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PROCESS TECHNOLOGY PROCEDURES

DEPART,ENTSUB0ECT-

Edited from existin do! "# $ Andr%&is

APPRO/ED BY

A'ri( )*+ 2***

PROCESS ENG.NEER.NG

0RB
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REBO.1ER CA1CU1AT.ONS DES.GN GU.DE

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TABLE OF CONTENTS Section 1.0 2.0 3.0 SCOPE............................................................................................................. RESPONSIBILITIES........................................................................................ DESIGN CRITERIA.......................................................................................... 3.1 3.2 4.0 Cold Side................................................................................................. Hot Side...................................................................................................

CALCULATIONS............................................................................................. 4.1 4.2 4.3 Horizontal Thermosyphon Reboiler Calculations................................... Kettle Reboiler Calculations.................................................................... Vertical Thermosyphon Reboiler Calculations........................................

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PROCESS SPECIFICATION........................................................................... LIST OF ILLUSTRATIONS

Fi!"#e 1 2 3 4 ) * Horizontal Thermosyphon Reboiler Side !ra"o##......................................... Horizontal Thermosyphon Reboiler $ottom !ra"o##..................................... Kettle Reboiler %ressured Type.................................................................... Kettle Reboiler &ra'ity (lo" Type.............................................................. Vertical Thermosyphon Reboiler $ottom !ra"o##......................................... Vertical Thermosyphon Reboiler Side !ra"o##.............................................

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1.0

SCOPE

This desi+n +uide1 co'ers the calculation o# 'essel s,irt hei+hts- pressure drops- line sizes- and calculation o# dri'in+ head to determine re.uired dra"o## nozzle ele'ations #or reboiler circuits. 2.0 RESPONSIBILITIES

The process en+ineer is responsible #or determinin+ 'essel s,irt hei+hts- pressure dropsline sizes- and dri'in+ heads #or reboiler circuits. 3.0 3.1 DESIGN CRITERIA Co$% Si%e

/ines carryin+ li.uid to the reboiler shall be sized usin+ a ma0imum li.uid 'elocity o# 4 to ) #eet per second. (or lines dra"in+ li.uid #rom the side o# a column- a 'elocity o# 2 #eet per second shall be used #or a minimum len+th o# ) #eet. 3.2 Hot Si%e

(or a reboiler 'apor outlet- V2 should +enerally not e0ceed )11. The mi0ed phase reboiler return line shall be sized usin+ a minimum 'apor 'elocity o# 1) #eet per seconde'en i# this produces unstable #lo" in the 'ertical up. 2n cases "here the density is lo"hi+her 'elocities "ill occur- but these should not e0ceed 111 #eet per second. The horizontal portion o# the mi0ed phase line may be lar+er 3'apor 'elocity may be lo"er4 than the 'ertical up portion o# the line- i# necessary to maintain stable #lo" in both the horizontal and 'ertical run o# lines. 4.0 CALCULATIONS

The reboiler calculations are se+re+ated on the #ollo"in+ arran+ements5 1. Horizontal Thermosyphon Reboiler Calculations a. Side dra"o## 3(i+ure 14 b. $ottom dra"o## 3(i+ure 24 2. Kettle Reboiler Calculations a. %ressured type 3(i+ure 34 b. &ra'ity #lo" type 3(i+ure 44

Re4. * of t5e Desi n G6ide &%s %d%'ted &it5 minim%( !5%n es from % P%s%den% do!6ment+ DSG-,P7+ 128)

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3. Vertical Thermosyphon Reboiler Calculations a. $ottom dra"o## 3(i+ure )4 b. Side dra"o## 3(i+ure *4 4.1 Ho#i&ont'$ T(e#)o*+,(on Re-oi$e# C'$c"$'tion*

Horizontal reboilers- "ith natural circulation- ha'e a simple circulation system. /i.uid #lo"s #rom a to"er side dra"o## nozzle- to"er bottom- or an ele'ated drum throu+h a do"ncomer pipe to the bottom o# the reboiler shell. The li.uid is heated- partially 'aporized- and lea'es the reboiler in the return pipin+ as 'apor li.uid mi0ture- then #lo"in+ bac, to the to"er or drum. The circulation is #orced by the static head di##erence bet"een the t"o #luid columns. 6se the e0chan+er centerline as a re#erence line. P1 = 1H1 7144 P2 = 2H2 7144 P1 P2 = P = ( 17144 ) ( 1H1 2H2 ) "here5 H1 9 hei+ht o# do"ncomer- in #t H2 9 hei+ht o# riser- in #t %1 9 do"ncomer static pressure at reboiler center line- in pounds per s.uare inch atmosphere 3psia4 %2 9 riser static pressure at reboiler center line- in psia % 9 pressure drop- in pounds per s.uare inch 3psi4 38.. 4 14 38.. 4 24 38.. 4 34

1 9 hot li.uid density- in lb7cu #t 2 9 li.uid7'apor density- in lb7cu #t

This % is the dri'in+ #orce necessary #or natural circulation. This is also the pressure a'ailable to o'ercome e0chan+er and pipin+ #riction losses. % %reboiler : %do"ncomer : %riser : % sa#ety #actor %reboiler +enerally ran+es #rom 1.2) to 1.)1 psi. 38.. 4 44

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%do"ncomer and %riser should be calculated usin+ the %arsons /ine Sizin+ and ;ptimization pro+ram and the desi+n criteria in section 3.1. These %s should include pipe inlet and outlet losses and acceleration losses. %sa#ety #actor 9 1.11 psi 38.. 4 )4

The riser pipe diameter is +enerally one or t"o sizes lar+er than the do"ncomer pipe diameter.

(i+ure 1 Horizontal Thermosyphon Reboiler Side !ra"o## 4.1.1 Side !ra"o## <ozzle 8le'ation

The minimum do"ncomer nozzle ele'ation abo'e the horizontal reboiler centerline 3H 14 may be #ound #rom the a'ailable !% 8.uation 4 3. The minimum 3H1 H24 is usually 3 #eet. 2nsert H 2 9 H1 e.uation and sol'e #or H15 H1 = 144P 3 2 1 2 3 into the a'ailable %

38.. 4 *4

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"here5 % 9 %reboiler : %do"ncomer : %riser : 1.11 sa#ety #actor The 'alue o# H1 is use#ul "hen ele'ation ad=ustments are made to 'essel hei+hts durin+ plant layout or "hen the 'essel can be located at a minimum ele'ation. >any to"ers ha'e a bottom dra"o## pump. %ump net positi'e suction head 3<%SH4 re.uirements +enerally ele'ate the process 'essel and the reboiler dra"o## nozzle hi+her than that o# the reboiler?s minimum. This increases the static head in the 'ertical le+s and also the dri'in+ #orce in the circuit. @ith the increased to"er hei+ht- it is "orth"hile to chec, the reboiler circuit #or a possible reduction o# li.uid and return line sizes- especially "here lar+e diameter lines are re.uired.

(i+ure 2 Horizontal Thermosyphon Reboiler $ottom !ra"o## 4.1.2 $ottom !ra"o##

At horizontal reboilers- "hether the dra"o## nozzle is ele'ated or located in the bottom o# the to"er- the hydraulic conditions are the same. To #ind the a'ailable ener+y- the % 8.uation 4 3 can be used.

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(or the minimum do"ncomer len+th 3H 14- the return line nozzle ele'ation 3H 34 must be ,no"n. 2nsert H2 9 H1 : H3 into !% 8.uation 4 3 and sol'e #or H 1- as sho"n in 8.uation 4 B5 H1 = 144P + 2H3 1 2 38.. 4 B4

4.2

.ett$e Re-oi$e# C'$c"$'tion*

There are t"o +eneral types o# ,ettle reboilers5 the pressured #lo" and the +ra'ity #lo".

(i+ure 3 Kettle Reboiler %ressured Type 4.2.1 Kettle Reboilers %ressured (lo"

2n this type o# ,ettle reboiler- the li.uid le'el in the reboiler is +enerally controlled by a le'el controller. 80cess li.uid #lo"s #rom the reboiler to a lo"er pressure destination throu+h a le'el control 'al'e. These reboilers are +enerally mounted at +rade- and the hydraulics in'ol'ed is the same as #or any pressured #lo" #rom a 'essel.

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Fi 6re 9 - <ett(e Re"oi(er - Gr%4it# - F(o& T#'e 9.2.2

Kettle Reboiler &ra'ity (lo" Type

2n this type o# ,ettle reboiler- the li.uid #lo"s by +ra'ity #rom a to"er side dra"o## nozzle into the reboiler. 2n the reboiler- the li.uid o'er#lo"s a "eir- "hich maintains the li.uid le'el. The o'er#lo" is returned to the bottom o# the to"er by +ra'ity. As in thermosyphon reboilers- the static head bet"een the to"er dra"o## nozzle and the top o# the reboiler "eir must be lar+e enou+h to o'ercome the reboiler and pipin+ pressure drops.

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3Ho H"4 speci#ic +ra'ity 0 1.4331 psi C %reboiler : %do"ncomer : %riser 38.. 4 D4 "here5 Ho 9 ele'ation o# to"er do"ncomer outlet nozzle- in #t H" 9 ele'ation o# top o# reboiler "eir- in #t %reboiler +enerally ran+es #rom 1.2) to 1.)1 psi. %do"ncomer and %riser should be calculated usin+ the %arsons /ine Sizin+ and ;ptimization pro+ram and the desi+n criteria in Section 3.1. These %s should include pipe inlet and outlet losses. A ,ettle type reboiler produces hi+h e'aporation rates and a lar+e diameter return line mi+ht be necessary. The process #lo" dia+ram- o# course- should indicate #lo"rates and the physical properties o# the #lo"in+ #luid. The static head bet"een the top o# the "eir in the reboiler and the to"er hi+h li.uid le'el must be +reat enou+h to o'ercome the li.uid return line pressure drops- includin+ the pipe inlet and outlet losses. 3H" HH//4 0 speci#ic +ra'ity 0 1.433 psi C % li.uid return line "here5 H" 9 ele'ation o# top o# the "eir in the reboiler HH//9 ele'ation o# hi+h li.uid le'el in the to"er 4.3 /e#tic'$ T(e#)o*+,(on Re-oi$e# C'$c"$'tion* 38.. 4 E4

/i.uid #lo"s #rom a to"er side dra"o## nozzle- to"er bottom- or an ele'ated drum throu+h a do"ncomer to the bottom o# the 'ertical reboiler shell. The li.uid is heated and lea'es the reboiler in the return pipin+ as 'apor or 'apor li.uid mi0ture. 2t then #lo"s bac, to the to"er or drum. A simpli#ied- conser'ati'e- and con'enient assumption is made that density 'aries alon+ the 'ertical reboiler len+th in a strai+ht line proportion.

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(i+ure ) Vertical Thermosyphon Reboiler $ottom !ra"o## 4.3.1 Vertical Thermosyphon Reboiler $ottom !ra"o##

Assumin+ that the #luid density in the reboiler "ill be an a'era+e o# the li.uid do"ncomer and return line densities "e ha'e

3 =

1 + 2 2

38.. 4 114

The sum o# the static heads +i'es the #ollo"in+ e.uation5 P = ( 17144 ) ( 1H ?1 2H2 3H4 ) "here5 H?1 9 relati'e ele'ation bet"een the to"er bottom tan+ent and bottom o# the reboiler H2 9 hei+ht o# riser- in #t H3 9 ele'ation bet"een the to"er bottom tan+ent and 'apor return nozzles- in #t H4 9 hei+ht o# the 'ertical reboiler- in #t 38.. 4 114

1 9 density o# the li.uid- in lb7cu #t

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2 9 density o# the 'apor7li.uid mi0ture- in lb7cu #t 3 9 a'era+e density o# #luid in the reboiler- in lb7cu #t
This % is the dri'in+ #orce #or 'ertical reboilers. (riction losses should be smaller than this. The relati'e position bet"een the to"er bottom tan+ent and the bottom o# the reboiler must be a minimum o# H?1 #eet. 80pressin+ H?1 #rom the abo'e e.uation and insertin+ H2 = H ?1 + H3 H4 or H ?1 + H3 = H2 + H4 The relati'e ele'ation di##erence as sho"n in 8.uation 4 125 H ?1 = 144P + 2 ( H3 H 4 ) + 3H4 ( 1 2 ) 38.. 4 124

Assumin+ that the to"er bottom tan+ent line and the top tubesheet are on the same ele'ation- the abo'e 8.uations 4 11 and 4 12 can be simpli#ied- because H? 1 9 H4 and H3 9 H2. Conse.uently5 P = ( 17144 ) H ?1 ( 1 3 ) 3H3 and H ?1 = 144P + 2H3 ( 1 3 ) - no sa#ety #actor has been included 38.. 4 144 38.. 4 134

The H2 dimension can be +reater than H 3. The minimum li.uid le'el static head abo'e the bottom tan+ent line can also be ta,en into account as an additional dri'in+ #orce.

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(i+ure * Vertical Thermosyphon Reboiler Side !ra"o## 4.3.2 Vertical Thermosyphon Reboiler Side !ra"o##

(or a 'ertical reboiler "ith a hi+h dra"o## nozzle- the dri'in+ #orce is5 P = ( 17144 ) ( 2H F1 2H2 3H4 ) "here5 HF1 9 relati'e ele'ation bet"een the to"er dra"o## nozzle and the bottom o# the reboiler- in #t This % is the dri'in+ #orce #or 'ertical reboilers. (riction losses should be smaller than this. The minimum hei+ht bet"een the li.uid dra"o## nozzle and the 'apor return nozzle is 3 #eet. There#ore- the minimum dra"o## nozzle ele'ation "ill be as sho"n in 8.uation 4 1*5 H F1 = 144P 2 3H4 + 34 + 3H4 - no sa#ety #actor has been included 1 2 38.. 4 1*4 38.. 4 1)4

;nce more the total system loss 3 %4- ,no"n densities- and e0chan+er len+th 3H 44 "ill +i'e the distance bet"een the dra"o## nozzle and the reboiler bottom tubesheet 3HF 14. .0 PROCESS SPECIFICATION

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The process en+ineer is responsible #or selectin+ the type o# Reboiler re.uired #or the ser'ice. The process speci#ication shall include the type- either by indication the type on the data sheet or better include a s,etch- e0amples #i+ure 1 throu+h * - depictin+ the type o# boiler speci#ied.