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Kettle Reboilers PDF
Kettle Reboilers PDF
Assuming that the coefficient changes linearly for the inlet to outlet, then the average
coefficient will be given by:
[inlet coefficient (all liquid) C outlet coefficient (liquid C vapour)]/2
ReL at inlet D 36,833 ð 0.4/0.3 D 49,111 4.9 ð 104
From Figure 12.23, jh D 3.2 ð 103
The overall coefficient, U, neglecting the resistance of the tube wall, and taking the steam
coefficient as 8000 Wm2Ž C1 , is given by:
So the area available in the proposed design is more than adequate and will take care of
any fouling.
The analysis could be improved by dividing the tube length into sections, calculating
the heat transfer coefficient and pressure drop over each section, and totalling.
More accurate, but more complex, methods could be used to predict the two-phase
pressure drop and heat transfer coefficients.
The pressure drop over the inlet and outlet pipes could also be estimated, taking into
account the bends, and expansions and contractions.
An allowance could also be included for the energy (pressure drop) required to accel-
erate the liquid vapour mixtures as the liquid is vaporised. This can be taken as two
velocity head, based on the mean density.
The freeboard between the liquid level and shell should be at least 0.25 m. To avoid
excessive entrainment, the maximum vapour velocity uO v (m/s) at the liquid surface should
be less than that given by the expression:
1/2
L v
uO v < 0.2 12.75
v
When only a low rate of vaporisation is required a vertical cylindrical vessel with
a heating jacket or coils should be considered. The boiling coefficients for internal
submerged coils can be estimated using the equations for nucleate pool boiling.
Mixtures
The equations for estimating nucleate boiling coefficients given in Section 12.11.1 can be
used for close boiling mixtures, say less than 5Ž C, but will overestimate the coefficient if
used for mixtures with a wide boiling range. Palen and Small (1964) give an empirical
correction factor for mixtures which can be used to estimate the heat-transfer coefficient
in the absence of experimental data:
Example 12.12
Design a vaporiser to vaporise 5000 kg/h n-butane at 5.84 bar. The minimum temperature
of the feed (winter conditions) will be 0Ž C. Steam is available at 1.70 bar (10 psig).
HEAT-TRANSFER EQUIPMENT 753
Tube outer limit dia.
420 mm
45
90
Solution
Only the thermal design and general layout will be done. Select kettle type.
Physical properties of n-butane at 5.84 bar:
boiling point D 56.1Ž C
latent heat D 326 kJ/kg
mean specific heat, liquid D 2.51 kJ/kgŽ C
critical pressure, Pc D 38 bar
Heat loads:
sensible heat (maximum) D 56.1 02.51 D 140.8 kJ/kg
5000
total heat load D 140.8 C 326 ð D 648.3 kW,
3600
add 5 per cent for heat losses
maximum heat load (duty) D 1.05 ð 648.3
D 681 kW
From Figure 12.1 assume U D 1000 W/m2 Ž C.
Mean temperature difference; both sides isothermal, steam saturation temperature at
1.7 bar D 115.2Ž C
Tm D 115.2 56.1 D 59.1Ž C
681 ð 103
Area (outside) required D D 11.5 m2
1000 ð 59.1
Select 25 mm i.d., 30 mm o.d. plain U-tubes,
Nominal length 4.8 m (one U-tube)
11.5
Number of U tubes D D 25
30 ð 103 4.8
754 CHEMICAL ENGINEERING
D 1.5 ð 30 D 45 mm
Proposed layout gives 26 U-tubes, tube outer limit diameter 420 mm.
Boiling coefficient
Use Mostinski’s equation:
heat flux, based on estimated area,
681
qD D 59.2 kW/m2
11.5
0.69 3 0.7 5.84 0.17 5.84 1.2 5.84 10
hnb D 0.10438 59.2 ð 10 1.8 C4 C 10
38 38 38
Take steam condensing coefficient as 8000 W/m2 Ž C, fouling coefficient 5000 W/m2 Ž C;
butane fouling coefficient, essentially clean, 10,000 W/m2 Ž C.
Tube material will be plain carbon steel, kw D 55 W/mŽ C
30
1 1 1 30 ð 103 ln 30 1 1
D C C 25 C C 12.2
Uo 4855 10,000 2 ð 55 25 5000 8000
Uo D 1341 W/m2 Ž C
Close enough to original estimate of 1000 W/m2 Ž C for the design to stand.
Myers and Katz (Chem. Eng. Prog. Sym. Ser. 49(5) 107 114) give some data on the
boiling of n-butane on banks of tubes. To compare the value estimate with their values
an estimate of the boiling film temperature difference is required:
1341
D ð 59.1 D 16.3Ž C 29Ž F
4855
Myers data, extrapolated, gives a coefficient of around 3000 Btu/h ft2 Ž F at a 29Ž F temper-
ature difference D 17,100 W/m2 Ž C, so the estimated value of 4855 is certainly on the
safe side.
Check maximum allowable heat flux. Use modified Zuber equation.
326 ð 103
qc D 0.44 ð 1.5 ð p [9.7 ð 103 ð 9.81550 12.612.62 ]0.25 12.74
52
D 283,224 W/m2
D 280 kW/m2
Applying a factor of 0.7, maximum flux should not exceed 280 ð 0.7 D 196 kW/m2 .
Actual flux of 59.2 kW/m2 is well below maximum allowable.
Layout
From tube sheet layout Db D 420 mm.
Take shell diameter as twice bundle diameter
340
500
420
so actual velocity is well below maximum allowable velocity. A smaller shell diameter
could be considered.