PiEvap

Real-Time Double Effect Evaporator Simulator

Experience two-stage evaporation and steam economy dynamics in real time — purpose-built for chemical engineering education, process training, and research.

info@PiControlSolutions.com, Tel: (832) 495-6436

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Overview

PiEvap is an advanced, interactive chemical engineering simulator that models a double effect evaporator (DEE) in real time. The simulator replicates the behaviour of a bench-scale two-effect evaporation system in which live steam drives the first effect at positive pressure (∼ 110°C) and the vapour produced there drives a second effect under vacuum (∼ 60°C) — the defining feature that makes multi-effect evaporation one of the most energy-efficient unit operations in chemical engineering.

Users manipulate feed water, steam supply, cooling water, inter-effect transfer, and product drain flows through on-screen hand-control valves and observe the immediate effects on vessel temperatures, pressures, liquid levels, vapour production rates, and steam economy. All process variables update continuously, giving the feel of operating a real instrument panel rather than running a static textbook calculation.

Developed by PiControl Solutions LLC, PiEvap is used by universities and colleges to support courses in heat transfer, mass transfer, evaporation, and process control — and can run equally well as a standalone desktop application or as part of a virtual laboratory.

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Key Features

Steam Economy Calculation: Users calculate per-effect steam economy (SE₁, SE₂) and total steam economy (SEₜ) directly from condensate and feed flow rate measurements. These are the primary performance metrics that distinguish multi-effect from single-effect evaporators.
Heat Duty Analysis: Evaporator heat duties (Qₑ₁, Qₑ₂) and condenser duty (Qᶜᵒⁿᵈ) are calculated from measured vapour flow rates and an IAPWS-validated latent heat correlation (hᵀᵍ = 2501 − 2.361 T °C, ±1 % for 0–150°C). A condenser cross-check independently verifies V₂ from cooling water data.
Mass Balance Verification: Complete overall and per-effect mass balances are closed from six flow meter readings, confirming true steady state and teaching material balance methodology.
Real-Time Trend Charts: Separate chart panels display time-histories of all key process variables. Charts scroll automatically and can be zoomed for detailed transient analysis.
Data Logging & CSV Export: All process variables are logged at every simulation step and exported to a comma-separated values (CSV) file for post-processing in Excel, MATLAB, or Python.
Configurable INI File: Heat transfer coefficients, valve Cᵥ values, heat loss coefficients, and Antoine equation constants are stored in a plain-text INI file, allowing instructors to recalibrate the model without recompiling the software.
No Internet Connection Required: Installs and runs entirely on a Windows PC. No licence server, no cloud dependency, and no user data ever leaves the local machine.

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Process Diagram & Instruments

The main window displays a P&ID-style process diagram of the full double effect evaporator system. Each instrument tag corresponds to a live measurement; valve positions are adjusted with on-screen sliders. A startup configuration screen allows initial vessel levels and ambient temperatures to be set before the simulation begins.

Figure 1. PiEvap main process diagram — P&ID view with live instrument readings.

Tag	Description	Unit	Typical Range
HV-01	Feed water to EF-01	%	0 – 100
HV-03	Steam supply to EF-01	%	0 – 100
HV-04	Cooling water to HE-01	%	0 – 100
HV-05	Inter-effect liquid transfer EF-01 → EF-02	%	0 – 100
HV-07	EF-02 sump drain	%	0 – 100
HV-08/09	HE-01 condensate drain to PV-01 / PV-02	%	0 – 100
HV-10/11	Product vessel drains PV-01 / PV-02	%	0 – 100
P-01	Vacuum pump (liquid ring)	ON/OFF	—
TI-01	EF-01 vapour space temperature	°C	100 – 115
TI-02	EF-02 vapour space temperature (vacuum)	°C	55 – 65
TI-03	Cooling water inlet temperature	°C	20 – 30
TI-04	Cooling water outlet temperature	°C	30 – 42
TI-05	EF-01 steam coil inlet temperature	°C	115 – 130
PI-01	EF-01 vessel pressure	kPag	14 – 28
PI-02	EF-01 steam coil pressure	kPag	80 – 115
PI-03	EF-02 vacuum level (absolute)	kPa abs	15 – 30
PI-04	EF-02 heating coil pressure (V₁ vapour)	kPag	5 – 15
LI-01	EF-01 liquid level	cm	8 – 15
LI-02	EF-02 liquid level	cm	8 – 14
LI-03	Product vessel PV-01 level	cm	2.5 – 15
LI-04	Product vessel PV-02 level	cm	2.5 – 15
FI-01	Feed water volumetric flow rate	L/min	4 – 8
FI-02	Cooling water volumetric flow rate	L/min	40 – 75
FI-03	EF-01 steam condensate — Barrel 1 (BR-01)	kg/min	1.4 – 2.2
FI-04	EF-02 heating coil condensate — Barrel 2 (BR-02)	kg/min	1.0 – 2.0
FI-05	EF-02 sump drain flow rate	kg/min	2.5 – 4.0
FI-06	Product vessel combined drain (V₂)	kg/min	0.9 – 1.6

Real-Time Trends & Data Export

PiEvap continuously logs and plots key process variables. Real-time scrolling trend charts are provided for:

Temperatures: TI-01 (EF-01), TI-02 (EF-02), TI-04 (cooling water outlet), TI-05 (steam inlet)
Pressures: PI-01 (EF-01 vessel), PI-03 (EF-02 vacuum level)
Levels: LI-01 (EF-01), LI-02 (EF-02), LI-03 and LI-04 (product vessels)
Flow rates: FI-01 (feed), FI-03 (steam condensate), FI-04 (V₁), FI-06 (V₂)

All data can be exported to a CSV file at any time. The export includes a timestamped header and a column for each instrument tag, making it straightforward to import into Excel, MATLAB, or Python for further analysis, graphing, and comparison against theoretical energy and mass balance calculations.

Figure 3. PiAbsorb virtual titration panel

Target Audience

Chemical Engineering Students: Visualise and experiment with multi-effect evaporation theory studied in unit operations, heat transfer, and separation processes courses. Close real mass balances and calculate steam economy from live flow readings — no physical equipment required.
Process Engineers & Technicians: Use the simulator for preliminary exploration of industrial evaporator performance, steam economy optimisation, or vacuum system dynamics before implementing changes on real plant.
Educators & Instructors: Design structured experiments around steam economy, mass balance closure, heat duty calculation, and vacuum effects — or demonstrate live how PI-03 controls the boiling temperature in EF-02 and directly sets steam economy.
Researchers: Validate energy balance models, explore heat transfer coefficient sensitivity, and generate synthetic steady-state and transient datasets for comparison with experimental data.

Benefits

Hands-On Without the Hazards: Industrial evaporators involve high-pressure steam, vacuum systems, and high-temperature surfaces. PiEvap eliminates all associated risks while preserving the full learning value of a real startup, steady-state run, and disturbance experiment.
Cost-Effective: No equipment, consumables, or maintenance costs. A single software licence supports an entire class of users simultaneously.
Flexible & Repeatable: Users can reset the simulator instantly and repeat startup procedures or steady-state experiments as many times as needed — impossible on shared physical equipment with limited laboratory hours.
Accessible Anywhere: Runs on any Windows PC. Users can continue their work at home, in the library, or remotely — making it ideal for hybrid and online delivery.
Instructor Customisable: The plain-text INI configuration file lets instructors adjust heat transfer coefficients, valve characteristics, heat loss factors, and steam supply pressure to create different operating scenarios without modifying source code.
Industry 4.0 Ready: Simulates a process operator station experience, preparing users for the digital control environments found in modern food processing, pharmaceutical manufacturing, pulp and paper, and chemical plant operations.

System Requirements

Component	Requirement
Operating System	Windows 10 or Windows 11 (64-bit recommended)
Processor	1 GHz or faster (Intel/AMD)
Memory	512 MB RAM minimum; 2 GB recommended
Display	1280 × 720 or higher resolution
Storage	50 MB free disk space
Additional Software	Microsoft Visual C++ Redistributable (included in installer)
Internet Connection	Not required for normal operation

Available Documentation

User Manual: Step-by-step guide to all simulator features: startup configuration screen, process diagram overview, startup procedure, steady-state operation, real-time trends, CSV data export, and INI configuration reference.
Case Study: Five guided laboratory tasks covering steam economy, heat duty calculation, vacuum level effects, mass balance closure, and dynamic disturbance response — with startup procedures, data tables, calculation templates, Excel model guide, and discussion questions.
Configuration Reference: Description of every parameter in PiEvapConfig.INI with units, default values, physical basis, and guidance for customisation.

Get PiEvap

Request a demo, ask about pricing, or schedule an online walkthrough.

Get PiAbsorb

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Phone (832) 495-6436

Email info@PiControlSolutions.com

Website www.picontrolsolutions.com