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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
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Refluxing Condensation
Systems (Dephlegmator)
CONTENTS
SECTION
INTRODUCTION/PURPOSE
SCOPE
FIELD OF APPLICATION
DEFINITIONS
BACKGROUND
DESIGN CALCULATIONS
10
5.1
5.2
5.3
Flooding
Estimation of Thermal Performance
Estimation of Pressure Drop
10
12
13
NON-CONDENSING GASES
13
13
7.1
7.2
7.3
7.4
Distillation Columns
Knock-back Condensers
Boiling Coolants
Economic Considerations
13
14
14
14
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
ADVICE ON INSTALLATION
14
8.1
14
NOMENCLATURE
15
10
BIBLIOGRAPHY
16
FIGURES
18
16
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
INTRODUCTION/PURPOSE
Most condensers are designed such that the vapor and condensate flow in a cocurrent fashion. There is a class of condenser, known variously as Reflux
condenser, Dephlegmator or Knock-back condenser in which the condensate
flows in a counter-current fashion to the vapor. This design offers certain
advantages, but poses some design problems.
SCOPE
FIELD OF APPLICATION
This Guide is intended for process engineers and plant operating personnel in
the GBH Enterprises worldwide, who may be involved in the design or operation
of refluxing condensers.
DEFINITIONS
BACKGROUND
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
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FIGURE 1
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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4
Four types of reflux condenser geometry are common:
(a)
(b)
(c)
Stab-in horizontal bundle, (see Figure 4). This design is only suitable for
columns of a reasonable diameter. Tubeside drainage is not a problem.
The use of low fin tubing to enhance the heat transfer is possible. Design
methods for avoiding flooding are uncertain.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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(d)
Cross flow spiral heat exchanger, (see Figure 5). (Note that
Alfa-Laval also offer their type G spiral condenser, which although
mounted directly onto a distillation column, has a central pipe up which the
vapor flows before passing back down the spirals in co-current flow with
the condensate, (see Figure 6)). This latter type is not a reflux condenser;
it can be treated as a conventional down-flow condenser.
FIGURE 2
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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FIGURE 3
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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FIGURE 4
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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FIGURE 5
Note:
The exchanger may be mounted directly onto a distillation column, whereupon
the lower end plate and nozzle may be omitted.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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FIGURE 6
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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DESIGN CALCULATIONS
(b)
5.1
Flooding
If a liquid film is flowing down the walls of a vertical tube and a vapor is flowing
upwards, the interfacial shear will result in a thickening of the film. As the vapor
flow is increased, further thickening of the film takes place, and waves are
induced on the surface. Finally, a point will be reached where some of the liquid
will be carried back up the tube by the vapor. This phenomenon is known as
flooding, and represents the limits of operation of a vertical tubeside reflux
condenser.
Flooding is a complex phenomenon, and there are considerable uncertainties in
data and disparities between the various correlations.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
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Droplets will be unstable and shatter if the Weber number (We) exceeds 10.
This gives the maximum velocity for drops to be collected. As for the tubeside
flooding, a margin of safety should be placed on this figure; 75% is suggested.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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5.2
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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There are no reliable methods for estimating pressure drop in the counter-current
flow of liquids and vapors in tubes or other geometries. However, for designs well
away from the flooding point, the pressure drop is likely to be low. The pressure
drop will rise sharply as the flooding point is approached.
NON-CONDENSING GASES
The in-tube reflux condenser may not be well suited to duties where there is a
significant quantity of inert gas present, as the low velocities necessary to avoid
flooding in the lower part of the tube will result in high gas phase resistances in
the upper parts of the tube. A more appropriate design here could be the
shellside condenser with a variable baffle pitch, but, as was pointed out above,
there are no reliable flooding correlations for this geometry.
However, even though the high resistance in the upper part of the exchanger
results in a larger unit than is desired, it could still be financially attractive
because of the large savings in pipework, reflux drum and pumps.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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7.1
Distillation Columns
The cost saving and separation effects of a reflux condenser have been exploited
to our advantage in, for example, the Amines and Alkyl Phenols areas, using
internal U-tube condensers with shellside condensation. Experience suggests
that as a general rule, 2m of tube gives approximately one separation stage.
Spiral exchangers are increasingly being used in the NE for design pressures
below 10 bar. Both these designs lead to a compact plant without the vapor and
liquid return pipework.
7.2
Knock-back Condensers
Boiling Coolants
Economic Considerations
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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ADVICE ON INSTALLATION
8.1
(a)
(b)
(c)
A wall wiper ring, fixed between the collector pan and the bundle should
be fitted to divert condensate flowing down the wall into the collector pan.
If this is not fitted there is a risk that insufficient condensate will enter the
collector pan to meet the product draw-off requirements, particularly at
reflux ratios below 1:1.
(d)
(e)
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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NOMENCLATURE
a
Bo
Di
Do
d
F
Fr
g
Kg
n
p
Ql
Tbd
Tbi
Td
U crit
Ut
u
v gf
We
ml
rg
rl
s
(m)
(m)
(m)
(m)
(m/s2)
(m)
(m3/s)
C
C
C
(m/s)
(m/s)
(m/s)
(Ns/m2)
(kg/m3)
(kg/m3)
(N/m)
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
10
BIBLIOGRAPHY
Ref
Source
[1]
[2]
[3]
GBHE-PEG-FLO-301
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com