5.10.

Example of Design Problems for Trufin in Boiling Heat

Transfer

5.10.1. Design Example - Kettle Reboiler

Size a kettle reboiler to transfer 43.3(10
6
) Btu/hr to vaporize a hydrocarbon mixture at 170 psia using
steam available at 395F. The critical pressure of this liquid is 434 psia and it has a boiling range of 60F.
The boiling temperature is 330F.

Design the reboiler using 3/4-in. OD tubes on 1.125-in square pitch. We will estimate the latent heat as
144 Btu/Ib
m
and liquid density as 41 lb
m
/ft
3
.

Step 1. Calculate or estimate heating medium, tube wall, and fouling coefficients.

For this example (and in order to compare to a test unit) the steam coefficient is 2000 and the tube wall is
4800. This reboiler was claimed to be clean; hence,

f
w o
o
R
h h
R + + =
1 1


R
o
= 1/2000 + 1/4800 = 0.000708

Step 2. Calculate the mixture correction factor, F
m
from eq. 5.38.

F
m
= exp( 00.015 x 60) = 0.41

Step 3. Calculate B and R
o
B and find q. From eqns. 5.8a, 5.10 and 5.62.

A
*
= 0.00658(434)
.69
= 0.435

F(P)
2
= 1.8( )
17 .
434
170
= 1.535

B = [(0.435)(1.535)]
3.33
= 0.26

Correcting B for the mixture, use fig. 5.29 at BR of 60F,

B = 0.26 x 0.41 = 0.1066

hence

R
o
B = 0. 1066 x 0.000708 = 7.5(10
-5
)

At T=65 Figure 5.33 gives q/B=280,000 hence

q = 0.1066 x 280,000 = 29,848 Btu/hr ft
2

Step 4. Calculate single tube maximum q
1
, eq. 5.5
284


q
1max
= 803(434)(170/434)
.35
(1 170/434)
.9
= 160,488 Btu/hr ft
2

Step 5. Preliminary estimate of bundle size

For a bundle

q
b
= q
1max

b

where

b
= 2.2(D
B
L/A B
s
).

If we approximate

= 2.2

by letting be (for square pitch)

o B
t
p
d L D
B
s
B
d D
p L D
A
L D
t
o B



2
4
4
2
2
=

=

Now let

max 1
2
4
2 . 2
q
q
d D
p
b
o B
t
b
=

ft
d q
q P
D
o b
t
B
118 . 2
) 12 / 75 . 0 )( )( 848 , 29 (
) 488 . 160 ( ) 12 / 125 . 1 )( 4 )( 2 . 2 ( ) 4 )( 2 . 2 (
2
max 1
2
= = =



As the above approximation ignores the additional effect of circulation on the boiling coefficient, D
B
= 2 ft. B

Step 6. Calculate bundle maximum flux, eqn, 5.23

For U-tube on this pitch a total of 180 U-tubes or 360 ends will form a 2 foot diameter.

For one foot of bundle length

0889 . 0
) 12 / 75 (. ) 360 (
) 1 )( 2 (
= = =

s
B
A
L D

b
= 2.2 = (2.2)(0.0889) = .1956

maximum bundle flux

q =
b
q
1max
285


q = 0. 1956 x 160,488 = 31,392 Btu/hr ft
2

Step 7 Calculate the bundle heat transfer

For a 2 ft bundle assume q = 28,600 Btu/hr ft
2
and calculate heat transfer coefficients based on this flux
and the values obtained in steps 3 and 5.

From eqn. 5.8 calculate h
nbl

h
nbl
= (0.435)(1.535)(28,600)
0.7
= 878.3 Btu/hr ft
2
F

Step 8. Calculate natural convection coefficient, eqn 5.7

We have insufficient information to calculate this coefficient but we will assume it is 40 Btu/hr ft
2
F.

Step 9. Calculate bundle coefficient, eqn. 5.22

h
b
= 878.3 x 0.41 x 1.5 + 40 = 580.1 Btu/hr ft
2
F

U = 1/(115 80.1 + 0.000708) = 411.2 Btu/hr ft
2
F

q=UT

q = 411.2 x 65 = 26,730 Btu/hr ft
2
F

The measured coefficient for this reboiler (72) was 440 Btu/hr ft
2
F or 7% higher.

Step 10. Check bundle design.

Step 9 heat flux (26,730) is less than the maximum allowed bundle flux of step 6 (31,392) hence OK.
Since
b
in step 6 is greater than 0. 1 no vapor lanes or larger pitches are required; therefore, bundle is
OK.

Step 11. Size the bundle.

Required length =
1963 . 360 730 , 26
6
10 43

= 22.8 ft

This length checks with the test unit length of 23 ft.

Step 12. Check for entrainment.

Number of vapor nozzles per eqn. 5.64

N
n
=
2 5
23

= 2.3 round up to 3

Vapor per nozzle

286

W
n
=
3 144
000 , 300 , 43

= 100,231 lb
m
/hr

Entrainment limit, eq. 5.63

VL = 2290 X 1.725
5 .
725 . 1 41
5

= 1409 lb
m
/hr ft
3

(Note dynes/cm = [Ib
f
/ft] / 6.86 x 10
-5
)

Therefore the vapor volume/nozzle = 100,231/1409 = 71.1 ft
3
. If the shell is 25 ft long then the cross
section area for vapor above the liquid level is 71.1/8.33 = 8.537 ft
2
. The shell diameter is then
determined from tables of segmental areas; however, for first approximation assume a liquid level at the
center line then

D
s
= (2 x 8.537 x 4/)
0.5
= 4.66 ft

This is a large shell compared to the bundle diameter; therefore, consider the use of entrainment
separation devices.

5.10.2. In-Tube Thermosyphon - Example Problem

Size a vertical thermosyphon vaporizer to transfer 1,483,000 Btu/hr to an organic liquid with the following
properties: boiling point @ 17 psia = 185.5F, = 0.45, latent heat= 154.8 Btu/lb,
l p
c
l
= 0.96 lb/ft. hr,
v

= 0.0208 lb/ft. hr, k = 0.086 Btu/hr ft. F, and densities lb/ft
3
liquid = 44.8, vapor = 0. 18 1,
c
P = 593.9
psia. Heating medium is steam at 217.4F. Use 1-in. 12 BWG carbon steel tubes 8 ft. long. For this
problem assumes no other fouling is present. This example is based on a test by Johnson (73). Boiling
point elevation for 8 ft static head is 9F. The heat source is steam condensing on the outside of the
tubes with a coefficient of 1000.

Step 1.

Calculate R
o

R
w
=
) 891 )(. 30 (
) 1 )( 12 / 109 . 0 (
= 0.00035

R
o
=
1000
1
+ 0.00034 = 0.00135

Step 2

Calculate the maximum limiting flux using eqn. 5.37

q
max
= 16066
( )
35 .
2
8
12 / 782 .

(593.9)
.61
25 .
9 . 593
17

(1 .0286) = 22,548 Btu/hr ft

2

287



288

This is a high flux and would require a 22548 x.00135 = 30.4 temperature drop across the steam tube
wall. As only 217.4 185.5 = 31.9F is available it is obvious the operation is well below the maximum.

Step 3. Determining a boiling flux

Calculate a nucleate boiling flux using Figure 5.33

Here

B = [0.00658(593.9)
.69
(1.8)(17 / 593.9)
.17
]
3.33
= 0.1214 (5.62)

hence

R
o
B = 0.00135 x 0.1214 = 0.00016

For T = 31.9 from the figure we should calculate

q = 44,000 x 0.1214 = 5342 Btu/hr ft
2

This flux represents only the nucleate boiling coefficient and this is a lower limit. To include a two-phase
convective effect assume a 50% increase in the boiling side. Hence, from the above flux and T get U
(167.4), subtract the R
o
(.00135) resistances to get the boiling coefficient (216.4) increase the nucleate
coefficient by the assumed ratio (= 324.6), then recalculate the new overall coefficient (225.7) and heat
flux (7200).

Step 4. Determining the recirculation rate.

Vapor per tube = 8 x 0.2618 x 7200 / 154.8 = 97.4 lb/hr

Now one has to assume the fraction vaporized. We will short cut this trial and error by assuming the
experimental value of 9%. Therefore, the feed rate/tube = 97.4/.09 = 1082 lb/hr.

Step 5. Calculate basic values needed to check pressure drop, circulation rate, and preheat zone.

G
t
= 1082 / ( x (.782)
2
/ [4 x 1441) = 324,404 lb/ft
2
hr

V = 324,404 / (3600 x 44.8) = 2.01 ft/sec

Re = .782 x 324,404 / (12 x .96) = 22,021

From friction factor charts f = 0.0075

Hence in the liquid zone the head loss per foot of tube is by eqn. 5.51

H = (4 x .0075 x 12 / .782) x 2.01
2
/ 64.4 = 0.029 ft/ft

Using an average vaporization of 9/2 = 4.5% we can calculate X
tt
, (eqn. 5.29)

398 . 1
0208 . 0
96 . 0
8 . 44
181 . 0
045 . 0
045 . 1
X
11 . 0 57 . 0
tt
=

=
289


Next get (eqn. 5.55)
2
tt

l

2
tt

l
= 1 + 20 / 1.398 + (1 / 1.398)
2
= 15.82

The two-phase AH based on average liquid content of 0.955 is

H = 15.82 x .029 (0.955)
2
= 0.42 ft/ft

The two-phase density due to slip is (eqn. 5.48 and 5.49)

R
v
= 82 . 15 / 1 1 = 0. 749

tp
= (.749 x .181) + [(1 .749) x 44.8] = 11.38 lb/ft
3

The boiling zone static head loss is

H = 11.38/44.8 = 0.254 ft/ft

Using eqn. 5.50 for P
m

G
t
= 324,404/3600 = 90.11 lb/ft
2
sec

( ) ( ) ( )
ft 751 . 0 lb/ft 64 . 33
749 . 181 .
09 .
251 . 8 . 44
09 . 1
2 . 32
11 . 90
P
2
2 2 2
m
= =

=

Heat transfer in preheat zone; eqn. 5.25

( )

=
782 .
782 . 12 086 .
086 .
96 . 45 .
22021 023 . 0 h
3 / 1
8 .
= 121.1 Btu/hr ft
2
F on outside area

Therefore

U = 1 / (1 / 121.1 + .00135) = 104. 1 Btu/hr ft
2
F

Using a T = 31F the temperature rise in preheat zone is

45 . 1012
31 2618 . 1 . 104

= 1.86 F/ft

Step 6. Estimating preheat and boiling lengths.

Assume preheat zone = 3 ft

Friction loss in preheat zone = 3 x .029 = 0.087 ft

290

Effective submergence at this point = total head (8) friction loss (.087) preheat zone (3) = 4.91 ft liquid

which is equivalent to a boiling point elevation of

(4.91/8) x 9 = 5.53 F

Length required for this temperature rise is 5.53/1.74 = 3.18 ft. Close enough.

Check on circulation and pressure drops

Available head = 8 ft liquid neglecting liquid line losses

Overall momentum loss = .751 ft

Friction losses

boiling zone 5 x .42 2.100
preheat zone .087

Static heads

boiling zone 5 x .254 1.270
preheat zone 3.000
7.21ft

Considering there is some losses in the liquid recirculating line the above agreement is close enough.

Step 7. Calculate heat transfer in boiling zone

From eqn. 5.8

h
nbl
= 0.00658(593.9)
.69
(7200)
.7
[1.8(17 / 593.9)
.17

= 266.2 x .782 / 1 = 208. 1 Btu/hr ft
2
F on OD area

From eqn. 5.28

226 . 2 213 . 0
398 . 1
1
35 . 2 F
73 . 0
ch
=

+ =

Determines from eqn. 5.31

Re
tp
= 22,021 x 2.226
1.25
= 59,874

s = 1 / {1 + [2.53(10
-6
) x (59,874)
1.17
]} = 0.504

From eqn. 5.27

h
cb
= 121.1 x 2.226 = 269.6 Btu/hr ft
2
F on an outside area basis

From eqn. 5.26
291


h
b
= (.504)(208.1) + 268.6 = 374.5

Adding the steam and wall resistance to obtain U for the boiling section

U = 1 / [(1 / 374.5) + 0.00135] = 249

Step 8. Calculate average coefficient for tube and area

An average coefficient for the preheat and boiling zone is

U
av
= (3 x 104.1 + 5 x 249.0)/8 = 194.5 Btu/hr ft
2
F

Required area = 1,483,000/194.5 x 31.9 = 239 ft
2
vs. 201 ft
2
in the test vaporizer.

Thus, this simplified calculation came within 19% of predicting the test results which is acceptable. In
design case after calculating the required area (239 ft
2
) a safety factor should be added to allow for the
error spread in all the involved equations. Also fouling should be considered and should be included in
the term R
o
term. We did not include fouling in this example since we were trying to compare the
calculation method with data obtained in a clean vaporizer.

5.10.3. Boiling Outside Trufin Tubes - Example Problem

To illustrate the value of and methods of calculation for Trufin tubes in boiling, a comparison of the
performance of a plain surface and finned surface tube will be made. The plain tube is 0.75 and o.d., 18
B.W.G. wall and 90/10 Cu-Ni. The Trufin is Wolverine Cat. No. 65-265049-53. This tube has a surface
area of 0.640 ft
2
/ft with an A
o
/A
i
ratio of 4.61, a fin height of 0.057 and width of 0.012 inches. There are 26
fins per inch. The tubes are heated with steam having a coefficient of 2000. A pure hydrocarbon having a
critical pressure of 489 psia will be boiled at 100 psia with an overall temperature difference of 10'F. The
bundle factor, F
b
, is 1.5 and the surface factor, F
s
, for this temperature is 1.0 for the plain tube and 1.5 for
the Trufin tube.

Evaluation of the Plain Tube Performance

1. Calculate R
o
.
where R
o
= wall resistance + tube-side resistance

( )( )
( )
000162 .
652 . 29
75 . 12 / 049 .
R
wall
= =

h
wall
= 6174

( )
00074 .
652 . 2000
75 .
6174
1
R

= + =


2. Calculate the single tube boiling coefficient using eq. 5.32

h
nbl
= (5.43)(10
-8
)(489)
2.3
[1.8(100 / 489)
0.17
]
3.33
T
2.3
= 0.24 T
2.3

292

assuming the maximum possible T of 10F

h
nbl
= (0.24)(10)
2.3
= 47.9

3. Calculate the bundle boiling coefficient, overall U, and the heat flux then check the assumed T.
Assume a natural convection coefficient, h
nv
= 40, and using the bundle factor of 1.5 in eq. 5.22.

h
b
= (47.9)(1.5) + 40 = 111. 8

U
0
= 1 / (1 / 111.8 + .00074) = 103.2

the available boiling T is then

T
b
= 10 (10)(.00074)(103.2) = 9.2F

This is not close enough to the assumed value of 10 so repeat steps 2 and 3.

2 Assume Tb = 9.2

h
nbI
= (0.24)(9.2)
2.33
= 42.25


3' h
b
= (42.25)(1.5) + 40 = 103.4

U
0
= 1 / [(1 / 103.4) + .00074] = 96

4. Calculate available boiling T.

T
b
= 10 (10)(.00074)(96) = 9.29F

q = UT = (96)(10) = 960 Btu/hr ft
2
(outside area)

Evaluation of the Trufin Tube Performance

1. Calculate R
o

The inside area basis will be used

( )( )
( )( )
0.00013
579 . 29
53 . 12 / 049 .
R
wall
= =

R
o
(wall + steam resistance) = 0.00013 + 1/2000 = 0.00063

2. Calculate the boiling coefficient using eq. 5.32 with a surface factor of 1.5

h
nbl
= (1.5)(0.24) T
2.33
= 0.36 T
2.33

assume a boiling T of 8F

h
nbl
= (0.36)(8)
2.33
= 45.8

293

using eq. 5.22 with F
b
= 1.5 and h
c
=30

h
b
= (45.8)(1.5) + 30 = 98.7

3. Adjust for fin efficiency.
Figure 5.37 is used. This was derived for the case boiling liquids on fins where h = bT
2
.

using the assumed T of 8 and h
b
= 98.7

b = 98.7 / (8)
2
= 1.542

the abscissa for fig 5.37 is then

( )( )
( )( )
320 . 8
12 / 018 . 0 29
542 . 1 2
12
057 .
=


an efficiency of 87% is read and

h
b
= (98.7)(.87) = 85.9 on an outside area basis

On an inside area basis;

h
b
(85.9)(4.61) = 396

U = 1/ (1/396 + .00063) = 317

q = UT = (317)(10) = 3170 Btu/hr ft
2
(inside basis)

Check assumed value of boiling T of 8F.

T (wall + steam) = (0.00063)(3170) = 2.0

T
boiling
= 10 2 = 8F

This checks with assumed value. If not then, repeat steps 2 and 3 with a new value.

Comparison of Performance

Since the area per foot of the two tubes are different, comparison will be made on a per foot of length
basis.

1. For plain tube

q/foot = (960)(.1963) = 188.5 Btu/hr-foot length

2. For Trufin

q/foot =(3170)(.640/4.61) = 440.1 Btu/hr-foot length

Therefore the performance ratio of Trufin to plain is: 440.1 / 188.5 = 2.3
294


Table 5.1

Simple dimensional equation for nucleate pooling boiling heat transfer (after Borishanski)

Liquid Pressure
range atm.
A
*
from exp
A
*
Eqn 5.9
Critical
pressure atm.
No. in
Fig 5.18

Water
Water
Water
Water
Water
Water

Pentane
Heptane (80%)
n-heptane
Benzene
Benzene
Diphenyl

Methanol
Ethanol
Ethanol
Butanol

R11
R12
R12
R13
R13B1
R22
R113
R115

RC318
Methylene
chloride
Ammonia
Methane

1 70
1 196
0.09 1
1 72.5
1 170
1 5.25

1 28.6
0.45 14.8
0.45 14.8
1 44.4
0.9 20.7
0.9 8

0.08 1.39
1 20.7
1 59
0.17 1.38

1 3
1 4.9
6 40.5
2.8 10.5
17 39
0.4 2.15
1 3
8 31

3.6 27

1 4.5
1 8
1 42

1.61
1.58
2.28
1.76
1.75
2.26

.429
.464
.642
.417
.520
.441

(.272)
.720
1.019
(.173)

.768 [.681]
.956
1.37 [1.01]
.705
1.744 [.976]
[.941]
.488
1.49 [.934]

1.23 [.984]

(.752)
1.54
1.06

1.66
1.66
1.66
1.66
1.66
1.66

.449
.381
.381
.588
.583
.425

.815
.701
.701
.547

.539
.516
.516
.496
.508
.586
.453
.425

.394

.677
1.039
.563

216.9
216.9
216.9
216.9
216.9
216.9

32.8
25.9
25.9
48.1
48.1
30.4

78.0
62.6
62.6
43.8

42.9
40.3
40.3
37.9
39.1
48.4
33.4
30.6

27.3

59.6
110.8
45.6

1
2
3
4
5
6

7
8
9
11
--
--

13
10
12
14

--
15
--
--
--
--
--
--

--

--
--
--


Values shown in round brackets ( ) are uncertain.

Values shown in brackets [ ] relate to the use of Equations 5.11 for F(P).
295

NOMENCLATURE

A
*
Constant defined in equation 5.9. dimensionless

A
s
Surface area. ft
2

B Constant defined in equation 5.62. dimensionless

BR Boiling range, dew point-bubble point. F

c
p
Specific heat, for liquid and c
l p
c
pv
, for vapor
Btu/lb
m
F

d Tube diameter, d
o
for outside and d
i
for inside. ft.

D
p
Diameter of tube bundle. ft.

D
s
Shell diameter. ft.

F
b
Tube bundle correction factor. dimensionless

F
cb
Chen Factor. dimensionless

F
m
Mixture correction factor. dimensionless

f Friction factor. dimensionless

G Mass velocity. Ib
m
/ft
2
hr

G
t
Mass velocity based on total flow. Ib
m
/ft
2
hr

G
tmax
Total mass velocity based on minimum cross flow area. Ib
m
/ft
2
hr

G
mm
Mass velocity at beginning of mist flow. Ib
m
/ft
2
hr

g Gravitational constant. ft/hr
2

g
c
Conversion constant. Ib
m
ft/lb
f
hr
2

H Height. ft

H
l
Height of liquid zone. ft

H Head loss per foot of tube. ft/ft

h Film heat transfer coefficient; h
b
= boiling, h
c
= convective, h
f
film, =
liquid, h
l
h
r
= radiation, h
cb
= convective boiling, h
ft
= film total, h
nb
= nucleate
boiling, h
nbl
= single tube nucleate boiling.
Btu/hr ft
2
F

296

K Constant in equation 5.23. dimensionless

k Thermal conductivity. Btu/hr ft
2
F

L Length. ft

L
c
Minimum unstable wave length. ft

m Exponent. dimensionless

N Number of tube rows. dimensionless

N
n
Number of vapor nozzles. dimensionless

Nu Nusselt number. dimensionless

P Pressure. lb
f
/ft
2

c
P Critical pressure. lb
f
/in
2

P
r
Reduced pressure = P/P
C
. dimensionless

Pr Prandtl number. dimensionless

P
sat
Saturation pressure at plane interface. lb
f
/ft
2

p
t
Transverse tube pitch. ft

P Pressure drop; P
T
= total, P
s
=static, P
m
= momcntum, P
f
= friction. lb
f
/ft
2

q Heat flux; q
max
= maximum, q
mf
= minimum film, q
nc
= natural convection, q
cr

= critical.
Btu/hr ft
2

Re Reynolds number. dimensionless

R
l
, R
v
Volume fraction of liquid, vapor. dimensionless

R
o
Sum of thermal resistances other than the boiling resistance. hr ft
2
F/Btu

r
c
Radius of bubble. ft

s Chen suppression factor.

T Temperature; T
s
= steam, T
w
= wall, T
sat
= saturation. F

T Temperature difference; T
b
= tube wall-saturation, T
c
= critical, T
O
= tube
waIl-bulk liquid, T
min
= difference at minimum film boiling coefficient.
F

V Velocity. ft/hr

297

V

Velocity approaching tube. ft/hr

VL Vapor load. lb
m
/hr ft
3

X
tt
Martinelli parameter, equation 5.29.

x Weight fraction of vapor.

y Mole fraction low boiling component in liquid.

GREEK

Coefficient of thermal expansion. 1/R

Flow rate per unit length. Ib
m
/hr ft

Latent heat;
e
, = effective latent heats see eqn. 5.17, 5.19. Btu/Ib
m


Dynamic viscosity;
l
= liquid,
v
= vapor
lb./ft hr


Density;
l
= liquid,
v
= vapor,
b
= bulk average,
tp
= two-phase.


Surface tension. lb
f
/ft

v Specific volume change liquid-vapor. ft
3
/lb
m

b
Bundle maximum flux correction factor. dimensionless

2
vtt
2
tt
,
l

Martinelli two phase factors. dimensionless

298

BIBLIOGRAPHY

1. Zuber, N., Hydrodynamic Aspects of Boiling Heat Transfer, doctoral dissertation, Univ. of California at
Los Angeles, (1959).

2. Happel, O. and K. Stephan, Heat transfer from nucleate to the beginning of film boiling in binary
mixtures. Paper B7.8 Heat Transfer 1974. Proc. 5th Int. Heat Transfer Conf., Vol. IV, pp. 340-344.

3. Drew, T. B. and A.C. Mueller, Boiling, Trans. Am. Inst. Chem. Engrs. 33, (1937)

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