A Study on the Types of

Reboilers
Ruben Chatterjee
10/28/2016

The report starts by describing the distillation process and the role of reboilers in the same. Further, the
report briefly describes the types of reboilers that are used in the industry.

Table of Contents

1. Introduction ........................................................................Error! Bookmark not defined.

2. Types of Reboilers...3
2.1Kettle Reboilers: ............................................................................................................. 3
2.1.1 A Strategy for design of Kettle Reboilers: .............................................................. 4
2.2 Vertical Thermosyphon Reboilers ................................................................................. 5
2.3 Horizontal Thermosyphon Reboilers ............................................................................. 6
2.4 Forced Circulation Reboilers ......................................................................................... 7
2.5 Internal Reboilers ........................................................................................................... 8
3. Parameters for selection of reboiler.9
4. Conclusion.10
5. References and Bibliography .......................................................................................... 10

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1. Introduction
Reboilers are heat exchangers that provide heat to the bottom products of a distillation column.
Figure 1.1 [1] shows the basic equipment involved in a distillation process. The liquid at the
bottom of the distillation column is heated to generate the vapours that are then returned to the
bottom tray of the distillation column to drive the distillation separation. The process of
distillation is based on varying boiling temperatures of different components. Once the preheated feed enters the column, the heavier products, generally liquid, settle down at the bottom
of the distillation column while the lighter components vaporise to the condenser. The liquid at
the bottom of the column is then heated in the reboiler to generate vapours which are then sent
back to the fractionating column to carry out the distillation process.
Effective design and proper operation of reboilers are essential for successful distillation. All
vapours that drive the separation come from a reboiler in the typical column of classical
distillation. Generally, a variant of shell-and-tube exchanger are employed because such
exchangers can be used for a wide variety of processes, and the mechanical requirements are
satisfied at reasonable costs [2]. Reboilers could be considered similar to vaporisers except that
in a reboiler, the liquid feed is partially vaporised whereas in a vaporiser the liquid feed is
vaporised

completely.

Figure 1.1: Basic Equipment of a Distillation

Column [1].
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2. Types of Reboilers
Reboiler configurations may be classified into different types according to their orientation of the
type of circulation employed. The most commonly used types are described below.

2.1

Kettle Reboilers

A kettle reboiler consists of a bundle of U-tubes or straight tubes (regular or finned) in a

horizontally mounted, oversized TEMA1 K-shell, with a pull- through (type T) floating head.
The tube bundle is unbaffled, so support plates are provided for tube support. Vapour leaving the
reboiler shell is always in equilibrium with the liquid [3]. An overflow weir, typically 5-15 cm 2
higher than the topmost tubes ensures that the entire tube bundle is submerged [4]. This ensures
that a perfect pool boiling takes place so that maximum value of heat transfer coefficient is
achieved in the nucleate boiling region3. Further, an open tube bundle is preferred, with pitch to
diameter ratios in the range of 1.5-2. The temperature in the kettle is substantially uniform.
Residence time is high so
that

kettles

are

not

favoured for thermally

sensitive materials. The
large

shell

diameters

make kettles uneconomic

for

high-pressure

operations. Tube bundles

installed directly in the

Figure 2.1.1: Schematic Diagram highlighting the different

components of a Kettle Reboiler (TEMA K) [4]

bottom of the tower are inexpensive, but the amount of surface that can be installed is limited
[4].

TEMA - Tubular Exchanger Manufacturers Association

cm- centimetre
3
To achieve the nucleate boiling region, the temperature difference between the temperature of the heating surface
and boiling temperature of the liquid should be less than close to the critical temperature drop of the liquid [3].
2

Page 3

Figure 2 depicts the typical configuration of a kettle reboiler. The liquid mixture is fed by
gravity from the bottom of the distillation column and enters at the bottom of the shell through
single or multiple nozzles. The liquid flows upward across the tube bundle, where boiling takes
place on the exterior surface of the tubes. The separation of the
vapour and liquid takes place in the space above the bundle. The
vapour flows overhead to the column, while the liquid flows over
the weir and is drawn off as the bottom product. Low circulation
rates, horizontal configuration, and all vapour return flow make
kettle reboilers relatively insensitive to system hydraulics.
Therefore, kettle reboilers tend to be reliable over a wide range of
pressures, from near vacuum to near-critical pressures. Kettle
Figure 2.1.2: Typical
Configuration
for
a
Kettle Reboiler [5].

reboilers can also operate efficiently with small temperature

driving forces, as high heat fluxed can be obtained by increasing
the tube pitch. However, low circulation rates make the reboiler

susceptible to fouling, and an oversized TEMA K-shell is relatively expensive [5].

2.1.1 A Strategy for design of Kettle Reboilers:

Figure 3 shows a schematic representation of the circulation
in a kettle reboiler. A balance between the static head of the liquid
outside the bundle and the pressure drop across the bundle
determines the circulation rate through the tube bundle. Further, a
two-phase mixture exists in the bundle, and the vapour fraction
varies with the position. Therefore, the bundle hydraulics is coupled
with the heat transfer, and generally, a computer model such as
HTRI is utilised to perform these calculations [5].
Figure 2.1.3: Schematic
representation of the
circulation in a kettle
reboiler [5].

Relatively low circulation rate usually results in a small pressure

drop in the unit. Since the kettle reboilers utilise once-through
operation, the feed rate is equal to the flow rate of the liquid from the
bottom of the distillation column. Hence, the feed and return lines

can be sized to accommodate the required liquid and vapour flows based on the available static

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head of liquid in the column sump. Although a two-phase system exists in the shell, the flow in
each line is in single phase (liquid feed and vapour return), the hydraulic calculations are
straightforward. Furthermore, the heat transfer and hydraulic calculations are independent of one
another, making the entire approximate design procedure relatively simple and suitable for hand
calculations [5].

2.2

Vertical Thermosyphon Reboilers

A vertical thermosiphon reboiler consists of a TEMA E shell with a single pass tube bundle [5].
The boiling liquid usually flows through the tubes as
shown in figure 2.1; however shell boiling may be
employed in special circumstances where the heating
medium cannot be placed on the shell side, such as a
corrosive heating medium. A partial vaporisation takes
place, and a mixture of liquid and vapour is sent back to
the distillation column where further phase separation
takes place. The circulation of fluid is promoted by the
Figure 2.2.1: Typical
Configuration for a Vertical
Thermosyphon Reboiler [5]

difference in the static heads of the liquid in the feed

circuit and the two-phase mixture in the boiling region
and return line. The exit weight fraction should be in the
range of 0.1-0.35 for hydrocarbons and 0.02-0.10 for

aqueous solutions [4]. This circulation may be controlled using a valve in the supply line. To
provide an adequate static head, the topmost tube sheet is often placed at the level of the liquid in
the column sump. However, such operations may be difficult in services near vacuum because of
the boiling point elevations imposed by the static head. For vacuum operations, the liquid level
in the column sump is typically maintained at 50% to 70% of the tube height to reduce the effect
of the boiling point elevation of the liquid fed to the reboiler [5]. The flow area of the outlet pipe
is kept similar to that of all the tubes, with diameters in the range of 19-25 mm and tube lengths
varying from approximately 12ft to about 20ft in some cases [4].
It is rather usual to attach vertical thermosyphon reboilers directly to the fractionating column.
This reduces the cost of support structures and the piping required along with the overall

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required plot space for construction. Further, since the flow is driven by the difference in the
static heads of the feed liquid and the column of the partially vaporised material; the natural
circulation of fluid removes the need for a pump making it one of the most economical of all the
reboilers.

Another advantage is that the TEMA E-shell is relatively inexpensive and the high

velocity attained in these units tends to minimise fouling. On the other hand, tube length is
limited by the height of liquid in the column sump. Although greater tube lengths reduce the
required ground space, at the same time, they also necessitate taller tower skirts which make
these units relatively expensive for services with very large duties. Another drawback of vertical
thermosyphon reboilers is its inefficiency for services with small temperature driving forces
because the large static head increases the boiling point significantly. Further, maintenance of
these units is difficult due to the vertical configuration, especially when the heating medium
causes fouling on the exterior of the tubes or the area near the unit is congested [5].

2.3

Horizontal Thermosyphon Reboilers

Horizontal thermosyphon reboilers usually employ a TEMA G-, H-, or X-shell, although E- and
J-shells are also used sometimes [5]. The tube bundle may be configured for a single pass;
however, either U-tubes or straight tubes (plain or finned) may be utilised for multiple passes.
Figure 3.1 [5] shows a typical configuration of a
Horizontal Thermosyphon Reboiler with a TEMA Hshell, carrying out a double split flow. Liquid from the
bottom of the distillation column is fed into the shell
and flows upward across the tube bundle. A partial
vaporisation of the liquid from the bottom of the
column sump boils on the exterior surface of the tubes,
Figure 2.3.1: Typical
Configuration for a Horizontal
Thermosyphon Reboiler [5]

and a two-phase mixture of vapour and liquid is

returned

to

the

column.

Similar

to

Vertical

Thermosyphon Reboilers, the circulation is driven by

the difference in the static head of the liquid at the
bottom of the sump and the two-phase mixture of liquid

and vapour in the reboiler and return line. However, it may be noted that the static difference

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required for recirculation is less in comparison to the vertical units. The fraction of liquid
vaporised in thermosyphon reboilers is much less than in kettles, and the holdup is much less [4].
The pattern of the flow in horizontal thermosyphon reboilers is similar to kettle boiler, but the
higher circulation rates and lower vaporised fractions, make horizontal thermosyphon reboilers
less susceptible to fouling. Although this circulation may be controlled by throttling the inlet
line, this circulation results in a temperature gradient from the inlet bubble point to the exit
bubble point. This is contrary to kettle reboilers where the boiling temperature in nearly uniform
at the exit bubble point. Consequently, for same percentage vaporisations, the mean temperature
difference between the shell and tube sides for thermosyphon reboilers is greater than that for
kettle reboilers. Due to the horizontal configuration and separate support structures, horizontal
thermosyphon reboilers are preferred over vertical thermosyphon reboilers for heavy services or
for operations where there is a requirement for large surfaces. The horizontal configuration also
helps in handling liquids of moderately high viscosity because a relatively smaller static head is
required to overcome the fluid friction and drive the flow. As a rule of thumb, a horizontal
thermosyphon reboiler should be considered over a vertical thermosyphon reboiler if the
viscosity of the liquid feed exceeds 0.5cp4 [5]. Further, horizontal tube bundles are easier to
maintain.

2.4

Forced Circulation Reboilers

In a forced circulation reboiler system, the flow of the liquid feed from the bottom of the
distillation column is propelled using a pump into a TEMA E-shell with a tube bundle
configured for single pass. Since the fluid flow is driven by a pump rather than by gravity, the
reboiler may be oriented either horizontally or vertically.

Forced circulation reboilers are

characterised by high linear tube-side velocities of 15-20ft/sec [4] and the fraction of liquid
vaporised is usually less than 1% to mitigate fouling [5]. Since the feed liquid from the bottom of
the column sump is at its bubble point, adequate NPSH5 must be assured for the pump if it is
centrifugal type [4].

4
5

cp- centi Poise

NPSH Net Positive Suction Head.

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Forced circulation reboilers are of last resort when

the mode of operation involves severe fouling
problems or when the liquid feed is highly viscous
with a viscosity greater than 25cp6, as kettle and
thermosyphon reboilers are not well suited for such
operations [5]. One of the major disadvantages of
forced circulation reboilers are the costs for pumps
and power which render these units uneconomical
for routine services [4].

Figure 2.4.1: Typical Configuration

for a Forced Circulation Reboiler [5]

2.5

Internal Reboilers

Internal reboilers also referred to as stab-in reboilers or stab-in bundles [6] usually consist of a
bundle of U-tubes that is directly inserted into the sump of the distillation column. A perfect pool
boiling takes place at the bottom of the tower, while the heating fluid being inside the bundle of
tubes. The absence of a shell or external piping makes
internal reboilers the least expensive of all the types of
reboilers; however, the amount of heat transfer area
that can be accommodated is severely limited.
Therefore, this type of design is generally chosen for
operations where minimising potential piping leaks is
critical, or the service has to be clean with minimum
bundle

maintenance

[2].However,

operational

problems caused due to the formation of froth and

foam due to boiling liquid in the column sump rather
Figure 2.5.1: Typical
Configuration for an Internal
Reboiler [5]

limits the utilisation of this type of reboiler. Some of

the applications where internal reboilers are used could
be:

cp- centi poise

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1.

batch distillation where the tube bundle can be easily fitted into the batch drum and
periodic cleaning can be carried out economically;

2.

this unit can be employed in very low heat duty services where the reboiler tube
bundle is small, and the column diameter is large due to other considerations [6].

3. Parameters for selection of a reboiler:

Designs of reboilers essentially depend on the demand of the distillation process that needs to be
carried out. However, there are some parameters which may be considered essential for most
types of reboilers.
i.

Fouling: (Cleanability): Generally, the tube side is easier to clean than the shell side.

ii.

Corrosion: May dictate the use of expensive alloys

iii.

Pressure: High-pressure fluids are placed on the tube side to avoid the cost for thick
walled shells.

iv.

Temperatures: Very hot fluids are placed inside the tube to reduce shell costs.

v.

Heating Medium: These requirements may be more significant than the boiling liquid
requirements.

vi.

Boiling Fluid Characteristics: Boiling range of the liquid and the mixture
concentration affect the circulation requirements to avoid stagnation.

vii.

Temperature Difference and Type of Boiling: Whether film or nucleate boiling

affects the design selection.

viii.

Space Constraints: If the headroom is limited, construction of vertical units may be

inappropriate.

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4. Conclusion
An analogy between the distillation process and the human body may help us realise the
significance of reboilers; in the sense that reboilers function as the heart of the distillation
process as it facilitates the energy requirement for the distillation process. Although this report
covers all the type of reboilers that are commonly used in the industry, the scope of the report is
limited to how the process is applied to each configuration along with their advantages and
limitations. It is therefore suggested that the reader may further read through the references to
understand the design specifications and the parameters involved in the design of each type of
reboiler. A study of this report along with the references will provide a comprehensive
understanding of the subject to the reader.

5. References and Bibliography

6.
[1 M. T. Tham, Distillation, R.C. Costello and Associated, Inc., [Online]. Available:
] http://www.rccostello.com/distil/distileqp.htm.
[2 A. Sloley, Chemical Processing, 04 June 2012. [Online]. Available:
] http://www.chemicalprocessing.com/articles/2012/select-the-right-reboiler/.
[3 S. B. Thakore and B. I. Bhatt, 6.13.1 Process Design of Kettle- type Reboilers, in
] Introduction to Process Engineering and Design, McGraw-Hill Education.
[4 J. R. Couper, W. R. Penney, J. R. Fair and S. R. Walas, Heat Transfers and Heat
] Exhchangers, in Chemical Process Equipment- Selection and Design, Elsevier, 2012, p. 199.
[5 R. W. Serth and T. G. Lestina, Reboilers, in Process Heat Transfer- Principles,
] Applications and Rules of Thumb, Elsevier, 2014, p. 361430.
[6 KLM Technology Group, KLM Technology Group, August 2013. [Online]. Available:
] http://www.klmtechgroup.com/PDF/EDG/ENGINEERING_DESIGN_GUIDELINES_reboile
r_R01web.pdf.

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