are using 9.0 bar saturated steam having temperature 175.43 ⁰C, which has condensate outlet temperature at 155 ⁰C.

The overall boiling point difference is: 113.33 – 45.75 = 67.58 ⁰C

Total water evaporation quantity is: 13117 kg/h (1^st effect: 2791 kg/h, 2^nd effect: 3305 kg/h, 3^rd effect: 3426 kg/h & 4^th effect: 3594 kg/h)

Steam feed rate to first effect is: 2900 kg/h

Hence steam economy for this MEE is: 2900/13117 = 0.221 kg/kg

Cooling water requirement (32 ⁰C supply and 36 ⁰C return) is: 518.6 m³/h

Conclusion

The intent of this article is to understand types of multiple effect evaporators and their operation. Also, we discussed one example of four effect evaporator. We gone through the material and energy balance. I guess, this will help you to carryout the material and energy balance for your multiple effect evaporator requirement.

You can sustain the performance of the MEE by arresting the leakages and removing the scale formed in evaporator by high pressure and chemical cleaning processes. Because both the problems will decrease the overall temperature gradient between first and last effect. Other than this cooling water supply temperature at last effect vapour condenser is very important. If cooling water supply temperature is higher it will increase the condensing vapour temperature and will reduce vacuum also. In result this will reduce the efficiency of MEE. Moreover, you should regularly clean the condenser from cooling water side.

Thanks for your reading.

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