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Criteria for the vapor space design in kettle reboilers

Article · December 2008

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 297

SCIENTIFIC BULLETIN OF
THE „POLITEHNICA” UNIVERSITY OF TIMISOARA, ROMANIA
TRANSACTIONS ON MECHANICS
BULETINUL ŞTIINŢIFIC AL
UNIVERSITĂŢII „POLITEHNICA” DIN TIMIŞOARA, ROMÂNIA
SERIA MECANICĂ
Tom 53 (67) ISSN 1224 - 6077 Fasc. S2, 2008

CRITERIA FOR THE VAPOR SPACE DESIGN IN

KETTLE REBOILERS
Branislav JACIMOVIC*, Srbislav GENIC*, Nikola BUDIMIR**, Marko JARIC**
*Department of Process Engineering, Faculty of Mechanical Engineering, University of Belgrade, Kraljice Marije 16,
11000 Beograd, Serbia, bjacimovic@mas.bg.ac.yu, sgenic@mas.bg.ac.yu
**Innovation Center of the Faculty of Mechanical Engineering, University of Belgrade, Kraljice Marije 16, 11000
Beograd, Serbia, nbudimir@mas.bg.ac.yu, mjaric@mas.bg.ac.yu

Abstract. There are several design criteria concerning the dimensions of the vapor space in kettle reboilers. These
criteria are listed and commented in this article. An numeric example illustrates the usage of this criteria.

Keywords: kettle reboiler, vapor space, liquid entrainment

1. Introduction 2 Design criteria

The most commonly used type of evaporator
in refining industry is a kettle reboiler.
This kind of reboiler is often used in many
other industries (refrigeration systems, distilled
water production, desorption systems, etc.). Kettle
reboiler consists of either a U-tube bundle or
floating head tube bundle inserted into an
enlarged shell.
The shell provides disengaging space
(volume) for the vapor separation of liquid
droplets. Liquid level in shell is usually controlled
by level controller or simply held by the weir. The
hot fluid in this kind of apparatus flows inside the
tubes. Generally speaking the size (diameter) of
the kettle reboiler shell depends on the vapor and
liquid flow rates, their physical properties and the
exchanger geometry. It must be noted that if dry
vapor is really required, as in the case of a
compressor feed, additional protection, such as
mechanical mist eliminators, is needed.
There are several design criteria that can be
found in the open literature sources. Further on
these criteria are listed and commented.
Two phase flow of vapor/liquid mixture in
disengagement space in kettle reboilers is
complex. Although several authors tried to
develop the adequate mathematical model, it can
be said that nowadays the design is still based on
the empirically gathered information. Design
criteria can be grouped in the following manner.
2.1 Criteria based on the simple geometry
ratios
Palen [2] suggests that the distance from the
centerline of the uppermost tube in a horizontal
bundle to the top of the shell should not be less
than 40% of the kettle shell diameter
Ds / Db ≥ 1.4 .
The freeboard between the liquid level and shell
should be at least H s = 250 mm [1], [9].
For practical reasons (better separations of
entrainment) liquid level at kettle horizontal
reboilers settings that one or two upper rows of
tubes does not in liquid [2]. In these cases the
height of the vapor space should be at least
H s = 300 mm .
 298
In [1] and [9] the required shell diameter is column the entrainment coefficient ( K ) is
defined as the function of the heat flux. estimated by the relation from [5]
Summarizing the data from both references the 0.25
0.33 ⎛ σ ⎞
following equation can be formed K = 3.14 ⋅ e ⋅ ⎜⎜ ⎟⎟ (6)
Ds ⎝ ρ − ρ ⎠
= 1 + (0.015 ÷ 0.025 ) ⋅ q
L G
(1)
Db Specific entrainment (carryover of the liquid with
vapor phase) shouldn’t be above 2%, or can be
where q is in kW/m 2 . found by the
⎛ 1 ⎞ m& 1
2.2 Criteria based on the volume of the vapor e = ⎜⎜ − 1⎟⎟ ⋅ L ⋅ (7)
=0
⎝1 − fe ⎠ m& G E
e
space
The role of the vapor space is to separate the where
mixture of liquid and vapor. E e =0 − E a
In [11] for steam boilers at the atmospheric fe = (8)
pressure, the following equation is given E e=0
V&G 0.011
= 0.14 + (2) 2.3 Criteria for estimation of the diameter and
V 0.01 + H 1sep
,5
the number of inlet/outlet nozzles
In [10] this equation is recommended for kettle According to [8] an impingement plate, or other
reboilers with drop eliminators (figure 1). For means to protect the tube bundle against
pressures other than 1 bar the right side of impinging fluids, shall be provided when entrance
equation should be multiplied with line values of ρ L ⋅ w L2 exceed the following: non-
p corrosive, nonabrasive, single phase fluids, 2250
f = (3)
1,22 ⋅ p − 0,22 Pa; all other fluids including the liquids at its
for absolute pressure in range 0.5÷5 bar. boiling point, 750 Pa.
On the other hand, according to [12] the
Vapor recommended diameter of the feed nozzle is
2
determined using ρ mix ⋅ wmix < 1000 Pa .
In kettle reboilers design it’s necessary to keep the
vapor velocity below 30 m/s [3] in the outlet
nozzle. According to [4] the outlet nozzle is
Hsep
designed using
ρ G ⋅ wG2 ,out < 3750 Pa (9)
For both kettle and horizontal thermosyphon
reboilers, steps should be taken to adequate
longitudinal flow distribution. Above a certain
Figure 1 Cross section of the vapor space bundle length-to-diameter ratio, the number of
inlet and outlet nozzles should be increased. As a
According to Palen [2] the minimal vapor volume rule of thumb, the number of pairs of nozzles
should be (liquid and vapor) is given by [6]
V&G σ Lb
= 80,5 ⋅ (4) NN = (10)
V ρ L − ρG 5 ⋅ Db
The calculated value should be rounded up.
2.3 Criteria based on the Souders - Brown
equation 3 Example
The most commonly cited reference is based on Kettle reboiler (shown in figure 2) is used for the
Souders-Brown equation in the form condensation of the process stream inside tubes
ρL (CO2 - O2 mixture). Cold fluid is ammonia at 0.9
wG,max = K ⋅ −1 (5) bar absolute pressure (-35.91°C). Liquid ammonia
ρG
enters the bottom of the shell. After vaporization
In [1] and [9] it is said that the entrainment the vapor is sucked by the compressor.
coefficient K ranges between 0.03 m/s and 0.09 Tube bundle diameter is Db = 440 mm and the
m/s.
shell diameter is Ds = 700 mm , so the ratio is
If the kettle reboiler is connected with distillation
 299
Ds / Db =1.59 and the height of the separation
space is H sep = 260 mm
Heat power of the apparatus is 472 kW (ammonia
flow rate is 1194 kg/h), and the heat transfer
surface is S = 63.9 m 2 , that provides heat flux
q = 7.39 kW/m 2 . Using equation (1) the
diameter ratio should be Ds / Db = 1.11 ÷ 1.18 or
according to Palen Ds / Db = 1.4 .
Accordingly to (5) using K = 0.03 m/s the
maximal vapor velocity should be wG ,max =0,889
m/s. Real vapor velocity is wG =0,110 m/s, so
wG / wG ,max = 12,4% . If the equation (6) is used
to obtain the entrainment factor is K = 0.03 m/s ,
the corresponding value of specific entrainment is
e = 0.0013 , which is way beyond usually adopted
e = 0.02 .
According to Palens equation (4) minimal volume
of the vapor space is V = 0.798 m 3 , and this value
is by 8% lesser than the real V = 0.858 m 3 .
Since the bundle length is Lb = 5500 mm , the
minimal number of nozzle pairs is N N = 2.5 .
The outlet vapor velocity is wG ,out = 26.5 m/s
2
and the ρG ⋅ wG ,out = 549 Pa
It can be concluded that all of the design
criteria noted in the this article are satisfied.

Figure 2 Kettle horizontal reboiler (all dimensions in millimeters) A- inlet of process fluid, B-outlet of
process fluid, C-inlet of ammonia, D-outlet of vapor ammonia

4. Conclusion K , m/s , the entrainment coefficient

There are several design criteria in open literature Lb , m , length of tube bundle
concerning the dimensions of the vapor space in m& , kg/s , mass flow rate
kettle reboilers. These criteria (recommendations)
are listed in this article, so the design procedure N N , number of pairs (inlet plus outlet) of nozzles
can be easily formed. The procedure is p, bar , pressure in vapor space
demonstrated on kettle reboiler that condenses Q, W , heat power
CO2 at the tube side, using ammonia as a cold
fluid. q, W/m 2 , heat flux
S , m 2 , heat transfer surface
5. Nomenclature
Ds , m , diameter
V , m 3 , vapor volume
w, m/s , velocity
Db , m , tube bundle diameter
E e=0 , tray efficiency at zero entrainment Greek
E a , apparent tray efficiency ρ , kg/m 3 density
H sep , mm , the height of the separation zone σ , N/m surface tension
H sep = D s − Db
Indexes
 300
max, maximal 8. ***Standards of Tubular Excangers
min, minimal Manufactures Association, Sixth Edition, New
mix, mixture York 1978.
G, gas (vapor) 9. Ernest L.: Applied Process Design for Chemical
L, liquid and Petrohemical Plants, Volume 3, Third
out, outlet Edition, Gulf Professional Publishing, Boston
1999.
10. Billet, R.: Evaporation Technology, VCH
6. References Verlagsgesellscahft mbH, Weinheim, 1989.
1. Sinnott R. K.: Chemical Engineering Volume 6: 11. Vorkauf, H., Forschung auf dem Gebiet des
Chemical Engineering Design, Pergamon Press, Ingenieurwesens, VDI Forschungsheft B341,
Oxford, 1983. 1931.
2. Palen J. W. Small W. M.: A New Way to Design 12. ***Engineering standard for process design of
Kettle and Internal Reboilers, Hydrocarbon gas (vapour)-liquid separators, original edition
Processing, V. 43, No. 11, p. 199 1964. May 1997. Iranian Petroleum Standard IPS-E-
3. Vujic, S..: Colling Devices [in Serbian], Faculty PR-880.
of Mechanical Engineering, Belgrade, 1997.
4. *** Iranian Petroleum Standards IPS-E-PR-880,
Engineering Standard For Process Design Of RELAŢIA CRITERIALĂ PENTRU
Gas (Vapor)-Liquid Separators, May 1997. DIMENSIONAREA SPAŢIULUI DE VAPORI
5. Tammami B., Simplifying reboiler entrainment DIN CAZANUL DE ABUR TIP KETTLE
calculations, Oil Gas Journal, June 1985.
6. Heat Exchanger Design Handbook (HEDH)
Rezumat
Volume 3, Hemisphere Publishing Company,
In literatura de specialitate există o serie de relaţii
Washington, 1986.
criteriale cu care se dimensionează spaţiul de vapori
7. Jacimovic B., Genic S.: The Study Of The
din cazanul de abur tip Kettle. In lucrarea de faţă aceste
Revitalization Of The CO2 Production Fascility relaţii sunt analizate şi comentate. Compararea lor s-a
In Becej Serbia [in Serbian], Belgrade 2007. realizat pe baza unui exemplu numeric.

Scientific reviewers: Prof. Dr. Ing. Habil Ioana IONEL

Prof. Dr. Ing. Mihai NAGI

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