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CHEMICAL ENGINEERING
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 0.4/0.3 D 49,111 4.9 104
From Figure 12.23, jh D 3.2 103
Nu D 3.2 103 49,111 2.780.33 D 220.2
3
2
12.15
C
1
HEAT-TRANSFER EQUIPMENT
751
which the heat-transfer coefficient calculated using equations for boiling on a single tube
is reduced by an empirically derived tube bundle factor, to account for the effects of
vapour blanketing. Later work by Heat Transfer Research Inc., reported by Palen et al.
(1972), showed that the coefficient for bundles was usually greater than that estimated for
a single tube. On balance, it seems reasonable to use the correlations for single tubes to
estimate the coefficient for tube bundles without applying any correction (equations 12.62
or 12.63).
The maximum heat flux for stable nucleate boiling will, however, be less for a tube
bundle than for a single tube. Palen and Small (1964) suggest modifying the Zuber
equation for single tubes (equation 12.64) with a tube density factor. This approach was
supported by Palen et al. (1972).
The modified Zuber equation can be written as:
pt
p
qcb D Kb
[gL v v2 ]0.25
12.74
do
Nt
where qcb D maximum (critical) heat flux for the tube bundle, W/m2 ,
Kb D 0.44 for square pitch arrangements,
D 0.41 for equilateral triangular pitch arrangements,
pt D tube pitch,
do D tube outside diameter,
Nt D total number of tubes in the bundle,
Note. For U-tubes Nt will be equal to twice the number of actual U-tubes.
Palen and Small suggest that a factor of safety of 0.7 be applied to the maximum flux
estimated from equation 12.74. This will still give values that are well above those which
have traditionally been used for the design of commercial kettle reboilers; such as that
of 37,900 W/m2 (12,000 Btu/ft2 h) recommended by Kern (1950). This has had important
implications in the application of submerged bundle reboilers, as the high heat flux allows
a smaller bundle to be used, which can then often be installed in the base of the column;
saving the cost of shell and piping.
25,000
25,000 to 40,000
40,000
1.2 to 1.5
1.4 to 1.8
1.7 to 2.0
752
CHEMICAL ENGINEERING
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:
L v
uO v < 0.2
v
1/2
12.75
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 5 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:
hnb mixture D fm hnb single component
12.76
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 0 C. Steam is available at 1.70 bar (10 psig).
HEAT-TRANSFER EQUIPMENT
753
90
45
52 Tube holes
26 u-tubes
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 56.1 C
latent heat D 326 kJ/kg
mean specific heat, liquid D 2.51 kJ/kg C
critical pressure, Pc D 38 bar
Heat loads:
sensible heat (maximum) D 56.1 02.51 D 140.8 kJ/kg
total heat load D 140.8 C 326
5000
D 648.3 kW,
3600
11.5
D 25
30 103 4.8
754
CHEMICAL ENGINEERING
hnb
681
D 59.2 kW/m2
qD
11.5
5.84 0.17
5.84 1.2
5.84 10
0.69
3 0.7
D 0.10438 59.2 10
1.8
C4
C 10
38
38
38
D 4855 W/m2 C
12.63
Take steam condensing coefficient as 8000 W/m2 C, fouling coefficient 5000 W/m2 C;
butane fouling coefficient, essentially clean, 10,000 W/m2 C.
Tube material will be plain carbon steel, kw D 55 W/m C
30
30 103 ln
1
30
1
1
1
1
25
C
C
C
C
D
Uo
4855 10,000
2 55
25 5000 8000
12.2
Uo D 1341 W/m2 C
Close enough to original estimate of 1000 W/m2 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:
D
1341
59.1 D 16.3 C 29 F
4855
Myers data, extrapolated, gives a coefficient of around 3000 Btu/h ft2 F at a 29 F temperature difference D 17,100 W/m2 C, so the estimated value of 4855 is certainly on the
safe side.
Check maximum allowable heat flux. Use modified Zuber equation.
Surface tension (estimated) D 9.7 103 N/m
L D 550 kg/m3
273
58
755
HEAT-TRANSFER EQUIPMENT
326 103
p
[9.7 103 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 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
Ds D 2 420 D 840 mm.
Take liquid level as 500 mm from base,
freeboard D 840 500 D 340 mm, satisfactory.
340
420
500
D 0.06 m/s
Vapour velocity at surface D
3600 12.6 1.9
Maximum allowable velocity
uO v D 0.2
550 12.6
12.6
1/2
D 1.3 m/s
12.75
so actual velocity is well below maximum allowable velocity. A smaller shell diameter
could be considered.