DFF Venus

D.F.F. Venus
multiple effect continuous evaporator
D.F.F. VENUS · multiple effect continuous evaporator
Venus
Among all the units which have contributed to Rossi & Catelli's
worldwide success, certainly the last generation Venus
evaporators represents one of the most important examples
of our continuous research for new technologies, capable of
ensuring the highest quality of all final products, and in turn
contributing to higher profitability and competitiveness on the
market together with maximum reliability.
Designed originally for tomato juice concentration,
our Venus evaporators are used nowadays in all the food
Lateral view of two triple effect T 1000 D.F.F.
Venus with work capacity of 1000 t/day.
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industry sectors where it is necessary to remove water from
raw material, and can guarantee a final product with high
concentration values as well as ideal organoleptic characteristics.
The Venus series, articulated in a wide range of potentialities
which fulfils all possible market requests, includes:
• Single effect units
• Double effect units
• Triple effect units
• Quadruple effect units
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Products that
can be processed
• Cold Break and
Hot Break
tomato juice
• Fruit purees
and
concentrates
Total view of a double and triple
tomato paste production plant installed in
province of Lodi (Italy).
This plant is composed by a triple effect
T 1500 D.F.F. Venus processing Hot Break,
and a triple
effect T 1000 D.F.F. Venus
processing Cold Break.
D.F.F. VENUS · multiple effect continuous evaporator
Avant-garde patented
technologies
Years of work and studies have led us to
observe how, inside the heat exchangers,
high viscosity product flow is of the
laminar type. Consequently, during the
heating phase inside the heat exchanger,
a temperature rise occurs primarily in the
product part contacting the pipe surface
for some 2-3 millimeters deep, while the
central part remains practically at the
original temperature.
Starting from this observation and after
long research and varied experiments,
we have derived the patents which
characterize and distinguish the Venus
evaporators, granting results which
cannot be attained with any other plants:
the heat exchanger, placed vertically on
the expansion chamber in direct
connection with it, as well as the
downward forced flow circulation.
Thanks to this innovative system all
product exiting the heat exchanger,
fed from the top by the product circulation
pumps (downward forced flow circulation)
enters directly into the expansion chamber
in the shape of small cylinders rather than
a single flow as in traditional plants.
Product surface exposed to vacuum in
the chamber is thus increased countless
times and the product, having preserved
its fragmentation, can easily and naturally
free the vapors contained.
In this case all overheating phenomena
are eliminated, due primarily to steam still
englobed inside the product and
temperature differences existing between
the product and the surrounding
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expansion chamber. In the Venus
evaporator these differences do not
exceed 2° C, while in older design plants,
such differences can reach 8° C.
Final outcome is lowering the average
circulating product temperature,
which in turn progresses into a remarkable
performance increase as well as high
color and consistency values.
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Construction
features
Besides the heat exchanger placed
directly onto the expansion chamber and
the downward forced flow circulation, the
most remarkable features of the Venus
evaporators can be summarized as
follows:
• Particular geometry of the heat
exchangers, composed of a high
number of pipes having limited length,
to reduce as much as possible any
pressure drop in the system.
• Special pumps with helical-centrifugal
impellers, suitable to grant large
hydraulic capacities coupled with high
head values. Designed and
manufactured by Rossi & Catelli, these
pumps can ensure the optimal filling of
all heat exchanger pipes.
efficiently recover in the heat
exchangers all steam used during
product heating inside the
enzymatic deactivation system.
In this way, in a triple effect evaporator
up to 3.2 kg of water are evaporated
for each kg of live steam fed.
• Furthermore, by fractioning temperature
leaps and limiting the vapor volume
produced in each single
self-evaporation stage, it is possible to
prevent any product carryover
phenomena, with a huge advantage
View of a tube chest header
Ø 1990 mm.
• Large expansion chambers, permitting
extremely low exit speeds of the vapors
which separate from the product and
suitable, in any case, to prevent any
product carryover phenomena. There
is no product loss, nor any
contaminating overload for the water
treatment system.
• Use of separating pre-chambers
(flash tanks) that, according to the plant,
can be either single or double stage.
Their usage, in particular for
Hot Break products, permits to
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Continuous request for plant with bigger and
bigger capacity, led to the design and
manufacture of a new helical-centrifugal
pump: T75 which, by placing itself at the top
of Rossi & Catelli production range, is the
biggest pump worldwide for pumping high
viscosity doughy products.
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D.F.F. VENUS · multiple effect continuous evaporator
for the heat exchangers: as a matter of
fact, these heat exchangers are fed
with acid vapors without any
suspended product and subsequently
do not foul, maintaining a very high
efficiency for several weeks on end.
• Each single effect is integral with its
own support structure, so that it can
be included in an existing plant with
just minor adaptation works.
Therefore, purchase of the evaporator
can be gradually programmed
according to Customer's own
production needs.
Series of D.F.F. Venus evaporators
during the assembly.
Transportation of a double effect
T 200 D.D.F. Venus plant
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Evaporator
supervision system
The supervision system displays all field
variables, records all historical processing
data and carries out all operations
required to achieve an optimum
performance of the unit.
Line management takes place by means
of a desk top personal computer, fitted
with touch screen color video and
connected to a PLC; while the supervision
system is a 32 bit application software
based on an open architecture running
in a Windows NT or 2000 environment.
Characteristics of the
supervision program:
data. This data can be downloaded
directly from the Ethernet network or
through floppy disk and administered
on other stations (optional).
Options
contemporaneous curves on each graph.
An alarm printout is also provided, by
selecting the day as well.
Suitable functions allow printing, at the
end of each day, a series of temperatures
and alarms by means of one single
control.
Software for PC data download
and historical file printing
A program for printing historical data from
the remote station is available. Data can
be moved to this station by floppy disk
or local network, if present.
All temperature values can be printed,
with selection of the day and of three
• Dynamic block diagram of the unit with
display of each motor status (run, shutdown, alarm, stop and rpm) and of
each valve (open, closed) with piping
color depending on the fluid contained
in each operational phase.
• Indication of all operational phases of
the unit (washing, production, rinsing,
etc.) and relevant sub-phases.
• Dynamic display of all PID controller
operations with real-time trend of the
last 10 minutes of work (set point,
controlled variables and controller
output graphs).
• Possibility of controlling each valve or
motor automatically or manually (in the
latter case there is a password
protection).
• Operational parameters input.
• Product parameters input.
• Recording of all process variables and
graphic display.
• Recording and display of all alarms.
• Recording and display of production
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D.F.F. VENUS · multiple effect continuous evaporator
Double Effect
continuous
evaporators
Working features
These are obtained by using two basic
units, both with downward forced flow
circulation.
By the name FIRST EFFECT one intends
the stage fed with live steam coming from
the boiler, while the produced vapors are
sent to the SECOND EFFECT.
Both effects work according to pressure
and therefore to descending
temperatures, from the first to the second
effect.
Raw product is sent to the second effect,
where a first concentration takes place,
and is then finished in the first effect,
therefore called FINISHING EFFECT.
The evaporator is completed with a
semibarometric mixing condenser, with
the function of condensating the acid
vapors coming from the second effect.
The product circulation pumps installed
on the various effects can be driven with
turbines fed with boiler steam, and once
discharged steam is then sent to the first
effect. If production needs arise, the
evaporator can also run in single effect,
consequently reducing the plant’s
potentialities.
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Frontal view of double effect tomato paste
processing T 600 D.F.F. Venus evaporator
installed in Edo de Mexico - (Mexico).
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A double effect tomato paste T 200
D.F.F. Venus evaporator installed in province
of Parma (Italy).
Double effect T 200 D.F.F. Venus evaporator
installed in Jugos del Valle (Mexico).
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D.F.F. VENUS · multiple effect continuous evaporator
Triple Effect
continuous
evaporators
Working features
Obtained by connecting three basic units,
the triple effect evaporator was designed
to answer the industry’s growing needs
of higher working capacities with the
greatest energy savings and little
personnel employment.
The working principle is the same as in
the double effect evaporator: raw product
is sent to the third effect running at low
temperatures, then onto the second, and
from here, to the first effect that is fed
with live steam.
All the effects are under vacuum with
descending pressures, from the first to
the third to limit product-heating
temperatures and safeguard its qualities.
It is also possible to partially divide the
plant, and run in double or single effect.
For particular needs the first effect can
also be split, obtaining two heat
exchangers fed with live steam.
The triple effect evaporator series
can reach working capacities
up to 1.200 tons of fresh
tomato per day.
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Triple effect T 1500 D.F.F. Venus evaporator
installed in province of Lodi - (Italy), with work
capacity of 1500 t/day.
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Triple effect T 900 D.F.F. Venus
installed in Miajadas - Spagna.
Frontal view of a quadruple effect Hot Break
tomato paste processing T 750 D.F.F. Venus
installed in Parma (Italy).
D.F.F. VENUS · multiple effect continuous evaporator
Quadruple Effect
continuous
evaporators
working features
These are evaporators that are ideal for
extremely high working capacities, up to
2.000 tons per day of fresh tomatoes, or
where energy requirements must be
reduced as low as possible.
The working principle is the same as
described before for the double or triple
effect evaporator: raw product is sent to
the fourth effect, while the heat
exchanger is fed with steam coming
from the other effects, then onto the
third, the second and lastly, the first
effect that acts as a finisher.
All steam that feeds the first effect
heat exchanger comes from the
boiler and the turbines that drive the
product circulation pumps.
According to this configuration, the
evaporator can concentrate highly
viscous Hot Break products,
up to values of 30 Brix.
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D.F.F. VENUS · multiple effect continuous evaporator
Advantages
• Technology based on the patented
principle of downward forced flow
product circulation and positioning of
the heat exchanger directly on top of
the expansion chamber.
- Product enters the expansion
chamber in the shape of small
cylinders, with its surface exposed
countless times to vacuum. The
product, having preserved its
fragmentation, can easily and
naturally free the vapors contained.
- All overheating phenomena are
therefore eliminated, this due primarily
to steam that remains englobed
inside the product.
- Lowering of the average product
circulation temperatures, with
considerable performance increase
as well as high color and consistency
values.
• Particular geometry of the heat
exchangers, composed of a high
number of pipes having limited length.
- Very short product residence times
inside the heat exchanger, thus
protecting final product
characteristics.
Total view of a triple effect 4-stage
T 2000 D.F.F. Venus evaporator
installed in Changji - (China).
Page 12: Frontal view of a quadruple effect
double and triple tomato paste processing
T 1500 D.F.F. Venus evaporator
installed in province of Parma (Italy).
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Page 13: Total views of quadruple effect
5-stage T 2400 D.F.F. Venus installed in
Leemore - (USA).
The total work capacity is of 4800 t/day of
fresh product.
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- Low pressure drop and high
circulation delivery capacities, up to
3.500 tons per hour of turbulent flow,
together with a high heat transfer
coefficient.
- Extremely low product/steam DT,
maximum 1° C. Fouling and soiling
exceptionally diminished, up to 50
days without the need to wash.
- Color safeguard.
- High product viscosity.
• Use of steam turbines instead of electric
motors on the product circulation
pumps.
- Softer slowing down of the plant in
case of power shortages, and easier
to empty.
- Lower costs for spare parts and
maintenance.
- Improved energy savings.
• Generous sizing of the expansion
chambers and heat exchangers.
- Absence of any product carryover
phenomena, meaning higher
efficiencies and minor costs for the
water treatment system.
• Use of centrifugal pumps for product
circulation with helical-centrifugal
impellers.
- High efficiency in pumping highly
viscous products such as Super Hot
Break.
• Use of high quality brand name
components.
- High reliability and availability on the
market.
• Higher project criteria and construction:
component quality, solidity and steel
thickness.
- Lack of vibrations, lower stress on
all piping, weldings and motor
bearings, minor wear and tear.
- Lower plant depreciation over time,
economical advantage for second
hand machinery.
• Use of mono pump and frequency
drive, controlled directly by the
refractometer instead of regulating
valves for tomato paste extraction.
- Limited product lamination.
- High Brix accuracy value.
• Vacuum flash tank inclusion on the third
effect (75-80° C).
- Thermal jump divided in several
passages.
- More gradual cooling.
Total view of triple effect 4-stage
T 2000 D.F.F. Venus evaporators installed
in Changji - (China).
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D.F.F. VENUS · multiple effect continuous evaporator
On the left: Frontal view of a triple effect
4-stage T 2000 D.F.F. Venus evaporator
installed in Wu Jia Branch - (China).
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The Genius in Food Processing
Page 16 and above:
Series of a triple effect 4-stage T 2000 D.F.F.
Venus installed in Williams – California (USA).
It is able to process up to 10.000 t/day
of Hot Break tomato with high viscosity.
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A
A
D.F.F. VENUS · multiple effect continuous evaporator
B
C
C
B
Venus
Triple Effect
Venus
Double Effect
Technical characteristics
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T 100 D.E.
T 300 D.E.
T 600 T.E.
Production
ton per day
100
300
600
Water evaporated
kg/h
3400
10200
20500
Steam consumption kg/h
1700
5100
6900
Power installed
kW*
280
320
Dimensions A B C
mm
6500 x 6000 x 14800
8500 x 6500 x 14800
14800 x 7000 x 14800
T 200 D.E.
T 450 D.E.
T 750 T.E.
450
Production
ton per day
200
450
750
Water evaporated
kg/h
6900
15400
25700
Steam consumption kg/h
3500
7700
8600
Power installed
kW*
280
330
Dimensions A B C
mm
7500 x 6500 x 14800
* Indicated power with all the electric motors
12700 x 7600 x 18200
660
14800 x 8500 x 18700
A
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C
B
Venus
Quadruple Effect
T 1000 T.E.
T 1500 T.E.
T 2400 Q.E./ 5s
Technical characteristics
1000
1500
2400
ton per day
Production
34200
51300
82100
kg/h
Water evaporated
11400
17100
20600
kg/h
Steam consumption
1560
kW*
Power installed
mm
Dimensions A B C
771
985
15100 x 9200 x 18500
17310 x 10200 x 21300
17900 x 18700 x 20400
T 1200 T.E.
T 2000 T.E./ 4s
T 3000 Q.E./ 5s
1200
2000
3000
ton per day
Production
41000
68500
102600
kg/h
Water evaporated
13700
22900
25700
kg/h
Steam consumption
780
1300
1850
kW*
Power installed
mm
Dimensions A B C
16000x 10000 x 21300
20300 x 10100 x 21300
18000 x 19000 x 20400
* Indicated power with all the electric motors
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01/2004
Rossi & Catelli S.p.A. - Via Traversetolo, 2/A
43100 Parma - Italy - ph. +39 0521 246611 - fax +39 0521 463284
www.rossicatelli.com - email: [email protected]
The Genius in Food Processing