Vaporizer Design
Vaporizer Design
Vaporizer Design
Vaporizers are heat exchangers which are specially designed to supply latent
heat of vaporization to the fluid. In some cases it can also preheat the fluid
then this section of vaporizers will be called upon preheating zone and the
other section in which latent heat is supplied; is known as vaporization zone
but he whole assembly will be called upon a vaporizer.
Vaporizers are called upon to fulfill the multitude of latent-heat
services which are not a part of evaporative or distillation process.
There are two principal types of tubular vaporizing equipment used in
industry: Boilers and Vaporizing Exchangers. Boilers are directly fired
tubular apparatus, which primarily convert fuel energy into latent heat of
vaporization. Vaporizing Exchangers are unfired and convert latent or
sensible heat of one fluid into the latent heat of vaporization of another. If a
vaporizing exchanger is used for the evaporation of water or an aqueous
solution, it is now fairly conventional to call it an Evaporator, if used to
supply the heat requirements at the bottom of a distilling column, whether
the vapor formed be stream or not, it is a Reboiler ; when not used for the
formation of steam and not a part of a distillation process, a vaporizing
exchanger is simply called a vaporizer.So any unfired exchanger in which
one fluid undergoes vaporization and which is not a part of an evaporation or
distillation process is a vaporizer.
The commonest type of vaporizer is the ordinary horizontal 1-2
exchanger or one of its modifications, and vaporization may occur in the
shell or in the tubes. If steam is the heating medium, the corrosive action of
air in the hot condensate usually makes it advantageous to carry out the
vaporization in the shell.
In the case of vaporizer, however, operation is often at high pressure,
and it is usually too expensive to provide disengagement space in the shell
m, since the inclusion of disengagement space at high pressures
correspondingly increases the shell thickness. For this reason vaporizers are
not usually designed for internal disengagement. Instead some external
means. Such as an inexpensive welded drum, is connected to the vaporizer
where in the entrained liquid is separated from the vapor.
When a 1-2 exchanger is used as a vaporizer, it is filled with tubes and
cannot be adapted for blowdown, since all the feed to a vaporizer is usually
of value and a rejection as blowdown is prohibitive. If the feed were
completely vaporized in the vaporizer, it would emerge as a vapor and any
dirt which was originally present would be left behind on the tube surface
over which total vaporization of occurred, fouling it rapidly, If the 1-2
exchanger (vaporization) were over-designed, that is, if it contained too
much surface, disengagement would have to occur on the tubes and due to
the excess surface the vapor would superheat above its saturation
temperature.
The feed to a vaporizer should not be vaporized completely. The value
of this rule is apparent. If less that 100 percent to the feed is vaporized in 1-2
exchangers, the residual liquid can be counted on to prevent the
accumulation of dirt directly on the surface of the heating element. A
maximum of about 80 percent vaporization appears to provide favorable
Types of Vaporizers
Vertical Vaporizer
It is widely used for chlorine, ammonia, propane,
methanol, sulfur dioxide, etc. Sizes range from 50, 000 to
15, 000, 000 Btu/h (12,500 to 3, 75, 000 Kcal/h) Very
compact, High productivity, easily combined with built in
super heater with common control. Many heating media can
be used, including steam, hot water, and heat transfer fluids
such as dowthrerm,, therminol, etc, electric heated
vaporizers also available, Small footprint.
Vertical bayonet
Cryogenic Vaporizer
For boiling very low temperatures [-3270F (-2000C)]. Flare drums
duty, to meet a few second startup emergencies. Heating medium in shell
and boiling fluids inside the tubes. Must be able to copy with thermal
expansion and adjustments in a few seconds with out damaging stresses.
Also must avoid metallurgical problems including fatigue for duties at high
pressure such as ethylene. Etc. Avoid freeze-up problem s and heat up the
fluid to required exit temperatures with no accompanying freeze up
problems. Also, used to heat subzero liquids being distributed on service
grids to multiple users and cold fluids from ships or rail cars needing heat up
to avoid fracture of steel or other non ductile piping systems of user Sizes
can bye up to 12ft (3.6m) in diameter and 40 ft (12m) long. Shells often steel
with tubes of stainless steels 604 / 613.
DESIGNING STEPS
1.
Q = Q 1 + Q2
Where 1&2 denote preheating and vaporization zones respectively
Q1= mCp T
Q2=m
2.
t, weighted = Q1 Q2
(t )1
(t ) 2
(t)1 = LMTD
(t)2 =
(T1 T2 ) (t1 t 2 )
2
2
3.
4.
A=
5.
Q
ft 2
U Dassumed t , w
Decide type, size, layout and assign fluids to shell and tube sides.
Heat.Transfer . Area
( Surface. per.linear. ft ) lenght.of .tubes
hio ho
.B.t.u. / hr
hio ho
ft2 F0
A1 = U .(t ) . ft
1
1
hio h ' o
. B.t.u./hr
hio h ' o
ft2 Fo
A2 = U (t ) . ft
2
2
15. Calculate total clean surface required
ft2
Ac = A1 + A2
u1 A1 . .u 2 A2
A1 A2
B.t.u./hr
ft2 Fo
1
. Rd
Uc
12 L p
B
DESIGN CALCULATIONS
966.7 lb/hr
Sat. Vaps
Sat. liquid
Steam
266o F
266o F
150.8o F
2501 lb/hr
233.6o F
Alcohol
Sat. Vaps
Sub-cooled
liquid
Heat Duty
Qt = Q1 + Q2
1)=> Preheating
Q1
2)=> Vaporization
= mCpT
= 1135.8 0.87 (112-66)
= 45454.7 Kmol/hr = 180.375.8 Btu/hr
Q2 = Qalcohol + QH2O
Latent heat of vaporization of H2O = 185.32 Kcal/Kg
Latent heat of vaporization of alcohol = 500 Kcal/Kg
Q2 = 863.2 + 45.43 + 500
Q2 = 182685 Kcal/hr = 724942.5 Btu/hr
Qt = Q1 + Q2
= 228140.2 Kcal/hr
= 905318.7 Btu/hr
For steam
T2 = 130o C = 266 oF
For process fluid,
T1 = 66o C = 150.8 oF
T2 = 112o C = 233.6 oF
t1 = LMTD
266 150.8
ln
= 65.27 oF
For Vaporization Zone
t2 = 266 233.6 = 32.4 oF
t, weighted =
t, w =
Q1
t 1
Qt
Q2
905318.3
180375.8 724942.5
65.28
32.4
t, w = 36 oF
assume UD = 95 Btu/hr. oF. ft2
as Qt = UD A t, w
A
905318.3
95 36
= 264.71 ft2
Exchange Layout
1-2, shell & tube heat exchanger
OD, 1 sq. pitch,
A = at Nt Lt
A = 0.1963 ft
Lt = 5 ft.
A = 0.1963 8 Nt
Nt =
264.7
= 168
0.1963 8
Nt = 166
(Nearest count)
So
A = 260.68 ft2
UD = 96 Btu/hr. ft2. oF
SPECIFICATIONS
Shell Side
Tube Side
17 , C = 0.25
B = 4 in
16. BWG
0.302 166
= 0.174 ft2
144 2
T = 130o C = 266 oF
0.052 5555.74
= 852.7
0.03388
I.D CB
144Pt
=
17.25 0.25 4
144 1
= 0.119 ft2
0.079167 21023
0.604
= 2745
JH = 29
ho = JH (K/De)(C/K)1/3
= 78 Btu/hr.ft2 oF
U1
= hioho/ho + hio
U1
= 74 Btu/hr.ft2 oF
A1
Q1
U1t1
= 37 ft2
= 0.012 Cp
= 0.012 2.42 = 0.029 lb/hr. ft
Re,s = DeGs/ =
Re,s
0.079 21023
0.029
= 57269
JH = 140
ho
= JH(K/De)(c/K)1/3
= 141.8 Btu/hr.ft2 oF
U2
h io ho
h io ho
U1A1 U 2A 2
A1 A 2
0.003
1/UD = 1/UC + Rd
UD
88 Btu/hr ft2 oF
(Correct)
Re,t = 8527
f = 0.00028
1
10.854 ftlb 62.5 ftlb
3
s = 0.00147
Gt = 5555.7 lb/hr. ft2
Pt = 1/2
= 1/2
fG 2tL n
Pt = 0.035 Psi
Shell Side Pressure Drop
For preheating zone
At Re,s = 2745
f = 0.0027
A1
Ac
= 1.41 ft
No. of crosses, (N + 1) =
12 1.4
8
= 4.2
s = 0.81
Ds = 17.25/12 = 1.44 ft
Ps1 =
f G s2D3 N 1
5.22 1010 s s
f = 0.0018
A
2
Length of vaporization zone) = Lv = L t A
c
= 6.6 ft
No. of crosses, (N+1)
= 12
Lv
B
= 19.74
outlet liquid = 0.81 62.5 = 50.625
outlet varps = PM/RT =
44.1 42.3
10.73 693.6
= 0.25
1135.8
soutlet mix =
908.7
0.25
62.5
227.1
50.625
= 0.005
smean =
0.81 0.005
N 1 2
Ps2 =
= 0.4
fG s2 Ds N 1 2
5.22 1010 De s 1
= 1.08 Psi
Ps
Ps1 + Ps2
Ps
1.3 psi
Function
Unit
Vaporizer
Item No.
V-1
Type
Forced Circulation
No. of Item
Operation Continuous
Heat duty
905318.7 Btu/hr
260.7 ft2
88 Btu/hr-ft2 oF
Dirt factor
0.003hr-ft2 oF/Btu
Shell side
Fluid circulated
Ethyl alcohol
Flow rates
2501.76 lb/hr
Temperature
Inlet = 150.8 oF
Outlet = 233.6 oF
Pressure
44.1 psi
Pressure drop
1.3 psi
Material of construction Carbon steel
Specifications
I.D = 17.25 in
C = 0.25 in
B = 4 in
Tube side
Steam
966.7 lb/hr
266o F
39 psi
0.035 psi
Carbon steel
OD = in 16 BWG
Pitch = 1 in
Square arrangement,
Length = 8 ft
Nt = 166