Re Boilers

REBOILER
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Waqar
Ahmad Farhan Ahmed Hafiz Ghulam Akbar Adnan Ahmad
06-chem-21 06-chem-27 06-chem-61 06-chem-99
Reboiler:
Reboiler is a vaporizing exchanger used to supply the heat requirement of a distillation process as vapors at the bottom of distillation column.
Types of Reboiler:

Kettle Reboiler Vertical Thermosyphon Reboiler Horizontal Thermosyphon Reboiler Internal Reboiler
Kettle Reboiler:
Kettle type, in which boiling takes place on tubes immersed in a pool of liquid; there is no circulation of liquid through the exchanger. This type is also, more correctly, called a submerged bundle Reboiler.
Advantages:

Relatively easy to design. Simple piping.
Disadvantages:

Not suitable for foaming liquids Not suitable for fouling liquids They have relatively lower heat transfer coefficients.
Vertical Thermosyphon Reboiler:

The vertical thermosyphon is usually a conventional 1-1 exchanger. Upper tube sheet is placed close to the liquid level of the bottoms in the distilling column.
Advantages:

Higher heat transfer coefficient. Used for fouling liquids.
Disadvantages:

Require higher head room. Design procedure is slightly difficult as compared to Kettle Reboiler.
Horizontal Thermosyphon Reboiler:

All the liquid from the bottom tray flows to the reboiler. None of the liquid from the bottom of the tower flows to the reboiler. All the bottoms product comes from the liquid portion of the reboiler effluent. None of the liquid from the bottom tray flows to the bottom of the tower.
Advantages:

No head room is required. Easily maintained than vertical.
Disadvantages:

More complex pipe-work Requires large plot area High structural costs
Internal Reboiler:
Tube bundles are inserted in the distillation column and steam is used as heating media.
Advantages:

No ground area separately required. Low capital cost.
Disadvantages:
Does not give sufficient heat transfer area to fulfill the requirement.
Choice of Type:
The choice of the best type of Reboiler for a given duty will depend on the following factors: 1. The nature of the process fluid, particularly its viscosity and propensity to fouling, 2. The operating pressure: vacuum or pressure. 3. The equipment layout, particularly the headroom available.
Example 15.4
Calculation of a Once-through Horizontal Thermosyphon Reboiler
STATEMENT
38,500lb/hr of 60API naphtha in a once-through arrangement is to enter a horizontal thermosyphon reboiler and produce 29,000 lb/hr of vapor in the temp range from 315 to 335F at an operating pressure of 5.0 psig. Heat will be supplied by 28API gas oil with a range from 525 to400F Available for the service is a 21.25 in ID reboiler containing 116, 1 in OD 14 BWG tubes 12 ft long laid out on 1.25 in square pitch. The bundle has a support plate above the single inlet nozzle and is arranged for 8 passes. What are the dirt factor and the pressure drops?
SOLUTION
REBOILER: Shell side: ID= 21.25 in Support plates =1/4 circles Passes = divided Tube side: Number & length =116, 12 ft OD, BWG, pitch = 1 in, 14 BWG, 1.25 in square Passes = 8
Enthalpy of liquid at 315F and 19.7 psia = 238 Btu/lb Enthalpy of liquid at 335F and 19.7 psia = 252 Btu/lb Enthalpy of vapor at 335F and 19.7 psia = 378 Btu/lb ( fig 11) Naphtha qv = 29,000(378-252) = 3650,000 qs = 38,500(252-238) = 540,000 Q= = 4,190,000 Btu/hr
HEAT BALANCE
Gas oil, Q = 51,000x0.66(525-400) = 4,190,000 Btu/hr
t:
525 400 125 High Temp 335 Lower Temp 315 Difference 20 190 85 105
LMTD = 131F R = 125/20 = 6.25 S = 20/(525-315) = 0.095 FT = 0.97 t = FTxLMTD = 0.97*131 = 127F
(fig 18)
Tc :
tc/ th = 85/190 = 0.447 Kc = 0.42 Fc = 0.41 Tc = 400+0.41(525-400) = 451F tc = 315+0.41(335-315) = 323F (fig 17)
Hot fluid; tube side, gas oil

at = 0.546 in2 at = Nt*at/144n = 116*0.546/(144*8) = 0.055 ft2 Gt = W/at = 51,000/0.055 = 928,000 lb/(hr)(ft2) At Tc = 451F, = 0.45*2.42 = 1.09 lb/(hr) (ft) (fig 14) (table 10)
D = 0.834/12 = 0.0695 ft (table 10) Ret = D*Gt / = 0.0695*928,000/1.09 = 59,200 jH = 168 (fig 24)
At Tc = 451F (28API) K(c/k)1/3 = 0.142 Btu/(hr)(ft2)(F/ft)

hi = (jH*k/D)(c/k)1/3*t hi/t = 168*0.142/0.0695 = 343 t = 1
(fig 16)
hio = hi*ID/OD = 343*0.834/1.0 = 286 Btu/(hr)(ft2)(F)
Cold fluid; shell side, naphtha

Assume weighted ho = 200 hio = 286 tw = tc+hio *(Tc-tc)/(hio +ho) = 323+286*(451-323)/(286+200) = 382F
(t)w = 382-323 = 59F From fig 15.11, hv >300, use 300 hs = 60 qv/hv = 3,650,000/300 = 12,150 qs/hs = 540,000/60 = 9,000 21,150
ho = 4,190,000/21,150 = 198 Btu/(hr)(ft2)(F) This is to check our assumption of 200 for ho.
Overall clean coefficient Uc

Uc = hio*ho/(hio+ho) = 286*198/(286+198) = 116 Btu/(hr)(ft2)(F)
Design overall coefficient UD:

Surface per linear foot = 0.2618 Total surface = 116*12*0.2618 = 364 ft2 UD = Q/A t = 4,190,000/(364*127) = 90.7 (table 10)
Check of maximum flux (based on total transfer through the surface): Q/A = 4,190,000/364 = 11,500 vs. 12,000 allowable
Dirt factor Rd
Rd = (Uc-UD)/(Uc*UD) = (116-90.7)/(116*90.7) = 0.0024
Pressure Drop:
TUBE SIDE: Ret = 59,200, f = 0.000168 ft2/in2 s = 0.73
Pt = f*(Gt)2*L*n/(5.22x1010*Ds* t) = 0.000168*(928,000)2*12*8/(5.22*1010*0.0695*0.73*1) = 5.3 psi
(fig 26) (fig 6)
V2/2g =0.11 at Gt = 928,000

Pr = 4nV2/(2sg) = 4*8*0.11/0.73 = 4.8 psi PT = Pt + Pr = 5.3+4.8 = 10.1 psi
(fig 27)
Pressure Drop
SHELL SIDE: De = 4 x flow area / frictional wetted perimeter Assume half of tubes above and half of tubes below longitudinal baffle. Flow area = shell cross-section tube cross-section = /8x(21.252-1.0*116) = 132 in2 as = 132/144 = 0.917 ft2 Wetted perimeter = *21.25/2+ /2*1*116+21.25 = 236.7 in de = 4*132/236.7 = 2.23 in
De = 2.23/12 = 0.186 ft Gs = (w/2)/as = (38,500/2)*0.917 = 21,000 lb/(hr)(ft2) For 60API at 315 use data in fig 14 for 56API gasoline as an approximation.
= 0.18*2.42 = 0.435 lb/(ft) (hr) Ret = De Gs/ = 0.186*21,000/0.435 = 8950 F = .00028 ft2 / in2 (fig 26) From fig 13.14, mol wt = 142 Density, = 142/(359*(795/492)*14.7/19.7) = 0.337 lb/ft3
Soutlet liquid at 335F = 0.61

outlet liquid = 0.61*62.5 = 38.1 lb/ft3 Soutlet mix = (38,500/62.5)/(29,000/0.337+9500/38.1) = 0.071 Sinlet at 315F = 0.625 Sav = *(0.625+0.071) = 0.35 Ps = f Gs2 Ltotal / 5.22*1010 De s s = 0.00028*21,0002*12/(5.22*1010*0.186**0.35*1.0) = 0.0004 psi
REFERENCE:
Process Heat Transfer by D. Q. Kern Chemical Engineering by Coulson & Richardson, vol-6, 3rd ed.
THANK YOU VERY MUCH

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REBOILER

Ahmad Farhan Ahmed Hafiz Ghulam Akbar Adnan Ahmad

06-chem-21 06-chem-27 06-chem-61 06-chem-99

Relatively easy to design. Simple piping.

Vertical Thermosyphon Reboiler:

Higher heat transfer coefficient. Used for fouling liquids.

Horizontal Thermosyphon Reboiler:

No head room is required. Easily maintained than vertical.

No ground area separately required. Low capital cost.

Gas oil, Q = 51,000x0.66(525-400) = 4,190,000 Btu/hr

Hot fluid; tube side, gas oil

At Tc = 451F (28API) K(c/k)1/3 = 0.142 Btu/(hr)(ft2)(F/ft)

hio = hiID/OD = 3430.834/1.0 = 286 Btu/(hr)(ft2)(F)

Cold fluid; shell side, naphtha

Overall clean coefficient Uc

Design overall coefficient UD:

(fig 26) (fig 6)

V2/2g =0.11 at Gt = 928,000

Soutlet liquid at 335F = 0.61

THANK YOU VERY MUCH

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