Evaporative Condensers

Evaporative Condensers

The vapor to be condensed is circulated through a condensing coil, which is continually wetted on the outside by a recirculating water system. Air is pulled over the coil, causing a small portion of the recirculating water to evaporate. The evaporation removes heat from the vapor in the coil, causing it to condense.

The evaporative condenser has a cabinet with a water-sprayed condenser, and it usually has one or more fans. The excess heat is removed by evaporating water. In an evaporative condenser the primary coolant of the cooling system is cooled, which is the opposite of a cooling tower. Evaporator condensers are more expensive than dry coolers and are primarily used in large cooling systems or systems where the outdoor temperature is high. In many locations around the world, regulations limit the physical size of a cooling system and this in turn limits the use of evaporative condensers.

Spraying a condenser with water exploits the fact that the dew point temperature is lower than the air temperature and that a wet surface transfers heat more efficiently.

 

1 Hot primary coolant

2 Cold primary coolant

3 Cold water

4 Water sprinklers

5 Centrifugal fan

Key benefits of Evaporative Condensers

• Low system operating costs: lower condensing temperatures for a more compact compressor using less power
• Low refrigerant charge, costs and environmental impact minimised
  
• Space-saving: up to 50% area savings compared to comparable air-cooled installations
  
  
  
  
  
  
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Water-Cooled Condensers

Three main types of water-cooled condensers are pipe in a Pipe", " shell and Coil and plate. Each type performs the same task, approximately in the same conditions using different designs for ships, which contain water and refrigerant in the condenser. Consider every type, from the smallest to the largest capacity.



Pipe-in-pipe", sometimes called the double pipe or coaxial capacitor. Its name reflects its design. One tube is placed in a big pipe, and the ends of large tubes are sealed. Water circulates through one of the tubes, while the refrigerant passes through the other. In this figure, the refrigerant passes through the space between the inner and outer tube. This is the normal arrangement.





These capacitors are flexible in their location and because they are long, as a rule, they are in different forms to fit the space limitations of the application. Product shown here, a boxed product, designed for installation indoors. The compact nature of pipe-in-Pipe " capacitor makes it ideal for this product.

Tube-in-tube condensers most often are used for air conditioning products up to 5 tons of cooling capacity. They are also used, however, the commercial products through approximately 20 tons, as this vertical air conditioning (VAC). This design is ideal for adding air conditioning to old buildings being renovated...

Air-cooled condenser types

There are two types under this category, viz.

 (a) natural convection and

(b) forced air type.

 

 

Natural Convection Condenser

Air movement over the surface of condenser tubes is by natural convection. As air comes in contact with the warm-condenser tubes, it absorbs heat from the refrigerant and thus the temperature of the air increases. Warm air being lighter, rises up and in its place cooler air from below rises to take away the heat from the condenser. This cycle goes on. Since air moves very slowly by natural convection, the rate of flow of heat from the refrigerant to air will be small. Thus a natural convection condenser is not capable of rejecting heat rapidly. Therefore a relati vely large surface area of the condenser is required. Hence the use of this type of condenser is limited to very small units such as domestic refrigerators. It, however, requires very 45 Refrigeration Equipment little maintenance.

 

In the small units, the condenser is fixed at the rear of the refrigerator cabinets. Generally, steel tubes are used, steel being cheaper than copper. To increase the heat-transfer area, wires are welded to the condenser tubes.These wires provide mechanical strength to the coil as well. In certain designs,widely-spaced fins are used. It is necessary to space the fins quite widely to avoid resistance to free (natural convection) air movement over the condenser. Still another design is the plate-type. The condenser coil is fastened to aplate. The plate being in contact with the condenser tubes, the surface area of the condenser is increased. The plate-type condenser is mounted on the back of the refrigerator cabinet with a small gap between the cabinet and the plate. This gap gives an air-flue effect and facilitates better natural convection air currents.It is obvious that while locating refrigerators or deep-freezes cabinets with a natural convection condenser fixed on the cabinet, sufficient care should be taken to allow free air movement. Also they should not be near an oven or

any warm location.

 

Forced-air Circulation Condenser

 

This type employs a fan or blower to move air over the condenser coil at a certain velocity. The condenser coil is of the finned type. Fins in such coils are closely spaced (ranging between 8 and 17 fins per inch). The space between the fins gets choked with dirt and lint. Therefore to obtain optimum capacity, the fins should be kept clean. For circulating air over the condenser, fans are mounted on the shaft/pulley of the compressor motor. 

 

For bigger-capacity plants a separate motor is used to drive the fan or blower as also for hermetic-compressor units

 

 

 

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Types of Condenser

1.Air Cooled
2.Water Cooled
3.Evaporative

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Condenser

The functions of the condenser are to desuperheat the high pressure gas, condense
it and also sub-cool the liquid.
Heat from the hot refrigerant gas is rejected in the condenser to the condensing
medium-air or water. Air and water are chosen because they are naturally
available. Their normal temperature range is satisfactory for condensing
refrigerants.
Like the evaporator, the condenser is also heat exchange equipment

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Atmospheric Fluidized Bed Combustion (AFBC) Boiler

Atmospheric Fluidized Bed Combustion (AFBC) Boiler

Most operational boiler of this type is of the Atmospheric Fluidized Bed Combustion. (AFBC). This involves little more than adding a fluidized bed combustor to a conventional shell boiler. Such systems have similarly being installed in conjunction with conventional water tube boiler.

Coal is crushed to a size of 1 – 10 mm depending on the rank of coal, type of fuel fed to the combustion chamber. The atmospheric air, which acts as both the fluidization and combustion air, is delivered at a pressure, after being preheated by the exhaust fuel gases. The in-bed tubes carrying water generally act as the evaporator. The gaseous products of combustion pass over the super heater sections of the boiler flow past the economizer, the dust collectors and the air preheater before being exhausted to atmosphere.

Pressurized Fluidized Bed Combustion (PFBC) Boiler

Pressurized Fluidized Bed Combustion (PFBC) Boiler

In Pressurized Fluidized Bed Combustion (PFBC) type, a compressor supplies the Forced Draft (FD) air and the combustor is a pressure vessel. The heat release rate in the bed is proportional to the bed pressure and hence a deep bed is used to extract large amount of heat. This will improve the combustion efficiency and sulphur dioxide absorption in the bed. The steam is generated in the two tube bundles, one in the bed and one above it. Hot flue gases drive a power generating gas turbine. The PFBC system can be used for cogeneration (steam and electricity) or combined cycle power
generation. The combined cycle operation (gas turbine &
steam turbine) improves the overall conversion efficiency by
 5 to 8%.

Atmospheric Circulating Fluidized Bed Combustion Boilers (CFBC)

Atmospheric Circulating Fluidized Bed Combustion Boilers (CFBC)

In a circulating system the bed parameters are so maintained as to promote solids elutriation from the bed. They are lifted in a relatively dilute phase in a solids riser, and a down-comer with a cyclone provides a return path for the solids. There are no steam generation tubes immersed in the bed. Generation and super heating of steam takes place in the convection section, water walls, at the exit of the riser.

CFBC boilers are generally more economical than AFBC boilers for industrial application requiring more than 75 – 100 T/hr of steam. For large units, the taller furnace characteristics of CFBC boilers offers better space utilization, greater fuel particle and sorbent residence time for efficient combustion and SO2 capture, and easier application of staged combustion techniques for NOx control than AFBC steam generators.

Stoker Fired Boilers

Stoker Fired Boilers

Stokers are classified according to the method of feeding fuel to the furnace and by the type of grate. The main classifications are spreader stoker and chain-gate or traveling-gate stoker.

Spreader Stokers

Spreader stokers utilize a combination of suspension burning and grate burning. The coal is continually fed into the furnace above a burning bed of coal. The coal fines are burned in suspension; the larger particles fall to the grate, where they are burned in a thin, fast-burning coal bed. This method of firing provides good flexibility to meet load fluctuations, since ignition is almost instantaneous when firing rate is increased. Due to this, the spreader stoker is favored over other types of stokers in many industrial applications.

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Chain-grate or Traveling-grate Stoker

Chain-grate or Traveling-grate Stoker

Coal is fed onto one end of a moving steel grate. As grate moves along the length of the furnace, the coal burns before dropping off at the end as ash. Some degree of skill is required, particularly when setting up the grate, air dampers and baffles, to ensure clean combustion leaving the minimum of unburnt carbon in the ash.

The coal-feed hopper runs along the entire coal-feed end of the furnace. A coal gate is used to control the rate at which coal is fed into the furnace by controlling the thickness of the fuel bed. Coal must be uniform in size as large lumps will not burn out completely by the time they reach the end of the grate.

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Waste Heat Boiler

Waste Heat Boiler

Wherever the waste heat is available at medium or high temperatures, a waste heat boiler can be installed economically. Wherever the steam demand is more than the steam generated during waste heat, auxiliary fuel burners are also used. If there is no direct use of steam, the steam may be let down in a steam turbine-generator set and power produced from it. It is widely used in the heat recovery from exhaust gases from gas turbines and diesel engines.




                          

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Pulverized Fuel Boiler

Pulverized Fuel Boiler

Most coal-fired power station boilers use pulverized coal, and many of the larger industrial water-tube boilers also use this pulverized fuel. This technology is well developed, and there are thousands of units around the world, accounting for well over 90% of coal-fired capacity.

The coal is ground (pulverized) to a fine powder, so that less than 2% is +300 micro meter (μm) and 70-75% is below 75 microns, for a bituminous coal. It should be noted that too fine a powder is wasteful of grinding mill power. On the other hand, too coarse a powder does not burn completely in the combustion chamber and results in higher unburnt losses.
The pulverized coal is blown with part of the combustion air into the boiler plant through a series of burner nozzles. Secondary and tertiary air may also be added. Combustion takes place at temperatures from 1300-1700°C, depending largely on coal grade. Particle residence time in the boiler is typically 2 to 5 seconds, and the particles must be small enough for complete combustion to have taken place during this time.

This system has many advantages such as ability to fire varying quality of coal, quick responses to changes in load, use of high pre-heat air temperatures etc.

One of the most popular systems for firing pulverized coal is the tangential firing using four burners corner to corner to create a fireball at the center of the furnace.

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Thermic Fluid Heater

Thermic Fluid Heater

In recent times, thermic fluid heaters have found wide application for indirect process heating. Employing petroleum - based fluids as the heat transfer medium, these heaters provide constantly maintainable temperatures for the user equipment. The combustion system comprises of a fixed grate with mechanical draft arrangements.

The modern oil fired thermic fluid heater consists of a double coil, three pass construction and fitted with modulated pressure jet system. The thermic fluid, which acts as a heat carrier, is heated up in the heater and circulated through the user equipment. There it transfers heat for the process through a heat exchanger and the fluid is then returned to the heater. The flow of thermic fluid at the user end is controlled by a pneumatically operated control valve, based on the operating temperature. The heater operates on low or high fire depending on the return oil temperature, which varies with the system load

The advantages of these heaters are:

• Closed cycle operation with minimum losses as compared to steam boilers.
• Non-Pressurized system operation even for temperatures around 250 0c as against 40 kg/cm2 steam pressure requirement in a similar steam system.
• Automatic control settings, which offer operational flexibility.
• Good thermal efficiencies as losses due to blow down, condensate drain and flash steam do not exist in a thermic fluid heater system.

The overall economics of the thermic fluid heater will depend upon the specific application and reference basis. Coal fired thermic fluid heaters with a thermal efficiency range of 55-65% may compare favorably with most boilers. Incorporation of heat recovery devices in the flue gas path enhances the thermal efficiency levels further.

 

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Fluidized Bed Combustion (FBC) Boiler

Fluidized Bed Combustion (FBC) Boiler

 

Fluidized bed combustion (FBC) has emerged as a viable alternative and has significant advantages over conventional firing system and offers multiple benefits – compact boiler design, fuel flexibility, higher combustion efficiency and reduced emission of noxious pollutants such as SOx and NOx. The fuels burnt in these boilers include coal, washery rejects, rice husk, bagasse & other agricultural wastes. The fluidized bed boilers have a wide capacity range- 0.5 T/hr to over 100 T/hr.

When an evenly distributed air or gas is passed upward through a finely divided bed of solid particles such as sand supported on a fine mesh, the particles are undisturbed at low velocity. As air velocity is gradually increased, a stage is reached when the individual particles are suspended in the air stream – the bed is called “fluidized”.

With further increase in air velocity, there is bubble formation, vigorous turbulence, rapid mixing and formation of dense defined bed surface. The bed of solid particles exhibits the properties of a boiling liquid and assumes the appearance of a fluid – “bubbling fluidized bed”.

If sand particles in a fluidized state is heated to the ignition temperatures of coal, and coal is injected continuously into the bed, the coal will burn rapidly and bed attains a uniform temperature. The fluidized bed combustion (FBC) takes place at about 840 OC to 950 OC. Since this temperature is much below the ash fusion temperature, melting of ash and associated problems are avoided.

The lower combustion temperature is achieved because of high coefficient of heat transfer due to rapid mixing in the fluidized bed and effective extraction of heat from the bed through in-bed heat transfer tubes and walls of the bed. The gas velocity is maintained between minimum fluidisation velocity and particle entrainment velocity. This ensures stable operation of the bed and avoids particle entrainment in the gas stream.

 

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Packaged Boiler

Packaged Boiler

The packaged boiler is so called because it comes as a complete package. Once delivered to site, it requires only the steam, water pipe work, fuel supply and electrical connections to be made for it to become operational. Package boilers are generally of shell type with fire tube design so as to achieve high heat transfer rates by both radiation and convection.

The features of package boilers are:

• Small combustion space and high heat release rate resulting in faster evaporation.
• Large number of small diameter tubes leading to good convective heat transfer.
• Forced or induced draft systems resulting in good combustion efficiency.
• Number of passes resulting in better overall heat transfer.
• Higher thermal efficiency levels compared with other boilers.

These boilers are classified based on the number of passes - the number of times the hot combustion gases pass through the boiler. The combustion chamber is taken, as the first pass after which there may be one, two or three sets of fire-tubes. The most common boiler of this class is a three-pass unit with two sets of fire-tubes and with the exhaust gases exiting through the rear of the boiler.

 

 

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Water Tube Boiler

Water Tube Boiler

 

In water tube boiler, boiler feed water flows through the tubes and enters the boiler drum. The circulated water is heated by the combustion gases and converted into steam at the vapour space in the drum. These boilers are selected when the steam demand as well as steam pressure requirements are high as in the case of process cum power boiler / power boilers.

Most modern water boiler tube designs are within the capacity range 4,500 – 120,000 kg/hour of steam, at very high pressures. Many water tube boilers nowadays are of “packaged” construction if oil and /or gas are to be used as fuel. Solid fuel fired water tube designs are available but packaged designs are less common.

The features of water tube boilers are:

• Forced, induced and balanced draft provisions help to improve combustion efficiency.
• Less tolerance for water quality calls for water treatment plant.
• Higher thermal efficiency levels are possible

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Fire Tube Boiler

Fire Tube Boiler

In fire tube boiler, hot gases pass through the tubes and boiler feed water in the shell side is converted into steam. Fire tube boilers are generally used for relatively small steam capacities and low to medium steam pressures. As a guideline, fire tube boilers are competitive for steam rates up to 12,000 kg/hour and pressures up to 18 kg/cm2. Fire tube boilers are available for operation with oil, gas or solid fuels. For economic reasons, most fire tube boilers are nowadays of “packaged” construction (i.e. manufacturers shop erected) for all fuels.

 

 

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What type of boiler do you need?

When choosing between boilers there are several things to consider. The size of your boiler, the type, construction and energy efficiency will all have an impact on your home and your energy bills. Take some time to consider your options and think carefully about which boiler to choose.

Conventional boilers
Conventional boilers use a storage tank to supply hot water. The water is heated via cast iron heat exchangers and combination boilers can supply gallons of hot water at one time. Once the stored hot water runs out, there may be a delay in supply as the tank refills.
Conventional boilers tend to require more space than combination boilers as the hot water cylinder requires connection with a cold water storage tank that will typically be placed in the loft. This also means that installation is often more complicated than with a combination boiler.
Older models of conventional boilers tended to be less energy efficient, but advances have been made and newer models can be adjusted to match the specific heating requirements of your home.
British Gas offer a range of conventional boilers including compact systems that can easily be fitted into most modern kitchens.

Combination boilers
Combination boilers, or combi boilers, supply water directly from the mains without the need for a storage tank. As a result, combination boilers supply hot water on demand in unlimited supply.
Combination boilers are ideal for smaller properties where space is at a premium.
Combi boilers also provide water at mains pressure, meaning you can enjoy a strong, hot shower without the need for an additional shower pump.
Combination boilers from British Gas include condensing technology and an ECO mode, both of which improve your control over water heating by maintaining boiler temperature whilst in standby mode.

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Boiler

A boiler is a closed vessel in which water or other fluid is heated. The fluid does not necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating applications, including central heating, boiler-based power generation, cooking, and sanitation.

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Disc mill type Pulverizer

Disc mill type Pulverizer- Economic pulverizing of plastic granules          
Our pulverizing systems, are high capacity systems for the profitable pulverizing of thermoplastic and other heat sensitive materials such as LDPE, LLDPE, MDPE and HDPE, as well as other heat sensitive thermoplastics such as PP and EVA without the added cooling of nitrogen.

Our  pulverizing systems produce quality powders with excellent flow properties and bulk densities nd are mainly used for the following applications:

    Pulverization of rigid PVC (pipe and profile granules)
    Pulverization of PE for Rotomolding
    Pulverization of PE for textile and metal coating
    Pulverization of PP for fiber manufacture
    Pulverization of compounds for floor coverings

This Pulverize machine is simple, clearly arranged and operates with a further developed screening machine. The advantages for the customer are obvious:

    Quality powders with best possible flow properties and high bulk density
    High throughput capacity at low specific power consumption
    Fully automatic, continuous operation

Low demands on operating personnel

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