CALCULATION METHODS

HEAT EXCHANGE

Fasci Tubieri

SECTION G

Boiling of Liquids
 Premise
The vaporization of liquids is an operation present in almost all chemical processes and
pharmaceuticals.
For the vaporization, standard exchangers are normally used summarized by
Theme Norm.

A very common type of device is the use of the kettle type exchanger.
The peculiarity of the Kettle is that it consists of a heating tube bundle.
and from a accumulator where steam is produced and its separation from
liquid.
There are two main uses for this type of equipment:
The complete vaporization of a process liquid
The function of the reboiler in distillation columns
The function of the Kettle as a reboiler in a distillation column
The use of the kettle as a reboiler for distillation columns has the advantage of being
more than a theoretical plate, depending on the ratio of vaporized liquid in the kettle / liquid output
from the Kettle, if the device is made as shown in the figure.
In fact, the liquid that comes out of the distillation column is introduced at the bottom of the kettle.
while the residual liquid that comes out of the kettle is in equilibrium with the steam that returns to the column.

General observation on Kettles for any type of application

It will also be necessary to pay attention:
The sizing of the tank located downstream of the Kettle overflow that will need to
allow an adequate residence time for the liquid exiting the Kettle (it is assumed to
Usually 2 minutes if the base product goes to storage and 10 minutes if it goes to another unit.
process.
At the height of the liquid in the tank that must not obstruct the draining of the liquid from the
squeegee to the basin, and must also ensure that there is no gas leakage together with the
liquid discharge.
To the gas disengaging area above the liquid in the Kettle to avoid carryover
of liquid with steam.
At the liquid level in the Kettle that exceeds the highest tube of the Kettle by at least 50 mm.
 The following is the calculation method for this type of device
The calculation is performed through successive approximations:
The physical quantities of the liquid to be vaporized are known, from the material and thermal balance.
I feel the warmth to be exchanged.

It is hypothesized a heat exchange surface and a geometry of the exchanger.

Using the calculation methods of the internal tube exchange coefficient, see sections.
previous (from A and F) and the mantle side below for the Kettle, the coefficient is determined
global exchange.
Once the Global exchange coefficient is known, on the tube side and the shell side, the calculation is made.
the logarithmic mean temperature difference between the tube side and the shell side is calculated by
exchange surface.

Calculation of the Logarithmic Mean Difference (∆TM) in a Kettle

If the hypothesized value does not correspond to the calculated value, a new surface of
intermediate exchange between the hypothesized surface and the calculated one, and the calculations are repeated.
One can notice the entry of a subcooled fluid at temperature T1 lower than
The temperature T2 present in the boiling liquid does not affect the calculation of the difference.
logarithmic mean of temperature calculated between t1-t2 and T2 (constant).
 Reboilers
Horizontal or Vertical with internal vaporization in the pipes

The physics of vaporization inside the tubes in a Reboiler

In a kettle, the vaporization inside the tubes caused by a heating fluid outside the tubes.
it generates a circulation in the radiator pipes since the liquid column entering the pipes has a density
higher than the liquid's beating plus vapor inside the pipes.
For this reason, a circulation of liquid is triggered inside the pipes of the reboiler.
The circulation will tend to reach a value determined by the fact that the difference in pressure generated
from the difference in specific weight between the cold fluid entering the pipes and the warmer mixture of liquid and vapor
The output from the pipes (Driving Force) is compensated by the pressure losses due to circulation.
The pressure losses on the pipe side are:
1) The inlet of the supply pipe to the boiler.
2) The friction in the incoming pipeline at the bottom of the distributor.
The outlet at the bottom header.
4) The inlet in the pipes of the riser
5) Pressure losses inside the pipes
6) The pressure losses due to acceleration in the riser pipes resulting from the vaporization of part of the
circulating liquid based on the heat to be exchanged.
7) The outlet from the pipes in the upper head of the boiler.
8) The inlet in the return pipe for the liquid plus the steam to the tank or bottom of the column.
9) The pressure losses in the return piping.
10) The outlet in the tank or at the bottom of the column.

The internal tube side exchange coefficient is calculated assuming that vaporization does not occur.
The method reported in section E-1 is therefore adopted for calculating the exchange coefficient without
state change for internal flow in pipes.
The Logarithmic Mean Temperature Difference between the hot fluid in the mantle and the fluid in
Vaporization in the pipes is obtained as shown in the figure below.

Calculation of Logarithmic Mean Difference (∆TM)

The figure shows a Vertical Boiler, but what is indicated also applies to a
Horizontal and, at the limit, also inclined boiler.
The temperature t at the outlet of the Boiling Tank is calculated at the actual pressure.
the output pressure from the reboiler. The actual pressure at the outlet of the reboiler is given by
pressure PAthe more the liquid flow the more steam present between exit and return in the
camera at pressure PAand from all the pressure losses between the exit from the tubes of the reboiler and
the return to the room at pressure PA.
In the first approximation, one can assume t = tA.
 Verification of the Preheating Zone
To identify the preheating zone, one proceeds by trial starting from
sizing in the first approximation:
1) It is assumed that the outlet temperature of the tubes is equal to TA.
2) A temperature T is setCslightly higher than TA.
3) The preheating heat is calculated between TCe TA.
4) The average logarithmic Delta T values are recalculated as indicated in the figure.
5) If the circulation ratio and the internal coefficient of the pipes from the previous calculation are maintained
approximation.
6) The new exchange surface is found as the sum of the preheating section + section of
vaporization (checking if the first approximation assumed is verified).
7) It is checked that the pressure at point C corresponds to the saturation vapor pressure at C at T.C.
FOR CALCULATIONS IN FIRST APPROXIMATION SEE
KERN PROCESS TRANSFER PAGES 486-491
FAIR PETROLEUM REFINER FEB. 1960
 CORE PROCESS TRANSFER PAGES 486-491
EXAMPLE: A vertical radiator boiler must evaporate 18482 kg/h of steam of
butane practically pure. The bottom column pressure is 19.3 Atm to which corresponds a
almost isothermal boiling range of 108°C. Heat is supplied by saturated steam at 8.8
Bake at 178°C. A recycling ratio of at least 4:1 will be used, and ¾" pipes, 16 BWG.
triangular step of 1". Find the exchange area.
Thermal Balance
Enthalpy of the liquid at 19.3 Ate and 108°C = 134 kcal/kg
Enthalpy of steam at 19.3 At and 108°C = 188 kcal/kg
Heat exchanged Q (butane) = 18482(188-134) = 998000 kcal/h
998000 kcal/h
Steam output: 998000/482 = 2070 kg/h
(2) LMTD
since the temperatures on the tube side (boiling) and on the shell side (condensation)
remain constant, LMTD=70°C.
PRIMOTENTATIVE
Since it is a reboiler, a global exchange coefficient will not be considered, but the flow.
maximum heat of about 32500 kcal/hm212000 Btu/hft2) from which A = 30.7 m2.
Let's assume now standard pipes with a length of 16' (4880mm), the maximum length for a kettle.
vertical to radiator; this reduces the diameter of the exchanger thus providing the
cheapest configuration, also requiring the highest elevation from the ground of the
column. The number of pipes will be 105 from A = 30.7 m2checked for 1-1 heat exchanger, ¾"
O.D., 1" triangular pitch leads to a real number of tubes that can be positioned on the tube plate
of 109, with a mantle diameter of 336.5 mm and an effective exchange surface of
30.7*109/105 = 31.8 m2This results in an effective exchange coefficient. UD=
2
998000/(70*31.8) = approximately 450 kcal/hm °C.
1) We assume a recirculation ratio of 4:1. The static pressure exerted
from the rebroadcaster is: [2,3L/(vo-vi)]*log vo/vi(see cited Kern) where L is the length
of the tubes, voand vithey are the specific volumes entering and exiting the exchanger. Yes
calculate:
vi= vliquid1/density = 1/430 = 0.0023 m3/kg
vovapor density (considered ideal) = (58/22.414)(20.39/1.033)(273/381) = 36.6 kg/m 3,
vsteam0.027 m3/kg. Weight flow rate liquid: 4*18482=73928 kg/h. Outgoing
rebollitore: volumetric flow rate of the liquid 73928/430 = 171.9 m3volumetric flow rate of
vapor = 18482/36.6 = 505.0 m3/h, so vo0.0073 m3/kg.
The static back pressure due to the kettle is therefore:
(2,3*4880/1000)*log(0.0073/0.0023)*1/(0.0073-0.0023) = 1126 kg/m20.11 kg/cm2.
2) Pressure drop of the heat exchanger: the free passage area of 109 pipes O.D ¾””, BWG 16
2 2
it's 0.021 m and therefore G = (73928+18482)/0.021*3600 = 1222 kg/sec.m The viscosity µ of butane
boiling at 108°C is 0.1 cP and the internal diameter dIa tube 15.75 mm and therefore Re = dI*G/µ =
157.5-3*1222/0.1*10-3= 192000 from which with f obtained from Fig. 5 of Section E one obtains
a pressure loss of = 0.15 kg/cm2.
The total resistance is therefore 0.11 + 0.15 = 0.26 kg/cm2.
The driving force is: (4880/1000)*430 = 2100 kg/m20.21 kg/cm2
Since the driving force is less than the total resistance, it will not be possible to achieve the
minimum required recirculation ratio of 4:1; therefore, it will be necessary to either make the pipes shorter or
raise the liquid level in the column or both if the correction needs to be consistent.

For a detailed calculation of the Exchange Coefficient Tube Side and Side
Cloak View Manual Methods of Calculation Heat Exchange Sections
E-1, E-2, F.
(4) SECOND ATTEMPT
Let's assume standard pipes 12 ft long (3660 mm) and a recirculation ratio of 4. From A =
30.7 m2N is obtainedtubi= 140 while the actual count leads to 151 tubes for exchanger 1-1,
O.D. ¾”, triangular pitch of 1”, internal diameter of the casing 394 mm.
Since the exchange surface becomes 30.7*151/140 = 33.1 m2the global coefficient UD
becomes 998000/(70*33.1) = 431 kcal/hm2°C
1) Recirculation ratio: we assume 4:1 and we will have as in the first attempt
vie vo respectively 0.0023 and 0.0073 m3/kg and therefore the back pressure
static is: (2.3*3660/1000)*log(0.0073/0.0023)*1/(0.0073-0.0023) = 844 kg/m 2=
0.084 kg/cm2.
2) Pressure drop of the exchanger: the new free passage area of 151
2 2
the tube is 0.029 m and therefore G = 885 kg/sec.m The Re = 138000 from which f is derived
with the attached diagram obtained from Fig. 5 of Section E, the value is obtained
0.062 kg/cm2.
The total resistance is therefore: 0.084 + 0.062 = 0.146 kg/cm2
The driving force is (3660/1000)*430 = 1574 kg/m20.157 kg/cm2
Since the driving force is slightly greater than the overall resistance, the ratio of
a recirculation of at least 4:1 is guaranteed.

Verification of the exchange surface

Heat exchange coefficient allowed by the configuration of the second attempt:
•Hot side: for condensing steam, 7500 kcal/hm is considered.2°C(ho)
Cold side: for Re = 138000, j is obtained.H= 330 (dimensional view
attached diagrams Fig. 2 Sheets 1 and 2 taken from section E-1 of the manual.
Neglecting the term (µ/µw)0.14you can write hi=(jHk/d)(cµ/k)1/3. The
108°C
kcal/hm°C. So hi =( 330*0.11/16*10 -3(0.7 * 0.1 * 3.6 / 0.11) = approximately 5000 kcal/hm2°C
Since the maximum exchange coefficient is limited by...
boiling is about 1500 kcal/hm2Thislastvalueisadoptedthat
corrected for the diameter ratio gives approx. 1200 kcal/hm2°C(h) I
2
UC= hIhoI+ho)= 1035 kcal/hm °C.
The dirt factor RDof the exchanger will be, remembering that UD=431:
RD= (UC-UD) / UCUD=(1035-431)/1035*431 = 0.00135 hm2°C/kcal
The high contamination factor is due to the limitations of the heat flow.
maximum; this is a case where the high temperature of the steam does not lead to
to some advantage: with a lower temperature, an U would be obtainedD
greater and the same exchange surface.
(6) NOTE ON THE KERN EXERCISE
The following notes are derived from the assumptions and simplifications made by Kern in his
exercise; the aim is to analyze them critically.
The Kern exercise requires that the liquid enters from the bottom of the reboiler.
it begins to boil immediately. This is a simplification because the liquid
it cannot immediately initiate the state change arriving at the exchanger at
a temperature lower than its boiling point at its actual pressure.
There will therefore be a preheating section in the heat exchanger until the start
boiling; in this section the temperature on the pipe side increases, worsening the
true LMTD. The question is: by how much? Is the simplification of
Core?
In the previous exercise, the bottom column pressure (in the gas phase) is 19.3 Ate and the
The inlet pressure of the liquid in the heat exchanger will be 19.3 + 0.146 (back pressure
static + head loss) = 19.446 Ate. Even without precise digital data, it
can assess that on the vapor pressure curve of butane there is a difference of
pressure of about 0.15 kg/cm2in the surroundings of 19 it is worth a temperature difference
less than 1°C therefore in our case it is completely acceptable to simplify the
Core.
 It would be different if the temperature difference between the inside and outside of the pipes were low and if the
the distillation pressure was also low; then a check followed by
correction of the thermal diagram of the process and of the LMTD would be necessary.
The pressure losses of the circuit consist of: pressure losses of the
liquid from column to exchanger, pressure drops across the exchanger,
pressure losses due to acceleration caused by evaporation, pressure losses
of the mixed phase from exchanger to column. Of all these, where there are also
including the entrances and exits, the Kern only considers the one through the
exchanger without inlet and outlet) judging others as negligible
entity.
Let’s take a closer look at them:
Pressure drop from column to heat exchanger: the liquid flow rate is 215 m3/h;
with a 12" pipe the speed is 0.83 m/sec (a fairly high value for a
natural circulation). The pipe will be about 10 meters long and contains an outlet
from the column an inlet in the exchanger and two 90° bends for a length
total equivalent of about 30 meters. We will have Re = 430*0.83*0.3/0.1*10-3around
106from which f = 0.015 and therefore
Delta P = f*v2*L/2*g*D = 0.015*0.8320.02279
23 kg/m20.0023 kg/cm2negligible
Pressure drop from column exchanger: it is about 10 meters in length
equivalent of tube traveled by 171.9 m3liquid with a density of 430 kg/m3e 505 m3h di
gas density 36.6 kg/m3The density of the mixed phase is therefore 135 kg/m3(media
volume of the two densities). With a 16" pipe, the speed is 1.5 m/sec and the loss of
load calculated approximately as a single-phase fluid:
Delta P = 0.015*1.52*10/2*9.8*0.4 = 0.043 m.c.l.= 0.043*430 = 19 kg/m20.0019 kg/cm2
negligible
It is nonetheless important to emphasize that the two calculated pressure losses are of significant magnitude.
negligible required a tailor-made design. With double speeds before and after
the exchanger these pressure losses would no longer be negligible and this means that
the circuit must be accurately sized in every case.
Pressure loss due to acceleration: Kern indicates a pressure loss equal to twice the
kinetic load calculated at the average of the inlet and outlet densities.
The formula is: G2/144gρavgdelta P (psi)
where G = 91410 / 0.453 * 0.029 * 10.76 * 3600 = 179.63 lb/sec.ft2
g = 32.15 ft/sec2ρavg(26.83 + 8.55) / 2 = 17.7 lb/ft3
from which DP = 0.39 psi is not negligible
From the Manual Methods for Calculation of Heat Exchange SECTION E-1
From the Manual Calculation Methods Heat Exchange SECTION E-1
From the Manual Methods of Thermal Exchange Calculation SECTION E-1
 A particular case of Heating Steam Flow Control

The figure shown indicates that the temperature at the bottom of the column is being controlled.
through the discharge in level control of the condensate storage tank.
This solution is recommended in case the heating steam is at low pressure.
In this case, if the temperature control were carried out with a flow control that
it acts on valve V-1 it may happen that the direct discharge from the jacket of the reboiler
without level control and without the presence of the condensate accumulation tank it could
to vacuum the jacket of the reboiler with inability for continuous steam discharge
condensate and uncontrolled pendulations of the condensate drain and of everything
operation of the column.
With the solution shown in the figure, the condensate pressure at the outlet remains practically
always constant (around the heating vapor pressure at the entrance of the reboiler) for
any operating load condition of the distillation.
It is not advisable to check the condensate discharge directly at the outlet from the jacket side.
from the rebuilder due to the small capacity of liquid present in the mantle.