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Condensers (liquefiers) play an overriding role wherever gaseous media are to be converted into a liquid state of aggregation. For example, they can be used in refrigeration plants or heat engines to liquefy exhaust steam or gaseous refrigerants, thus enabling a closed cycle process in combination with a steam generator (evaporator). In addition, condensers (liquefiers) are used in rectification columns as cooling at the top of the column to initiate condensation (liquefaction).

Definition and function of heating condensers

Condensers are special heat exchangers in which a vaporous (gaseous) substance, called vapour, is liquefied (condensed) by cooling. Condensers thus convert gaseous media into a liquid aggregate state. In surface condensers, the vapor condenses on the surface of a heat exchange wall. The vapor and the resulting condensate on the one hand and the coolant on the other flow in separate spaces. The heat exchange takes place indirectly through the condenser partition wall.

The most commonly used surface condensers are shell and tube condensers. Shell and tube condensers are usually installed horizontally with a slight incline. The coolant flows in at the low end and heats up as it leaves the condenser at the high end. The vapor flows around the tubes in the shell space and condenses on the outer tube surfaces. Baffles lead to vapor turbulence and thus to better heat transfer. The condensate formed drips down the pipes and collects at the lowest point, where it is discharged via a condensate drain. Foreign gases carried in (in natural gases that do not participate in the condensation process, e.g. air) are discharged by a deaerator. A remarkable extension of surface condensers is the constructive use of vapor passages and corridor tubes. Vapor passages are gaps in the tube into which the gas tubes are inserted. Compared to the exchanger tubes normally used in the condenser, the gas tubes have a greater wall thickness, as they are more exposed to the droplet impact of the incoming steam, which increases the service life of the appliance.

Condensers are used when the condensate, e.g. toxic substances or solvents, must not mix with the coolant. They can also be used in refrigeration systems or heat engines, for example, to liquefy exhaust steam or gaseous refrigerants and thus enable a closed cycle process in combination with a steam generator (evaporator). In addition, condensers are used in rectification columns as cooling units at the top of the column to initiate condensation (liquefaction).

With the special heat exchangers from ZILONIS Energy Solutions with U- and G-tube, you can implement a condenser (condenser) in your system.

The heat exchangers for condensation (liquefaction) calculated, designed and manufactured by ZILONIS Energy Solutions are available in various materials depending on the requirements. Stainless steel versions are particularly durable and less susceptible to corrosion and deposits - these are generally suitable for the condensation (liquefaction) of pure steam. For an optimum solution, we calculate each condenser individually. All local conditions (e.g. connections) and the customer's design requirements are taken into account.

Thanks to decades of experience in heat exchanger construction in a wide range of sectors and industries, we have the necessary expertise to optimally calculate and manufacture condensers for every application.

Rely on ZILONIS Energy Solutions for customized condensers that provide optimum support for your system and work reliably over the long term.

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