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05/10/2017 Concepts in Condenser System (Vacuum Equipment)

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Concepts in Condenser System (Vacuum Equipment)


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Condenser System for vacuum creations and its types with design criteria
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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.

The Barometric Column :


There are two dimensions of importance in the barometric column (http://www.sugarprocesstech.com/condenser-system/
)

Height of the barometric column


Cross-section of the column

Height of the barometric column :


The height of the column represents the sum of 3 terms:

Ho = head of water corresponding to the maximum vacuum in the condenser


h = head necessary to give the desired downward velocity of the water

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05/10/2017 Concepts in Condenser System (Vacuum Equipment)
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,

The values of coe cient given by Hausbrand as follows


Diameter of the column in mm
Column
50mm 100mm 200mm 400mm 800mm
Straight 6.1 2.6 1.2 0.6 0.4
With Double 90o bends at
6.7 3.2 1.8 1.2 1
base

S is the Safety margin for sudden variations in vacuum or flow in water. It may take in general 0.50 mtr.

Cross-section of the column:


The cross-section of the barometric column requires simply to have sufficient cross-section to assure discharge of the water.

D=

D = diameter of the column, in mtr

V = velocity of flow of water in the column, in m/sec

Q = weight of vapour to be condensed, in M3/sec

W = ratio of weight of injection water to weight of vapour condensed,

According to Peter rein More simply, following the form of equation

D > 1.116 x (Qw )0.4

Qw = Total Water and vapour flow rate in condenser in M3/sec.

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.

Types of Condenser System :


From the extraction of the air point of view the condensers can classified as

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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(http://www.sugarprocesstech.com/condenser-system/ )Height of the condenser:


The condenser is a device for exchange of heat between vapour and cold water. The exchange will be the more complete as contact between these two
fluids is more intimate.

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 .

Cross-section of the condenser.


The cross-section will depend directly on the quantity of vapour to be condensed.

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.

Diameter of cooling water pipe :


The cooling water may be supplied by a pump. Its effective head, h, will be equal to the geometrical head at the entry to the condenser, increased by the
vacuum in head of water. We have then:

V=ax

V = water velocity in the inlet pipe, in m/sec

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)

Multi Jet Condensers ( Wet air barometric condensers) :


Principle :
Jet condensers were first placed on the market by Schutte Koerting about 1930. They are based on the dynamic effect of jets of water which,
penetrating into the body of water in the barometric column, enter with them, by friction, the air contained in the condenser. If the cross-section of the
barometric column is small enough to ensure a suitable velocity, the bubbles of air do not rise into the condenser and are evacuated to the well at the foot of
the column.

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05/10/2017 Concepts in Condenser System (Vacuum Equipment)

(http://www.sugarprocesstech.com/condenser-system/ )

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.

Diameter of spray nozzle (Ds)

Ds =

As (area of the each spray nozzle ) = Qs / Vs

Qs = Quantity of water per each spray nozzle in M3/Sec = Quantity of water / No. of spray nozzles

Vs = Velocity of water at nozzle in m/sec =

h = Pressure of water at spray nozzle in kg/cm2 x head at mean sea level

Diameter of jet nozzle (Dj ):

Dj =

Aj (area of the each jet nozzle) = Qj / Vj

Qj = Quantity of water per each jet nozzle in M3/Sec = Quantity of water / No. of jet nozzles

Vj = Velocity of water at nozzle in m/sec =

h = Pressure of water at jet nozzle in kg/cm2 x head at mean sea level

Condenser Vapour pipe dia :


Quantity of vapour to condensed (Q) = Heating surface of the equipment x Evaporation rate.

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.

Single Entry Condenser:

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05/10/2017 Concepts in Condenser System (Vacuum Equipment)
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.

Condenser Water Requirement


In a condenser the vapours entering, transfer heat to the cold injection water, the heat transmission depending on the temperature and quantity of water.
Based on the heat balance the equation for arriving at the quantity of injection water is.

Cooling water ratio ( W ) i n Kg of injection water per Kg of vapour = where

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/)

Ti = temperature of injection water in C

To = temperature of condenser outlet water in C.

According to E.Hugot the optimum value of this Ti and To difference is 10C.

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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Evaporation (http://www.sugarprocesstech.com/category/evaporation/) | / 2 Responses / by siva alluri (http://www.sugarprocesstech.com/author/admin/)

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2 thoughts on Concepts in Condenser System (Vacuum Equipment)


Reply (http://www.sugarprocesstech.com/condenser-system/?replytocom=131#respond)
premkumar tamilnadu (June 27, 2017 - 9:46 am)

i read your article about condensor system. now i need detailed data of water consumption for vapour condensing calculation.thank you

siva alluri (http://www.sugarprocesstech.com) (June 27, 2017 - 3:05 pm)

Dear Prem, Reply (http://www.sugarprocesstech.com/condenser-system/?replytocom=132#respond)


water consumption calculation also given in the above article
Condenser Water Requirement

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