(3) Kettle Exchangers

What is Kettle Exchangers?

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Outline of Kettle Exchangers

Boiling regime is Pool Boiling.

Internal liquid circulation occurs.
A disengaged space is required to separate entrainment.
TEMA-U or -T is commonly used as the rear-end to remove the tube bundle.
Kettle exchangers is not recommended for wide-boiling range(*1) fluids because
there is a potential of heavy comps. accumulation.

(*1): Temperature difference between bubble and dew points is 11deg.C or more.
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Kettle Exchangers Sizing

VG,M

VG,V

NLL or Spillover LL

VG,H
droplet

VG,V: Vertical vapor velocity

VG,H: Horizontal vapor velocity
VG,M: Average vapor velocity

The kettle diameter is determined by the criterion that the actual vapor velocity is
less than the maximum allowable velocity.
These velocities are defined in the HTRI Design Manual.
Entrainment ratios for kettle sizing are as follows:
Steam generator = 0.001 liq-wt/vap-wt, Others = 0.01 liq-wt/vap-wt
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Kettle Exchangers Sizing

Vaporization percentage
For clean service:
100% of vaporization to the feed liquid is possible. Thus, the overflow weir is
not necessary.
For fouling service:
Vaporization to the feed liquid is limited to 80vol%, so that 20vol% and more
liquid is continuously drawn-off to remove the accumulated fouling material.
In addition, the tube bundle should be covered with liquid securely. Thus,
the overflow weir is provided.
WL,F = WV,P

WV,P

WL,F = WV,P+ WL,P

WV,P

WL,F

WL,F
Vaporization= WV,P / WL,F= 1.0
Without overflow weir

WL,P

Vaporization= WV,P / WL,F<1.0

With overflow weir
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Kettle Exchangers Sizing

Liquid height (H) above the top of tube bundle
The following values above the bundle as normal liquid level should be kept:
- For general service: 50mm
- For fouling service such as amine: 150mm
The liquid surface in the kettle is not stable by frothing. Thus, 75mm should
be added to normal liquid level for kettle sizing. Xist uses 127mm above the
tube bundle as default.

NLL

Without overflow weir

Spillover LL

With overflow weir

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Kettle Exchangers Sizing

Xists Sizing Method

Kettle Dia.(ID)

Based on the equation in the HTRI Design Manual.

The default entrainment ratio is 0.01 liq-wt/vap-wt.
The calm liquid height is the same as the top of bundle.
The froth height is 127mm above the top of bundle.

Bundle
Dia.
(OTL)

Shell DIa.
(ID)

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Xist Input : Shell Panel

Select K,
K then Xist calculate thermal performance as pool boiling.
Hot fluid location is Tubeside (Inside tubes)
If the shell inside diameter is specified, the program calculates the bundle
diameter. (recommend)

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Xist Input : Reboiler Panel

Xist can calculate the kettle ID. However, the kettle ID should be sized by manual.
The ratio of liquid level height and bundle diameter should be input if the liquid
level is different from the default. It affects the internal circulation calculation.
The entrainment ratio should be specified if that is different from the default and
the kettle ID is determined by the program.
Inlet pressure location:
At inlet nozzle: Xist calculates pressure at the top of bundle
At top of bundle: Xist calculates pressure at the bottom of bundle
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Xist Input : Nozzle Location Panel (Inlet Nozzle)

For single liquid phase, feed nozzle is located at Bottom.

For high sub-cooled liquid, feed fluid should not be introduced to a vapor space.
Because hammering would occur due to sudden volume decrease.
For two-phase, feed nozzle should be placed at the side of shell and a vapor space
of the kettle.
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Various types of inlet

Feed nozzle for two-phase
Baffle

Closed-end pipe

Closed-end pipe

Distributor

Distributor with slot holes

Baffle

Slit at bottom

Baffle Type

Distributor Type
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Outlet Vapor Nozzles

Vapor outlet nozzles should be positioned at the location corresponding to the

middle of tube length to ensure equal vapor path length.
As a rule of thumb, the number of outlet nozzle can be determined by the following
equation rounded up to an integer:
No. of nozzles = L/(5Db), L is bundle length, and Db indicates bundle diameter
But the number of outlet nozzles should be determined by considering with the
kettle ID.

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Control Methods : Total Vaporizer

Total Vaporizer : without the overflow weir
Vaporization to total feed liquid is 100%
Feed rate is controlled by LIC.
Pressure in the kettle is controlled by PIC, or is determined by the connected
header.
The holding time from LLL to HLL complies with BDM.
To header or K/O drum
PC
HLL
NLL

LLL

LC

Feed

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Control Methods : Partial Vaporizer

Partial Vaporizer : with the overflow weir

Vaporization to total feed liquid is less than 100%.

Draw-off rate of product is controlled by LIC.
The holding time from LLL to HLL in the product sump complies with BDM.
The liquid surface is always kept above the top of tube bundle by the overflow
weir.

P2 = P1+ p,v

p,v

P2 = P1+ p,v

p,v

P1

P1

P2

P2

HLL
HLL

LC

LLL

LC

LLL

Product

Product

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Xist Output / Kettle Performance

Shellside Performance
Confirm Kettle Circulation Ratio > 1.0.
If the circulation ratio is 1.0 or less, internal circulation may not occur.
Internal fluid flow is close to pure cross flow as TEMA X-shell.
Corrective measures to accomplish internal circulation are as follows:
- To increase liquid head, the bundle length is shortened and the bundle
diameter is enlarged.
- Square pitch is applied to reduce pressure drop across the tube bundle

Circulation Ratio = R/F

R

F
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Page-16

Xist Output / Vibration

Tube vibration problem also occurs in the kettle.
Engineers should check the results of vibration analysis, and
determine the number of support plate.
If the unsupported span of U-bend is longer than the TEMA criteria,
use Xvib to analyze a tube vibration potential of U-bend. Because
Xist can not analyze for U-bend.

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Practice
Kettle Type Chiller (Item Tag E-3133)
Since the kettle side fluid is a boiling fluid, the physical properties for the
actual mixture should be input.
In this case, in order to minimize the intricate work, use property
generator by VMG-Thermo in Xist.
Tube side data shall be input manually.
Use AKU type.
Tube diameter, tube pitch and so on should be determined referring to the
BD Manual.
Consider liquid residence time for level control.
The kettle ID should be sized by manual.

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