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1 Condenser System for vacuum creations and its types with design criteria
1.1 Creation of Vacuum:
1.2 The Barometric Column :
1.2.1 Height of the barometric column :
1.2.1.1 The values of coef cient given by Hausbrand as follows
1.2.2 Cross-section of the column:
1.3 Types of Condenser System :
1.3.1 Barometric condenser
1.3.1.1 Height of the condenser:
1.3.1.2 Cross-section of the condenser.
1.3.1.3 Condenser volume :
1.3.1.4 Diameter of cooling water pipe :
1.3.2 Multi Jet Condensers ( Wet air barometric condensers) :
1.3.2.1 Principle :
1.3.2.2 Diameter of spray nozzle (Ds)
1.3.2.3 Diameter of jet nozzle (Dj ):
1.3.2.4 Condenser Vapour pipe dia :
1.3.2.5 Condenser Diameter :
1.3.3 Single Entry Condenser:
1.4 Condenser Water Requirement
Condenser system and vacuum equipment are common to evaporators and vacuum pans. Nearly all these vessels use direct contact condensers, where
the cooling water comes into direct contact with the vapour to be condensed.
Creation of Vacuum:
In a condenser, we condense large volume of vapour and it will only produce a comparatively small volume of water or (condensate) and this water runs out
through the bottom of the condenser down the barometric leg with the waste water.
Therefore if we have condensed the large volume of vapor into small volume of water in a condenser, the remaining volume or area must be a
vacuum(reduced). Thus we have created a vacuum.
With the aid of an air pump or other, vacuum is produced in an enclosed vessel called a condenser, which communicates with the vessels to be maintained
under vacuum.
Cold water is pumped in to the condenser to ensure condensation of vapour coming from pan or multiple effect evaporator. The Condenser is placed
at a height that the water after condensation ow out by gravity together with condensed vapours. The Condenser is a barometric chamber extended
at bottom by a barometric column dipping into a well open to atmosphere.
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s = margin of safety as provision for abrupt variations in level of the water in the column.
H = Ho + h + s
Ho is the minimum head of water required to have maximum vacuum in condenser. The height of the column should be of the order of 10 (instead of 76
cm): (Vacuum in mtr of Hg x Density of mercury/ Condenser inlet water density)
0.76 m X 13.6 = 10.33 m where 13.6 = density of mercury relative to water.
h =The head necessary to give desired velocity of water
h= (1 + a) ( V2 / 2g)
h = head of water, in mtr necessary to maintain ow in the column, at velocity V
V = velocity of ow in the column, in m/sec
g = 9.8 m/sec2
a = coef cient,
S is the Safety margin for sudden variations in vacuum or flow in water. It may take in general 0.50 mtr.
D=
The velocity of water in the barometric column is maintained at 2 to 3 mtr /sec. So that the air bubbles do not escape and rise in condenser.
They should pass along with water through tail pipe. For single entry type condensers it may take upto 4 to 5 mtr/sec.
Wet air condensers : Condenser with combined vapour and air extraction.
Dry air condensers : Condenser with separate arrangement for air extraction.
In Sugar Industry generally used the following types of condensers
Barometric condenser
Multi-jet condenser
Single Entry Condenser
Barometric condenser
In Barometric condensers having two types. They are Co-Current barometric condenser and Counter Current barometric condenser.
Co-Current, barometric condenser water and vapour are introduced to the condenser from top and the worm water is let out removed from the bottom.
Counter Current barometric condenser. water and vapor are introduced in opposite direction. Baf es with perforation are provided to ensure more contact
time and surface between water and vapour
Compared to the co-current type, counter current type barometric condenser works more ef ciently.
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Height of Condenser is decided as per the time that is necessary for the water to remain in contact with steam. While proper arrangement of
baffles in condenser to increase the contact area than the overall height of 3.65 mt ( 12 ft) is sufficient .
S = 0.16 m2 / ton of vapour to be condensed per hour. where S = horizontal cross-section of the body of the condenser.
Condenser volume :
The condenser volume of 0.75 m3/ 1000 kg of vapour is recommended however 0.5 m3/ 1000 kg vapours can be considered as a
reasonable figure for rain type condenser. however, has determined experimentally that 0.6 m3/ 1000kg per hour was sufficient in most cases. In some
designs provide maximum effective contact area of water to vapour in that design it will take 0.4 to 0.3 m3/ 1000kg per hour.
Also can be cross checking by Volume of condenser = Cross sectional area x Height of the condenser
The cone at the bottom of the barrel should have a slope of 70 to the horizontal.
V=ax
a = coefficient depending on the length of the pipe, its bends, valves and other obstructions to flow. In general, a is of the order of 5
g = 9.8 m/sec2
h = head of cold water, at entry to condenser, in mtr (h = pressure Of water at inlet X head at mean sea level)
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The main difference with the Multi Jet condenser is that, it does not require air pump, and although it requires more water than the dry air type condenser,
it is more economical to operate and maintain.
This type of condenser has high pressure water jet nozzles tted in the lower section of the condenser, directed straight at the outlet or barometric leg. The
vapor inlet to the condenser is from the top of the condenser much above the level of the jet.
The nozzles are called as jet nozzles and they create vacuum in the system. The jet is given such manner, that the jet of water will ow exactly through the
center of the tailpipe. On the top portion of the jet box another set of nozzles is tted circumferential through which the ow of pressurized water is owing
towards the center of the box. This part of water is responsible for the condensation of vapour, which is called as spray nozzles.
As against the dry air type, the Multi Jet differs (wet type) in principle that due to the high velocity of water passing down the barometric leg, air or gas
bubbles will not rise but instead it will be drawn away through the outlet with the waste water.
The pressure of water in both the parts to be employed as between 0.5 to 0.7 kg/cm2 for observing the pressure the gauges are tted to inlet pipes. The
proportion of the quantity of water is in ratio of 40% water to jet and 60% to spray.
Ds =
Qs = Quantity of water per each spray nozzle in M3/Sec = Quantity of water / No. of spray nozzles
Dj =
Qj = Quantity of water per each jet nozzle in M3/Sec = Quantity of water / No. of jet nozzles
Cross sectional area of the vapour pipe = Quantity of vapour in M3/sec / Velocity of vapour in m/sec.
Condenser Diameter :
Cross sectional area of the condenser =( Quantity of vapour in M3/sec + Quantity of inlet water to the condenser in M3/sec) / Velocity of vapour in m/sec.
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Single entry condensers are having only one water distributing box for spray and jet nozzles. Out of total water about 60 to 80 % water is used at
Spray nozzles and 20 to 40 % water for jet nozzles.
Vapours are condensed by forming ne mist inside the condenser, increasing surface area of contact and nally minimum requirement of water.
The difference between approach temperature ( difference between vapour temp. and condenser water tail pipe temp) does not exceed 5 to 60C.
The Specially designed high ef ciency centrifugal spray nozzles tted on the jet box create micro ne atomized spray, resulting into wider surface contact
with incoming vapours.
The difference between water outlet temperature and inlet temperature of 10C is achieved. Under automation the difference can achieved upto 15C.
(http://www.sugarprocesstech.com/condenser-system/ )
Single entry and Multi jet condensers are of Parallel ow type wet air condenser. The Single entry condenser requires less water than conventional
Multijet condenser due to the following reason.
In the single entry condenser design the spray nozzles are tted in nozzle box which tted at the center of the condenser. Thus the spray water covers all the
available area inside the condenser hence the spray water particles contact area for the vapour condensation is more than the multi-jet condenser system.
Another impotent parameter in this design tail pipe diameter and velocity of water in the tail pipe .
The nozzles dia calculation same as multijet condenser. The velocity of warm water (outlet water ) goes upto 4 to 5 m/sec. The design of bottom cone, its
reducer and venture were placed important role.
I = Total heat of vapour in Kcal/kg ( For 55 oC temperature of vapour the total heat having 621 Kcal/kg)
For saturated online steam table purpose go through the link Online Steam Table for Saturated Steam (http://www.sugarprocesstech.com/steam-properties/)
The difference in temperatures of vapour being condensed and the outlet water termed as approach should be minimum since the efficiency of the
condenser operation depends on the fact that minimum quantity of water should absorb all the latent heat of vapour.
Under normal conditions the cooling water ratio to vapour condensed in around 50 to 60 for barometric condensers, 60 to 70 for Multi jet
condensers and 40 to 50 for single entry type condensers.
In the next revision of this article will provide online calculation sheet of condenser design.
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i read your article about condensor system. now i need detailed data of water consumption for vapour condensing calculation.thank you
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