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REBOILER (RB-101)
SPECIFICATION SHEET

Equipment Tag: RB – 101

REBOILER DATA SHEET Function: to vaporize a fraction of the
bottom product
Operating Conditions
Shell and Tube Heat Exchanger
Equipment Type TEMA Type K
(1 Shell – 2 Tube Pass)
Configuration Horizontal
Heat Transfer Area 15.9935 m2
Material of Construction Stainless Steel Type 316
Performance of One Unit
Shell-Side Tube-Side
Fluid Circulating Liquid Mixture Steam
Mass Flowrate 1.0178 kg/s 0.3465 kg/s
No. of Passes 1 2
Temperature 140.8 °C 184.12 °C
In Out In Out
Vapor Phase Yes Yes Yes
Liquid Phase Yes
Fouling Resistance 5000 W/m2·K 5000 W/m2·K
Heat Transfer Coefficient 2738.95 W/m2·K 8000 W/m2·K
Pressure Drop 0.07 Pa 0.26 Pa
Overall Heat Transfer
1027.50 W/m2·K
Coefficient
Percent Overdesign 2.50 %
NTU 48.16 Effectiveness 77 %
Tube
Outside Pitch Bundle No. of
Thickness Length Pitch
Diameter Type Diameter Tubes
0.0254 m 0.0018 m 4.8768 m 0.0508 m Square 0.3912 m 82
Shell Baffle
Inside Diameter Spacing No. of Baffles Percent Cut
0.7824 m 0.3912 m 12 25 %

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REBOILER (RB-101)

Isometric View

Tube Arrangement

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Table 9.17.1: Thermodynamic Properties of the Fluid

Thermodynamic Properties of the Fluid

Boiling Point (°C) 140.8
Latent Heat of Vaporization (kJ/kg) 634.3
Mean Specific Heat (kJ/kg·K) 1.4304
Liquid Density (kg/m3) 649.7484
Vapor Density (kg/m3) 3.3084
Surface Tension (N/m) 0.0285
Critical Pressure (bar) 52.40

Maximum Sensible Heat

Q S = mCP∆T

kJ
Q S = 1.4304 (104.8 − 95)K
kg ∙ K

𝐤𝐉
𝐐𝐒 = 𝟏𝟒. 𝟎𝟐
𝐤𝐠

Total Heat Load

Q T = m(Q S + 𝜆V )

kg 1 day kJ kJ
Q T = (87936.68 × ) (14.02 + 634.3 )
day 86400 s kg kg

𝐐𝐓 = 𝟔𝟓𝟗. 𝟖𝟓 𝐤𝐖

Add 5% Due to Heat Losses

Q Max = 1.05(659.85 kW)

𝐐𝐌𝐚𝐱 = 𝟔𝟗𝟐. 𝟖𝟒 𝐤𝐖

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Table 9.17.2: Thermodynamic Properties of Steam

Thermodynamic Properties of Steam at 1000 kPa

Steam Saturation Temperature (°C) 184.12
Latent Heat (kJ/kg) 1999.28
Specific Enthalpy of Saturated Steam (kJ/kg) 2780.71

Mean Temperature Difference

*Taking both streams as isothermal

∆TM = TSteam − TMixture

∆TM = 184.12 ℃ − 140.8 ℃

∆𝐓𝐌 = 𝟒𝟑. 𝟑𝟐 ℃

Table 9.17.3: Typical Overall Heat Transfer Coefficient

Reference: page 637 of Chemical Engineering Design by Sinnott

Assumed Overall Heat Transfer Coefficient

𝐔𝐎 = 𝟏𝟎𝟎𝟎 𝐖⁄ 𝟐
𝐦 ∙𝐊

Heat Transfer Area

Q
A=
UO ∆TM

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1000 W
692.84 kW × 1 kW
A= W
1000 (43.32 K)
m2 ∙K

𝐀 = 𝟏𝟓. 𝟗𝟗𝟑𝟓 𝐦𝟐

Heat Flux

Q
q=
A
692.84 kW
q=
15.9935 m2
𝐤𝐖
𝐪 = 𝟒𝟑. 𝟑𝟐
𝐦𝟐

Tube Length and Diameter Assumptions

Using Table 11-12 Characteristics of Tubing, page 11-42 of Perry’s ChE

Handbook 8th Edition

Tube O.D. Thickness Internal Area Tube I.D.

1 in 0.035 in 0.6793 in2 0.930 in

Length 16 ft

Area of a Single Tube

AT = πODT LT

AT = π(0.0254 m)(4.8768 m)

𝐀 𝐓 = 𝟎. 𝟑𝟖𝟗𝟐 𝐦𝟐

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Number of Tubes

A 1
NT = ( )( )
AT no. of shell pass

15.9935 m2 1
NT = ( )( )
0.3892 m2 1

NT = 41 tubes

For U-tubes NT will be equal to twice the number of actual U-tube. (page 751,
Chemical Engineering Design by Sinnott)

NT = 2(41)

𝐍𝐓 = 𝟖𝟐

Table 9.17.4: Typical Tube Arrangements

Reference: page 649 of Chemical Engineering Design by Sinnott

Tube Bundle Diameter

For square pitch,

1
NT n1
Db = ODT ( )
K1

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1
82 2.291
Db = 0.0254 m ( )
0.156

𝐃𝐛 = 𝟎. 𝟑𝟗𝟏𝟐 𝐦

Tube Pitch

A tube pitch of between 1.5 to 2.0 times the tube outside diameter should be used
to avoid vapor blanketing. (page 751, Chemical Engineering Design by Sinnott)

PT = 2 ODT

PT = 2 (0.0254 m)

𝐏𝐓 = 𝟎. 𝟎𝟓𝟎𝟖 𝐦

Shell Diameter

The shell diameter required will depend on the heat flux. Since the heat flux is
greater than 40,000 W/m2, the shell diameter to bundle diameter ratio is 1.7 to
2.0. (page 751, Chemical Engineering Design by Sinnott)

DS
= 2.0
Db

DS = 2 (0.3912 m)

𝐃𝐒 = 𝟎. 𝟕𝟖𝟐𝟒 𝐦

Number of Tubes in Center Row

Db
NTC =
PT

0.3912 m
NTC = = 𝟖 𝐭𝐮𝐛𝐞𝐬
0.0508 m

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Baffle Spacing

B = 0.5 IDS

B = 0.5 (0.7824 m)

𝐁 = 𝟎. 𝟑𝟗𝟏𝟐 𝐦

Number of Baffles

LT
= NB + 1
B
4.8768 m
= NB + 1
0.3912 m
𝐍𝐁 = 𝟏𝟐 𝐛𝐚𝐟𝐟𝐥𝐞𝐬

Check: BNB = (0.3912 m) (12 baffles) = 4.6944 m < 4.8768 m

Therefore, baffle spacing is acceptable.

Design Pressure

P = 1.1(Operating Pressure)

P = 1.1(101.325 kPa) = 111.46 kPa = 1.11 bar

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NUCLEATE POOL BOILING COEFFICIENT

Using the Mostinski equation

0.69 (
P 0.17 P 1.2 P 10
hnb = 0.104(Pc ) q )0.7 [1.8 ( ) + 4 ( ) + 10 ( ) ]
Pc Pc Pc

where P = operating pressure

Pc = liquid critical pressure

q = heat flux

0.69 (
1.11 0.17 1.11 1.2 1.11 10
hnb = 0.104(52.4) 43320)0.7 [1.8 ( ) + 4( ) + 10 ( ) ]
52.4 52.4 52.4

𝐖
𝐡𝐧𝐛 = 𝟐𝟕𝟑𝟖. 𝟗𝟓
𝐦𝟐 ∙ 𝐊

OVERALL HEAT TRANSFER COEFFICIENT

W
Outside dirt coefficient, hod = 5000 m2 ∙K

W
Inside dirt coefficient, hid = 5000
m2 ∙K

W
Tube wall material thermal conductivity, kw = 16 m∙K

W
Steam Condensing Coefficient, hi = 8000 m2 ∙K

OD
1 1 1 ODT ln ( T ) ODT 1 ODT 1
IDT
= + + +[ × ]+[ × ]
Uo hc hod 2kw IDT hid IDT hi
0.0254
1 1 1 0.0254 ln ( ) 0.0254 1 0.0254 1
0.0236
= + + +[ × ]+[ × ]
Uo 2738.95 5000 2(16) 0.0236 5000 0.0236 8000

𝐖
𝐔𝐨 = 𝟏𝟎𝟐𝟕. 𝟓𝟎
𝐦𝟐 ∙ 𝐊

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Percent Error

1027.50 − 1000
%Error = 0% < [ ] < 30%
1000
% 𝐄𝐫𝐫𝐨𝐫 = 𝟐. 𝟕𝟓 %

Therefore, the assumed overall heat transfer coefficient is acceptable.

Critical Heat Flux

Using the modified Zuber equation

PT λ
q cb = K b ( )( ) [σg(ρL − ρV )ρV 2 ]0.25
ODT √NT

where qcb = maximum (critical) heat flux for the tube bundle

Kb = 0.44 for square pitch arrangements

λ = latent heat

ρL = liquid density

ρv = vapor density

σ = surface tension

PT = tube pitch

ODT = tube outside diameter

NT= total number of tubes in the bundle

0.0508 634300
q cb = 0.44 ( )( ) [0.0285(9.81)(649.75 − 3.31)3.312 ]0.25
0.0254 √82
kW
q cb = 411.19
m2

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70% Safety Factor

kW
q cb = 0.70 (411.19 )
m2
𝐤𝐖
𝐪𝐜𝐛 = 𝟐𝟖𝟕. 𝟖𝟑
𝐦𝟐

Actual flux of 43.32 kW/m2 is well below maximum allowable.

Liquid Level

The freeboard between the liquid level and shell should be at least 0.25 m. (page
752, Chemical Engineering Design by Sinnott)

Freeboard = Liquid Level − Shell Diameter = 0.25 m

Liquid Level = 0.25 m + 0.7824 m

𝐋𝐢𝐪𝐮𝐢𝐝 𝐋𝐞𝐯𝐞𝐥 = 𝟏. 𝟎𝟑𝟐𝟒 𝐦

Width at Liquid Level

Width at Liquid Level = Liquid Level − Bundle Diameter

Width at Liquid Level = 1.0324 m − 0.3912 m

𝐖𝐢𝐝𝐭𝐡 𝐚𝐭 𝐋𝐢𝐪𝐮𝐢𝐝 𝐋𝐞𝐯𝐞𝐥 = 𝟎. 𝟔𝟒𝟏𝟐 𝐦

Surface Area of Liquid

AL = 0.6412 m (2.4384 m)

𝐀 𝐋 = 𝟏. 𝟓𝟔𝟑𝟓 𝐦𝟐

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Vapor Velocity at Surface

m
uv =
ρv A L
kg 1 day
87936.68 day × 86400 s
uv = kg
3.3084 (1.5635 m2 )
m3

𝐦
𝐮𝐯 = 𝟎. 𝟏𝟗𝟔𝟖
𝐬

Maximum Allowable Vapor Velocity

To avoid excessive entrainment, the maximum vapor velocity at the liquid surface
should be less than that given by the expression:
1
𝜌𝐿 − 𝜌𝑉 2
𝑢𝑣 < 0.2 [ ]
𝜌𝑉
1
649.7484 − 3.3084 2
𝑢𝑣 < 0.2 [ ]
3.3084
m m
0.20 < 2.80
s s
Acceptable, since the actual velocity is well below maximum allowable velocity.

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PERCENT OVERDESIGN

For Fixed Tube Sheet,

AC = πODT LT NT

82
AC = π (0.0254 m)(4.8768 m) ( )
2

AC = 15.9552 m2

Q
UC =
(AC )(∆TM )
1000 W
692.84 kW × 1 kW
UC = 2
(15.9552 m )(43.32 K)

W
UC = 1002.40
m2 ∙ K

Calculating for percent over design

UC − UO,Calc
% overdesign = [ × 100] < 50%
UC

1027.50 − 1002.40
% overdesign = [ × 100] < 50%
1002.40
% 𝐨𝐯𝐞𝐫𝐝𝐞𝐬𝐢𝐠𝐧 = 𝟐. 𝟓𝟎 %

Therefore, the over design is acceptable.

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SHELL – SIDE PRESSURE DROP

Clearance Between Tubes

C = Pt − ODt

C = 0.0508 m − 0.0254 m

𝐂 = 𝟎. 𝟎𝟐𝟓𝟒 𝐦

Cross-Sectional Flow Area

CIDS B
AS =
Pt

0.0254 m (0.7824 m)(0.3912 m)

AS =
0.0508 m

𝐀 𝐒 = 𝟎. 𝟏𝟓𝟑𝟎 𝐦𝟐

Shell – Side Mass Velocity

WS
GS =
AS
kg
1.0178 s
GS =
0.1530 m2
𝐤𝐠
𝐆𝐒 = 𝟔. 𝟔𝟓𝟐𝟑
𝐦𝟐 ∙ 𝐬

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Shell – Side Equivalent Diameter

1.27 2
de = (Pt − 0.785 ODt 2 )
ODt

1.27
de = (0.05082 − 0.785(0.0254)2 )
0.0254
𝐝𝐞 = 𝟎. 𝟏𝟎𝟑𝟕 𝐦

Shell – Side Reynolds Number

GS de
Re =
𝜇
kg
(6.6523 ) (0.1037 m)
m2 ∙s
Re =
3.781 × 10−4 Pa ∙ s
𝐑𝐞 = 𝟏𝟖𝟐𝟒. 𝟓𝟎

Estimate Jf from the figure below

25% baffle cut

Figure 9.17.1: Shell Side Friction Factor

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𝑗𝑓 = 6.5 × 10−2

Solving for pressure drop at shell – side

1 jfGS 2 IDS (NB + 1)

∆PS = ( )
2 7.5 × 1012 De SS ϕS

where jf = shell side friction factor

GS = shell side mass velocity in lb/ft2·hr

De = equivalent diameter in ft

NB = number of baffles

IDS = shell inside diameter in ft

ST = specific gravity of the tube side fluid

ФT = viscosity correction factor

lb 2
−2
1 6.5 × 10 (4904.99 ft2 ∙hr) (2.5669 ft)(12 + 1)
∆PS = ( )
2 7.5 × 1012 (0.3402 ft)(1.051)(1)

∆𝐏𝐒 = 𝟗. 𝟕𝟑 × 𝟏𝟎−𝟔 𝐩𝐬𝐢 ≈ 𝟎. 𝟎𝟕 𝐏𝐚

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TUBE – SIDE PRESSURE DROP

Tube Cross – Sectional Area

π
AT,C = (IDT )2
4
π
AT,C = (0.0236 m)2
4
𝐀 𝐓,𝐂 = 𝟎. 𝟎𝟎𝟎𝟒𝟑𝟕𝟒 𝐦𝟐

Tube per Pass

NT
NT,P =
no. of tube pass

82
NT,P =
2
𝐍𝐓,𝐏 = 𝟒𝟏 𝐭𝐮𝐛𝐞𝐬

Total Flow Area

AT,total = NT,PAT,C

AT,total = 41 (0.0004374 m2 )

𝐀 𝐓,𝐭𝐨𝐭𝐚𝐥 = 𝟎. 𝟎𝟏𝟕𝟗 𝐦𝟐

Tube – Side Mass Velocity

Wt
Gt =
At
kg
0.3465 s
Gt =
0.0179 m2

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𝐤𝐠
𝐆𝐭 = 𝟏𝟗. 𝟑𝟔
𝐦𝟐 ∙ 𝐬

Tube – Side Reynolds Number

Gt IDt
Re =
𝜇
kg
(19.36 ) (0.0236 m)
m2 ∙s
Re =
3.413 × 10−4 Pa ∙ s
𝐑𝐞 = 𝟏𝟑𝟑𝟖. 𝟔𝟗

Estimate Jf from the figure below

Figure 9.17.2: Tube Side Friction Factor

𝑗𝑓 = 6.0 × 10−3

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Solving for pressure drop at tube – side

1 jf GT 2 LT NP
∆Pt = ( )
2 7.5 × 1012 IDT ST ϕT

where jf = tube side friction factor

GT = tube side mass velocity in lb/ft2·hr

LT = tube length in ft

NP = number of tube passes

IDT = tube inside diameter in ft

ST = specific gravity of the tube side fluid

ФT = viscosity correction factor

lb 2
−3
1 6.0 × 10 (14274.86 ft2 ∙hr) (16 ft)(2)
∆Pt = ( )
2 7.5 × 1012 (0.0774 ft) (0.89) (1)

∆𝐏𝐭 = 𝟑. 𝟕𝟗 × 𝟏𝟎−𝟓 𝐩𝐬𝐢 ≈ 𝟎. 𝟐𝟔 𝐏𝐚

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EFFECTIVENESS OF HEAT EXCHANGER

For vaporizing liquid

kg kJ
Ch = mh Cp h = (1.0178 ) (1.4047 )
s kg ∙ K

𝐤𝐖
𝐂𝐡 = 𝟏. 𝟒𝟐𝟗𝟕 = 𝐂𝐦𝐚𝐱
𝐊

For steam

kg kJ
Cc = mc Cp = (0.3465 ) (1.996 )
c s kg ∙ K

𝐤𝐖
𝐂𝐜 = 𝟎. 𝟔𝟗𝟏𝟔 = 𝐂𝐦𝐢𝐧
𝐊

Capacity Ratio

Cmin
Cr =
Cmax

0.6916
Cr =
1.4297
𝐂𝐫 = 𝟎. 𝟒𝟖𝟑𝟕

Inside depth of the head

0.5
IDS IDS
di = Rc − [(Rc − ) (Rc + ) + 2Rk ]
2 2
where:

Rc = IDs = 0.7824 m

Rk = 0.06Rc = 0.0469 m

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0.5
0.7824 0.7824
di = 0.7824 − [(0.7824 − ) (0.7824 + ) + 2(0.0469)]
2 2

𝐝𝐢 = 𝟎. 𝟎𝟑𝟖𝟖 𝐦

Effective exchanger length

Leff = LT + 2di

Leff = 4.8768 m + 2(0.0388 m)

𝐋𝐞𝐟𝐟 = 𝟒. 𝟗𝟓𝟒𝟒 𝐦

Area effective

Ae = πODt Leff Nt

Ae = π (0.0254)(4.9544)(82)

𝐀 𝐞 = 𝟑𝟐. 𝟒𝟏𝟖𝟐 𝐦𝟐

Calculating for NTU

UO,Calc Ae
NTU =
Cmin
W
1027.50 (32.4192 m2 )
m2 ∙K
NTU = kW 1000 W
0.6916 ( )
K 1 kW

𝐍𝐓𝐔 = 𝟒𝟖. 𝟏𝟔

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Effectiveness

For Exchanger Type: Shell and Tube Heat Exchanger – 1 Shell – 2, 4, … Passes

Figure 9.17.3: Effectiveness – NTU Curve

𝜺 = 𝟕𝟕 %

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MECHANICAL DESIGN
Design pressure:
Take as 10 percent above maximum working pressure

P ′ = 1.1 × 101.325 kPa

𝐏 ′ = 𝟏𝟏𝟏. 𝟒𝟔 𝐤𝐏𝐚

Design temperature:
According to IS: 4503, the temperature used in the design of the heat
exchanger is taken as 10 °C higher than the maximum temperature that any part
of the heat exchanger is likely to attain in course of operation.

T ′ = 184.12 + 10 ℃
𝐓′ = 𝟏𝟗𝟒. 𝟏𝟐 ℃

Table 9.17.5: Mechanical Properties

Shell Tube
Material of Construction Stainless Steel 316 Stainless Steel 316
Allowable Design Stress 121.76 MPa

Reference: page 812 of Chemical Engineering Design by Sinnott

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SHELL DESIGN

Shell Thickness
For a cylindrical shell, the minimum thickness required to resist internal
pressure can be determined from the equation below based on the maximum
allowable stress and corrected for welded joint efficiency.

P ′ IDs
ts = +C
2Jf − P ′

where:
ts = minimum shell thickness required
f = design stress
J = maximum allowable joint efficiency of 0.7
C = corrosion allowance of 2 mm

Calculating for shell thickness:

(0.11146 MPa )(782.4 mm)

ts = + 2 mm
2(0.7)(121.76 MPa) − ( 0.11146 MPa)
𝐭 𝐬 = 𝟐. 𝟓𝟏 𝐦𝐦 ≈ 𝟓 𝐦𝐦

Shell Outside Diameter:

ODs = IDs + 2t s
ODs = 0.7824 m + 2(0.005 m)
𝐎𝐃𝐬 = 𝟎. 𝟕𝟗𝟐𝟒 𝐦

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COVER AND CHANNEL DESIGN

For the shell head design, a torispherical head is selected. According to

IS: 4503, the minimum thickness of the shell cover should be at least equal to the
thickness of the shell.

Crown Radius
R c = Do
𝐑 𝐜 = 𝟎. 𝟕𝟗𝟐𝟒 𝐦

Knuckle Radius
Rk = 0.06R c
R k = 0.06(0.7924 m)
𝐑 𝐤 = 𝟎. 𝟎𝟒𝟕𝟓 𝐦

Stress Concentration

1 Rc
Cs = (3 + √ )
4 Rk

1 0.7924
Cs = (3 + √ )
4 0.0475

𝐂𝐬 = 𝟏. 𝟕𝟕

Torispherical Head Thickness

pRc Cs
th = +C
2fJ + p(Cs − 0.2)
(0.11146 MPa)(792.4 mm)(1.77)
th = + 2 mm
2(121.76 MPa)(0.7) + (0.11146 MPa)(1.77 − 0.2)
𝐭 𝐡 = 𝟐. 𝟗𝟐 𝐦𝐦 ≈ 𝟓 𝐦𝐦

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Channel Cover Thickness

d √C1P ′
tcc = +C
10 f
where:
tcc = thickness of the channel cover in mm
d = diameter of the cover or the outside shell diameter in mm
C1 = factor equal to 0.25 for cover bolted with full faced gaskets
P’ = design pressure in kgf/cm2
f = allowable stress value in kgf/mm2

792.4 √0.25 (1.14 )

tcc = + 2 mm
10 12.42
𝐭 𝐜𝐜 = 𝟓 𝐦𝐦

Tube Sheet Thickness:

FGp P′
tts = √
3 kf

For the stationary tube sheet in floating type:

F=1
Gp = IDS

Mean ligament efficiency:

0.907
k= 1− 2
P
(ODt )
t

0.907
k=1−
0.0508 2
( 0.0254 )

k = 0.77

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Calculating for tube sheet thickness:

(1)(782.4 mm) ( 0.11146 MPa)

tts = √
3 ( 0.77 )(121.76 MPa)

𝐭 𝐭𝐬 = 𝟖. 𝟗𝟗 𝐦𝐦
19 mm is the standard tube sheet thickness for tubes with 1-inch tube OD.

NOZZLE DESIGN

For the nozzle inside diameter:

Dn = 2 in

Nozzle thickness:
P ′ Dn
tn = +C
2Jf − P ′
(0.11146 MPa)(50.8 mm)
tn = + 2 mm
2(0.7)(121.76 MPa) − (0.11146 MPa)
𝐭 𝐧 = 𝟐. 𝟎𝟑 𝐦𝐦

Since the pressure at the entry point of both shell-side and tube-side fluids
is the same, therefore, the same nozzle specification can be used for both.

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