Altitude Training Institute

REBOILER
WHAT IS A REBOILER?

 A Reboiler is a heat exchanger whose primary purpose is to vaporize the bottom of a

distillation, absorption or stripping column and return the vapor to the column to drive the
separation.
 The driving force, to promote flow through the reboiler, is the density difference between
the fluid in reboiler feed line and froth-filled reboiler return line.
 The selection of proper type of reboiler for any specific service is a design challenge.
 Reboilers are normally shell and tube heat exchanger that heat up the column fluid
utilizing the heat transfer from the steam.
 Special services may use other specialized designs including stab-ins, plate fins, spiral
plate, kettle-type and others.
HOW REBOILERS WORK?
Theory of working of reboiler can be illustrated by
airlift pump.

Where,
HRW= height of water above base (ft)
DRW= S.G. of fluid in riser
HRT= height of aerated water in riser tube (ft)
DRT= S.G. of aerated water in riser tube
ΔP= Differential pressure between A and B (psi)

Figure: Air lift Pump

ΔP of given example is:

Here, the developed ΔP of 4.71 psig is consumed in overcoming

frictional losses, due to flow in inlet line, reboiler, outlet line and
nozzles.
• If these frictional losses are less than 4.71 psig, the inlet line
does not run liquid full.
• If they are more than 4.71 psig, the reboiler draw-off pan
overflows, and the flow to the reboiler is reduced until the
frictional losses drop to the available force.
Figure: Column Example
 So, when comparing with a natural circulation reboiler, the aerated liquid
is a froth or foam produced by vaporization of reboiler feed.
 Without a source of heat, there can be no vaporization.
 And without vaporization, there will be no circulation.
 So we can say that the source of energy that drives the circulation in a
reboiler is the heating medium to the reboiler.
FACTORS INFLUENCING REBOILER SELECTION

 Many factors influence reboiler type selection.

 In the end, all these factors reduce to economics.
 Every plant will weight the trade-off between these factors differently.
 Major factors include:
• Plot space available
• Total duty required
• The fraction of tower liquid traffic vaporized
• Fouling tendency
• Temperature approach available
• Temperature approach required
REBOILER CONFIGURATIONS

 The major configuration selections include:

 Internal type (stab-in)
 Kettle type
 Vertical Thermosyphon
 Horizontal Thermosyphon
 Forced flow
INTERNAL TYPE REBOILER
 Features:
• Internal reboilers, also known as Stab-in, employ a tube
bundle which is inserted directly in the column.
• This is the cheapest construction since there is no shell or
shell side piping.
• Only small heat transfer area can be incorporated because
both the number of tubes and tube length are limited by the
column diameter.
• The maximum diameter of the opening to accommodate the
internal reboiler is usually one-half the column diameter.
• When determining the heat transfer area, part of the straight
length in the column nozzle is to be ignored since it is not
very effective.
• Usually U-tubes are used, but if the heating medium is dirty,
straight tubes and a floating-head construction (TEMA type
T) should be employed.
 Advantages
• The cost is considerably lower due to the absence of shell and shell-side piping.
• Remaining same as kettle type.
 Disadvantages
• Surface that can be incorporated in distillation column is very limited.
• They are rather very rare, the most common applications being in petrochemical plant
units such as ethylene glycol, benzene, butadiene, linear alkyl benzene, etc.
• For any maintenance work even on the distillation column, the reboiler has to be removed.
• Boiling takes place in the pool of liquid at the bottom of the tower, the heating fluid being
inside the bundle of tubes. Since the boiling liquid forms froth, which may vary in density,
controlling bottom level can be difficult. This fact makes this type of reboiler less
attractive, particularly in foaming and vacuum services.
• The designer has to make sure there is enough sump height to give good level control and
pump NPSH without exposing tubes
• Remaining same as kettle type.
 KETTLE TYPE REBOILERS
 Features:
• A kettle reboiler is so called because of its appearance due to
enlarged shell. This is provided for the disengagement of vapor.
• The boiling liquid enters at the bottom of the shell from the column
sump and partially vaporizes the fluid.
• The domed top section of the reboiler separates the vapor and the
liquid.
• The vapor leaves from the top of the shell and back to the tower
riser.
• Liquid level is maintained a little above the top of the tube bundle by
means of a baffle/ vertical weir located beyond the bundle. The
liquid overflows the weir, and this liquid is the bottoms product.
• Kettles can fully vaporize the column bottoms, thereby representing
an additional theoretical stage for the distillation process.
 Features
• A kettle reboiler maybe of fixed-tubesheet, U-tube, or floating-head construction.
• If heating medium is clean, a U-tube kettle is preferred due to lower cost and capability to permit
differential expansion between the shell and tube bundle.
• If heating medium Is dirty, fixed tubesheet construction for clean boiling fluid and floating-head
construction for dirty boiling fluid.
• Liquid level in shell is usually controlled by level controller or simply held by the weir.
• The size (diameter) of the reboiler shell depends on:
o The vapor and liquid flowrates
o Physical properties of fluid
o Exchanger geometry

• Distance from the centerline of the uppermost tube in a horizontal bundle to the top of the shell
should not be less than 40% of the kettle shell diameter Ds / Db ≥1.4
• The freeboard between the liquid level and shell should be at least H s=300 mm.
• For practical reasons (better separations of entrainment) consider that liquid level in reboiler is such
that one or two upper rows of tubes does not lie in liquid level. In these cases the height of the vapor
space should be at least Hs=300 mm.
 Advantages
• Use of kettle type incorporates an additional stage for distillation for cases where
number of stages is not very high
• Very high heat fluxes can be achieved
• Operate efficiently even at low ΔT
• Can fully vaporize column bottom stream
• No external two-phase piping needed from the reboiler to the column. So sizing and
determination of pressure drop of two-phase line can be avoided.
• At very high ΔT, high heat fluxes can be sustained by locating tubes at a higher pitch,
thereby providing vapor release lanes.
• Operation is better than Thermosyphons for the following:
o When there are fluctuations in operating conditions
o At very low pressure
o At high pressure (near critical)
 Disadvantages
• Relatively costly due to enlarged shell. When floating-head construction (TEMA
AKT) is required, because of dirty heating medium, the cost is even higher.
• Since very less turbulence in the reboiler, heavy materials accumulates continuously
on the tubes. Kettle type reboiler have a tendency to foul readily, even with fairly high
draw-off rate. High residence time may even result in degradation of boiling liquid.
Hence, fouling services are avoided.
THERMOSYPHON REBOILERS

 Vertical Thermosyphon Reboiler and Horizontal Thermosyphon Reboiler is divided

into two configurations: Once-through and Re-circulating type.
 The key difference between the two is that the vapor generated in the reboiler is not
allowed to mix with the column bottom (product) in the once-through type, whereas
it can do so in the recirculating type.
 Once-Through Thermosyphon
 In this reboiler, all the liquid from the bottom tray flows to the reboiler.
 None of the liquid from the bottom of the column flows to the reboiler.
 All the bottoms product comes from the liquid portion of the reboiler effluent.
 None of the liquid from the bottom tray flows to the bottom of the column.
 The reboiler outlet temperature is same as the column bottoms temperature.
 The column can be equipped with a vertical baffle. The reboiler return liquid goes only to the hot
side of the column bottoms.
 Re-Circulating Thermosyphon
 In this reboiler, the reboiler outlet temperature is always higher than column bottoms temperature
 Some of the liquid from the reboiler outlet will always circulate back into the reboiler feed.
 Some of the liquid from the bottoms tray ends up as bottoms product.
 Column bottoms product temperature and composition is the same as the temperature and
composition of the feed to the reboiler.
Once-through Reboiler Design
 Natural circulation is maintained if ΔP(driving force)≤ Δp (frictional losses)
 Driving force for circulation:
P1-P2= ΔP= (1/144) (ρ1H1- ρ2H2)
Where,
Pi- pressure (psi)
ρi- density (lb/ft3)
Hi-head (ft)
Introducing a safety factor of 2,
P1-P2= ΔP= (1/288) (ρ1H1- ρ2H2)
 Friction Losses:
Δp = Δpd + Δpe + Δpr
Δpe – Reboiler ΔP (psi) – usually 0.25- 0.5 psi
Δpd – Downcomer ΔP (psi)
Δpr – Riser ΔP (psi)
Δpd + Δpr – 0.1 -1 psi/ 100 ft by design
 Horizontal Reboilers:
The minimum downcomer nozzle elevation above
a horizontal reboiler centerline is:

Where, ΔH= H1- H2

Kern recommends a head difference of 3ft.

The density of fluid in riser is

Where, Wi – Mass flow (lb/hr)

 Vertical Reboiler (top draw-off):
Here,
ΔP= (1/288) (ρ1H1”- ρ2H2 - ρ3H4 )

Following Kern’s recommendation:

H1”= 3+ H2 + H4

The minimum draw-off nozzle elevation

Circulating Reboiler Design
 Draw-offs is from bottom
 Horizontal Reboiler
ΔP= (1/288) (ρ1H1- ρ2H2)

As before, the driving force must be at least

equal to the frictional losses.
ΔP ≤ Δp = Δpd + Δpe + Δpr

Here, H2= H1 + H3

Thus, the minimum downcomer nozzle

elevation is limited to:
 Vertical Reboiler (bottom draw-off)
Conservative estimate of exchanger fluid density:
ρ3= (ρ1 + ρ2) /2
Thus,
ΔP= (1/288) (ρ1H1’- ρ2H2 - ρ3H4 )
ΔP ≤ Δp = Δpd + Δpe + Δpr

However, since, H1’ + H3 = H2 + H4

The vertical reboiler should be flooded. The maximum elevation of the top
tubesheet should not be higher than the minimum liquid level in the column,
thus at minimum,
H1’ = H4 and H3= H2
ΔP= (1/288) (H1’ (ρ1- ρ3) - ρ2H2)
VERTICAL THERMOSYPHON REBOILER

 Features
• In a vertical thermosyphon reboiler, the column bottoms
stream enters at the bottom, rises, and partially vaporizes as it
flows up the tubes, and the two-phase mixture discharges into
the column.
• The driving force is the density difference between the
liquid in the column and the two-phase fluid in the tubes.
• They are invariably of fixed-tubesheet and single shellpass
(TEMA E) construction, having boiling on the tubeside.
• Boiling inside vertical tubes is favourable than outside
because of baffles.
• Since, boiling is inside tubes, it is essential to have a single
tube pass because the flow of a two-phase mixture against
gravity is likely to result in jeopardy.
• Fixed-tubesheet construction is normally employed.
 Features
• Because of fixed tubesheet construction, heating medium should be clean. As long as heating medium is
steam or hot oil, there is no problem.
• If the heating medium is dirty,
o Implement chemical cleaning program
o Use floating head construction
o Have boiling outside of tubes.
• Countercurrent flow is employed for condensing heating medium and sensible heating medium with wide
boiling-range mixtures.
• Co-current flow is employed for sensible heating medium with narrow boiling-range mixtures. This
provides higher ΔT and more nucleate boiling at the bottom of the tubes, thereby improving circulation.
• The difference in elevation between the liquid level in the column and the lower tubesheet represents the
driving head. The liquid level in the column is usually maintained at the level of the top tubesheet since
this normally represents the optimum balance between driving force and circuit resistance.
• In the case of reboilers operating at vacuum, however, it is common to elevate the reboiler so that the
driving head is 60 80% of the tube length.
• Higher circulation rate (and lower fraction vaporized) case will result in a higher pressure drop, and the
lower circulation rate (and higher fraction vaporized) case will result in a lower pressure drop.
 Features
• Due to static head of the liquid in the column, the liquid entering a vertical thermosyphon has a
higher boiling point than that in the distillation column. Consequently, there will be a region of
subcooled liquid heating before the liquid attains its boiling point.
• At vacuum, there will be substantial subcooled liquid heating zone. In order to minimize this, the
reboiler is elevated so that the driving head is reduced. The lower driving head will result in
lower elevation in boiling point and, thereby, a smaller subcooled liquid zone.
• Since, the pressure drop in the outlet piping of the reboiler is critical, the length of the outlet
piping and the number of bends should always be minimized. A valve should never be placed in
the outlet piping. However, a valve placed in the inlet liquid line is useful to stabilize fluctuations.
Lower the operating pressure and lower the vapor molecular weight, larger will be the outlet
piping diameter.
• Maximum weight fraction vaporized recommended as a rule of thumb is 30-35%. But, in case
of vacuum, the same can be relaxed to 50%, as otherwise, the subcooled liquid heating zone may
impose a severe penalty. Minimum weight fraction vaporized recommended is 10% because
lower vaporization may not produce good pumping.
 Advantages
• Due to fixed-tubesheet construction, the cost is the lowest.
• Fouling is less pronounced due to high circulation. Easier to clean the fouling as it is on the
tubeside. But, cleaning is not as convenient as for horizontal tubes unless the reboiler is dismantled
and placed horizontally.
• LMTD is highest, due to pure countercurrent and is straightforward to determine.
 Disadvantages
• Maximum heat flux that can be supported is lower than for shell side boiling, due to the reduced
boiling side flow area.
• Operation of these reboilers is sensitive to changes in operating conditions.
• Two-phase flow in the exit piping requires careful analysis and design. If exit piping is too small,
choke flow may result, thereby leading to instability. But, if the outlet piping is too large, phase
separation might occur. So, if it is wide boiling range mixture, there are chances of accumulation of
heavy components in the reboiler which will aggravate the fouling and increase boiling temperature,
decreasing the LMTD.
• Heat transfer area is likely to be much higher for low-pressure services due to elevation of boiling
point and consequent subcooled liquid heating.
 HORIZONTAL THERMOSYPHON REBOILER
 Features
• In a horizontal thermosyphon reboiler, vaporization is on the
shellside while the heating medium flows inside the tubes.
• Circulation is provided by the difference in elevation between the
column and the bottom of the shell. Since, there are no pumps in
thermosyphon reboiler circuits, the pressure drop has to be
restricted to a bare minimum.
• A split flow shell (TEMA G) or a double split-flow shell (TEMA
H) are usually employed. They are preferred as there are no cross
baffles.
• Longitudinal baffle also serve to minimize phase separation and
promote mixing of light and heavy components as vaporization
proceeds.
• When higher velocity is desired, E and J shells are used. Such a
requirement will arise when vaporizing a wide-boiling mixture. For
very low-pressure applications, it may become necessary to
employ pure crossflow in a TEMA X shell.
 Features
• U-tubes may be employed for clean heating mediums (TEMA BHU). For dirty medium, straight tubes are
employed, fixed tubesheet construction for clean boiling fluid and floating-head construction for dirty
boiling fluid.
• Vaporization is usually limited to 20-30% for best operation (and never more than 50%) in order to
avoid penalties of low heat transfer coefficient, excessive fouling due to high temperature and reductio in
LMTD.
 Advantages
• High circulation rates impart a high convective heat transfer component and, thereby, yield a high boiling
heat transfer coefficient.
• LMTD is higher as the liquid is partially vaporized (20-30%), the outlet temperature of vaporizing stream
is even lower.
• Compared to vertical reboiler, the increase in boiling point is less due to the much lower difference in
elevation between column and the reboiler. This can become significant in low ΔT applications,
especially at low operating pressures.
• Can handle dirty streams better than kettle reboilers because of higher velocity and lower exit vapor
fraction hence, reducing fouling.
• Compared to Vertical reboilers, horizontal reboiler is less sensitive.
 Disadvantages
• Whatever fouling occurs is on the shellside, which is more difficult to clean than
fouling inside tubes. Vertical reboilers are superior for vaporizing dirty streams.
• Besides the usual floating-head construction, multiple nozzles and manifold piping
increase cost.
• Two-phase flow in exit piping requires careful analysis and design. If exit piping is
too small, choke flow may result, thereby leading to instability. But, if the outlet
piping is too large, phase separation might occur. So, if it is wide boiling range
mixture, there are chances of accumulation of heavy components in the reboiler which
will aggravate the fouling and increase boiling temperature, decreasing the LMTD.
FORCED CIRCULATION REBOILER

 Features
• A forced circulation reboiler uses a pump to
circulate the column bottoms liquid through the
reboiler and hot liquid flows inside column.
• Here, the fluid is fouling liquids having a high
viscosity (so, the heat transfer coefficient could be
very low) or wide-boiling mixture operating at a
low pressure(so, reduction of LMTD due to head of
liquid could be dramatic).
• Then liquid is sensibly heated and then flashed
across a valve just before entry into distillation
column.
• The column bottom can either be on shellside ort
tubeside.
 Advantages
• Careful calculation of circuit ΔP is
not critical
• Can overcome large ΔPs in the
reboiler circuit.
• Causes minimal fouling and control
the circulation of liquid during
distillation.
 Disadvantages
• Additional cost due to amount of
power used during distillation
• Additional cost of pump and piping
and high operating cost.
 DISFAVORED
FACTOR FAVORED TYPE
TYPE

Low bottoms product fraction compared to boil-up Recirculating Kettle Once-through

High bottoms product fraction compared to boil-up Once-through Recirculating

Low relative volatility systems Recirculating

High relative volatility systems Once-through Recirculating

Large exchanger size or high duty requirements Horizontal Vertical

Small exchangers Vertical Stab-In

Leaks hazardous or difficult to deal with or Exotic

Stab-In
Materials
 DISFAVORED
FACTOR FAVORED TYPE
TYPE

Spiral –plate
Tight temperature approach Shell & Tube
Plate-fin

Kettle
Solids present Plate-fin
Spiral –plate

Kettle
Thermally unstable products Recirculating (no baffle)
Once-through
Tight plot plan Vertical Horizontal

Ample plot plan Horizontal

High temperatures Fired Heaters

Forced Circulation
High heat fluxes Natural Circulation
Flooded bundles
THANK YOU !