Chapter 7: Condensers

Course: Food Engineering 2 – CH3047

GV: TS Nguyễn Thị Lê Liên
Khoa: KT Hóa Học – BM Quá Trình & Thiết Bị

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 Condenser
A condenser is a heat exchanger used to condense a gaseous substance
into a liquid state through cooling. In so doing, the latent heat is released
by the substance and transferred to the surrounding environment.
Condensers are used for efficient heat rejection in many industrial
systems.
Condensers are used in air conditioning, industrial chemical processes
such as distillation, steam power plants, and other heat-exchange
systems. The use of cooling water or surrounding air as the coolant is
common in many condensers.

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 Classification
❑ By cooling agents:
o Condensing temperature > 300C: by water and air
o Temperature lower than outdoor or < 200C: by direct cooling system or indirectly through cooling agents
o Water-cooled condenser: large h, with a more compact structure
o Air-cooled condenser: small h, need to increase the area by fins, increase air velocity
o Evaporative: evaporative refrigerant directly condenses the vapor mixture (both processes are isothermal processes)

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 Classification
❑By pressure:
▪ Low pressure (vacuum): Baromet – placed at a height so that the column of liquid
condenses to form pressure in equilibrium with atmospheric as to flow freely out into
the atmosphere
▪ Normal pressure
▪ High pressure :
▪ Require suitable structure to remove condensate
▪ Condensate goes to the tube
=> double tube, spiral tube, snake condensers

❑contact between two fluids:

o Surface type (indirect contact): tube shell, evaporative
o Direct type (barometer)

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Air cooled condensers
• Air is the external fluid, i.e., the refrigerant rejects heat
to air flowing over the condenser.

Force convection
Natural convection
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Air cooled condensers (ACC)
• Changes in air temperature may cause the condensing pressures to fluctuate.

Force convection

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Air cooled condensers (ACC)
• The Induced Draft Air Cooled Condenser:
Movement of the cooling air across the finned tubes
is achieved by electrically driven axial flow fans that
are installed above the tube bundles in the warm
outlet air.
• Forced Draft Air Cooled Condenser: Movement of
the cooling air across the finned tubes is achieved
by electrically driven axial flow fans that are
installed in the cooler inlet air, below the finned
tubes.

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 Air cooled condensers (ACC)
General steps to consider while designing an Air-Cooled Condenser:
i. Dry Bulb temperature: The design of an air-cooled condenser is primarily based on dry
bulb temperature at the plant location. Since the cooling medium for steam is air, a higher
ambient temperature may lead to a lower heat transfer coefficient, thus a larger sized
condenser required. A smaller condenser is essential at lower temperatures. An air-cooled
condenser is designed for a temperature range of 2 to 5 % higher than that of the highest
ambient temperature at that location.
ii. Air Velocity: A higher air velocity may give a larger heat transfer coefficient, thus the
condenser size will be smaller. While it might need a supply of more power of fan which
also leads to increase in pressure drop. Thus, it is necessary to balance the range of power
requirement and overall heat transfer coefficient.

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 Air cooled condensers (ACC)
General steps to consider while designing an Air-Cooled
Condenser:
iii. Tube Arrangement: The tubes can be arranged in an
inline and staggered manner. The inline tube arrangement
gives lower pressure drop and poor heat transfer as the
flow tends to be channeled into a high-velocity region in the
center of the lanes between the tube rows. While staggered
tubes produce good mixing of the flow over the tube banks
but give a higher pressure drop.
iv. Pitch: As the distance between the successive tube size
increases, the pressure drop inside the fin side decreases
and also due to less obstruction. On the other hand, a
higher pitch occupies more space. Thus, it is necessary to
maintain the balance between space restriction and
pressure drop. TS. Nguyễn Thị Lê Liên_BM QTTB_Khoa KTHH_ĐHBK
 Water-cooled condenser
• Water conducts heat better than air, making water-cooled condensers smaller, cheaper,
and able to consume less energy per horsepower than air-cooled condensers.

Shell-and-coil Subcooling
Vertical shell-and-tube type condensers are usually used with ammonia in large capacity systems so that cleaning of
the tubes is possible from top while the plant is running
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Water-cooled condenser
Advantages:
• Where there is restriction for air-cooled condenser, water-cooled condenser is a perfect
replacement.
• There is thermal energy recovery to be used in other heating processes.
• This type of condenser can be housed indoors.
• A water-cooled system typically lasts years longer, assuming maintenance is not neglected.
• It has higher heat transfer rate.
• It consumes far less overall energy, which can lead to savings on energy costs and consumption.
• It does not require any external power.
• Since water cooling is more efficient than air cooling, time required for cooling is less.
• Length of the condenser pipe is reduced which decreases the compressor work and thus
increases its efficiency.
• With the incorporation of these condensers,
TS. Nguyễn the netKTHH_ĐHBK
Thị Lê Liên_BM QTTB_Khoa weight of the system increases.
Water-cooled condenser
Disadvantages:
• Using water as a cooling medium might cause corrosion
problem.
• Use of water as a cooling medium may result in the
formation of scales in the supply line.
• Because of shortages of fresh water around the world,
few countries can afford to run water to waste.
• Using water tank makes the system bulky which results in
problem during domestic use.

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 Air cooled vs water cooled condensers

• Air-cooled condensers:
Simple in construction since no pipes are required for air. The disposal of warm air is not a problem.
The fouling of condenser is small and maintenance cost is low.
However, since the specific heat of air is one fourth of that of water and density is one thousandth of that of water, volume flow rates
required are very large. The thermal conductivity is small; hence heat transfer coefficient is also very small.
Air is available at dry-bulb temperature while water is available at a lower temperature, which is 2 to 3 o C above the wet-bulb
temperature.
The temperature rise of air is much larger than that of water, therefore the condenser temperature becomes large and COP reduces.
Its use is normally restricted to 10 TR although blower power goes up beyond 5 TR.
The air-cooled condensers cost two to three times more than water-cooled condensers.
A ton of refrigeration (TR or TOR), also called a refrigeration ton (RT): the rate of heat transfer that results in the freezing or melting of 1
short ton (2,000 lb; 907 kg) of pure ice at 0 °C in 24 hours
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 Evaporative condenser
https://www.evapco.com/products/condensers-evaporative/lrc-evaporative-condenser
Both air and water are used to extract heat from the condensing refrigerant
Evaporative condensers combine the features of a cooling tower and water-
cooled condenser in a single unit.
The heat transfer coefficient for evaporative cooling is very large. Hence, the
refrigeration system can be operated at low condensing temperatures

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 Evaporative condenser

Evaporative condensers are used in medium to large

capacity systems.
These are normally cheaper compared to water cooled
condensers, which require a separate cooling tower.
Since water is used in a closed loop, only a small part of
the water evaporates. Make-up water is supplied to take
care of the evaporative loss. The water consumption is
typically very low, about 5 percent of an equivalent
water cooled condenser with a cooling tower.
Since condenser has to be kept outside, this type of
condenser requires a longer length of refrigerant tubing,
which calls for larger refrigerant inventory and higher
pressure drops

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Direct contact
condenser

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Surface condenser

❑ Vertical shell-tube :
o Downflow: Steam goes from the top down, the condensate escapes
to the bottom thanks to gravity and the pull of the gas => accelerates
the condensation
o Upflow: Steam goes from the bottom up, the condensate escapes to
the bottom by gravity. Steam occupies the entire pipe section.
❑Horizontal shell-tube:
o Vapors can go either the tube side or the shell side. Tube side: condensate
accumulates to reduce HT efficiency

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Surface condenser
Central flow type
• Downflow type

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 Jet condensers
• A type of direct contact between two substances:
usually steam and water. The steam is rapidly de-
cooled by the chilled water temperature and
condenses. Condensate mixture exits the unit
continuously
• Widely used in industries as an economical way
to remove (condensate) air, steam, and vapors
• Used for decades in the food industry: oil, milk, ...
and hundreds of years in the sugar industry

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Jet condensers
❑In jet condenser the condensate and the
cooling water are in direct contact and mix
with each other. Therefore, the final
temperature of the condenser and the
cooling water leaving the condenser is the
same.
❑Simple in design and low cost
❑Used when coolant is cheap and available.
❑Takes up less space
❑Condensate cannot be reused in the boiler,
as it contains impurities such as dust, oil,
metal particles, etc.

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Jet condensers
Parallel-Flow Jet Counter-Flow Barometric or
Condenser or Low-Level High-Level Jet
Ejector Condenser
Jet Condenser Condenser

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Jet condensers

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Condenser
selection

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Condenser in refrigeration
Isometric line on T-s diagram
Condensers: Qco
2-3g-3r-3 Purpose: release heat

Distinguish 3 regions:
- Superheat: steam
2
- Moisture saturation:
phase transition
3
- Overcold: liquid

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 Surface condenser
Problem: Qሶ 21 T ’
2
The steam entering the condenser is superheated steam, and the liquid Qሶ 23 T22 Qሶ 22 T21
coming out is too cold. Cooling: water
The above status points: T-s: 2-2’-3’-3 T2” t11 t1”
t12
Divided into 3 regions: t1’
+ F1: superheated steam – water: F3 F2 F1
+ F2: saturated steam – water
+ F3: subcooled – water
Có: Qሶ 2 = Gሶ 2 i2 − i3 , kW
Qሶ 2= Qሶ 21+ Qሶ 22+ Qሶ 23 3 3’ 2’ 2
Qሶ 21= Gሶ 2 i2 − i2′
Qሶ 22= Gሶ 2 i2′ − i3′
Qሶ 23 = Gሶ 2 i3′ − i3
Các giá trị: T2’ và T2”: Given;
T21=T22: diagram/table f(p)

Ví dụ tra: i2=300; i2’=265; i3’=105; i3=90 kJ/kgTS. Nguyễn Thị Lê Liên_BM QTTB_Khoa KTHH_ĐHBK
 Surface condenses
Qሶ 1 = Gሶ 1C1(t1”-t1’); Gሶ 1- lưu lượng nước, kg/s
Qሶ 1= Qሶ 11 + Qሶ 12 + Qሶ 13
Qሶ 11 = Gሶ 1C1(t1”-t11) → t11=t1”- Qሶ 21/(Gሶ 1C1)
Qሶ 12 = Gሶ 1C1(t11-t12) → t12=t1’+ Qሶ 23/(Gሶ 1C1)
Qሶ 11 = Gሶ 1C1(t12-t1’) → Hoặc t12=t11- Qሶ 22/(Gሶ 1C1)
Với: Qሶ 11 = Qሶ 21 ; Qሶ 12 = Qሶ 22; Qሶ 13 = Qሶ 23 Qሶ 21
Qሶ 23 T2’
T22 Qሶ 22 T21
(𝑇2′−𝑡1")−(𝑇21−𝑡11)
→ Δtlog1= ′
(𝑇 −𝑡 ") T2”
ln((𝑇 2 −𝑡1 ) t11 t1”
(𝑡11−𝑡12)
21 11
t12
→ Δtlog2= (𝑇 −𝑡 ) t1’ F2
ln((𝑇21−𝑡12)
21 11
(𝑇22−𝑡12)−(𝑇2"−𝑡1′) F3 F2 F1
→ Δtlog1= F3
(𝑇 −𝑡 )
ln( (𝑇22"−𝑡12′)
2 1

𝑄ሶ 21 𝑄ሶ 22 𝑄ሶ 23
F1 = ;F = ;F =
𝐾1∆𝑡𝑙𝑜𝑔1 2 𝐾2∆𝑡𝑙𝑜𝑔2 1 𝐾3∆𝑡𝑙𝑜𝑔3

→ F=F1+F2+F3
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Chú ý giá trị của khác nhau: K1≠K2≠K3
 Surface condenser
3 3’ 2’ 2

Given Qሶ 2 = 1000kW; C1=4,18kJ/kgK; t1’=18oC; t1” =

26oC
Refrigerant as graph has:i2=300; i2’=265; i3’=105; i3=90
kJ/kg; T2’=68oC (T2), T2’=T3’=40oC (T21=T22) , T2”=30oC
(T3) Qሶ 1000
→ Gሶ 2 = 2
= = 4,76kg/s
(i2−i3) (300−90)

→ Qሶ 21 = Gሶ 2 i2 − i2′ = 4,76 300 − 265 = 166,7kW

→ Qሶ 22 = Gሶ 2 i2′ − i3′ = 4,76 265 − 105 = 761,9kW
→ Qሶ 23 = Gሶ 2 i3′ − i3 = 4,76 105 − 90 = 71,4kW

Qሶ 2 =Qሶ 1 = Gሶ 1C1(t1”-t1’) Qሶ 21 T ’
2
Qሶ 23 T22 Qሶ 22 T21
𝑄ሶ 2 1000
→ Gሶ 1= = = 29,9𝑘𝑔/𝑠 T2” t11 t1”
𝐶1(𝑡1"−𝑡1′) 4,18(26−18)
t12
→ t11=t1”- Qሶ 21/(Gሶ 1C1)=26-167/(4,18.29,9)=24,66oC t1’
→ t12=t1’+ Qሶ 23/(Gሶ 1C1)=18+71/(4,18.29,9)=18,57oC F3 F2 F1
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 Surface 3 3’ 2’ 2

(T2′−t1")−(T21−t11)
→ Δtlog1= (T2′−t1") = 26,5oC
ln(
(T21−t11)
(t11−t12)
→ Δtlog2= (T21−t12) =18,2oC
ln(
(T21−t11)
(T22−t12)−(T2"−t1′)
→ Δtlog3= (T22−t12) =16,3oC
ln(
(T2"−t1′)

1 1
K1= 1 1 = 1 1 =19,87W/m2K
+ +
𝛼11 𝛼21 20 3000
1 1
K2= 1 1 = 1 1 =2250W/m2K
+ +
𝛼12 𝛼22 9000 3000
1 1
K3= 1 1 = 1 1 =631,58W/m2K
+
𝛼13 𝛼23
+
800 3000 Qሶ 21 T ’
2
Qሶ 23 T22 Qሶ 22 T21
Qሶ 166,67.1000
F1= 21 = = 317,0m2
K1Δtlog1 19,87.26,5
Qሶ 166,67.1000 T2” t11 t1”
F2= 22 = = 18,6m2
K2Δtlog2 19,87.26,5
Qሶ 166,67.1000
t12
F3= 23 = = 6,9m2 t1’
K3Δtlog3 19,87.26,5

→ F= F1+F2+F3 = 342,5m2 TS. Nguyễn Thị Lê Liên_BM QTTB_Khoa KTHH_ĐHBK F3 F2 F1

 spray condenser

Modern direct condenser type

+ Water is sprayed into the
steam stream to condense
steam, then partially removed
for cooling in the cooling tower
+ Used for condensing steam
after turbine

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 Ejector Condenser
+ Cold water and steam are mixed
through a series of ejector-type cones
Water enters from above. The lower part
of the hopper has an open cone, through
which the kinetic energy of the steam
flow will be converted into potential
energy (pressure) and the condensate will
discharge downwards.
+ Reduces the height compared to the
barometer
+ No need for vacuum pump
+ Condensate can be reused
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 Parallel Flow Jet Condenser

+ Steam and water go in the same

direction from top to bottom
When steam-water is mixed, the steam is
condensed and transported by the
condensate pump
+ Partially condensate is cooled and
returned to the recirculation

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Counter Flow or Low Level Jet Condenser

+Steam is brought to the bottom, water

from top to bottom is opposite.
The vapor is condensed in the water
stream.
The vacuum pump sucks in the air above
and holds the vacuum at the same time
creating a force to draw cold water up,
the water is poured into the conical
perforated plates creating a tiny water
flow to increase the contact between
the steam and the water.
Downward condensate is pumped away
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 Barometric or High Level Jet Condenser

• Place at the required height so that the

condensate can flow out on its own without a
pump (up to 10-11m)
• The barometer (or high level spray condenser)
requires a vacuum retaining tube. It does not
need condensate pump but needs vacuum
pump. Pump needed to pump cold water in.
• Steam coming in from below, cold water from
above, going against each other, meet to
condense and flow down by gravity

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 Baromet

The calculation includes:

▪ Determine the amount of water
consumed
▪ Number of compartments
▪ Barometer exhaust geometry dimensions

+ Pressure: 0,1-0,2bar (75-150mmHg)

+ Height: HΣ = 10-11m

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 Baromet

i: enthalpy , G1: cooling water, kg/s; G2: steam amount, kg/s

β –specific water consumption, kg nước/kg hơi
β = 15-60kg/kg; tw2=tc-(4-5oC); tc: saturated temperature pc
The diameter of condenser is expressed in terms of vapor velocity such that no
water droplets are involved. Internal steam velocity: v = 15-30m/s
Distance between two tray: H1= 0,35-0,6m
Number of tray: n=10-13, calculated by impirical formula

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Baromet
Pressure head due to vacuum in the baromet

Pressure resistance

Height of the (Preventive), m

discharging pipe

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Example 6.1
A shell-tube condenser consists of 20 brass tubes 18x2mm diameter, to
condense 500 kg/h saturated steam at normal pressure, taking an
overall heat transfer coefficient of 800W/m2.0C. The condenser exit
temperature be 800C. The initial and final temperature of the water be
200C and 500C.
a) Calculate the amount of cooling water required,
b) Calculation the length of condenser

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