Energy-Saving and Water-Saving Evaporative Condenser

Principle Brief

The evaporative condenser is mainly composed of an axial flow fan for exhaust heat and humidity, a water separator, a spray water distributor, a cooling (condensing) heat exchanger, a circulating water pump, etc. Circulating water is sprayed downward from the upper part, wets the outer surface of the tubes of the cooling (condensing) heat exchanger to form a uniform water film, undergoes heat and mass transfer with the air flow passing across the tubes, then flows into the lower air layer for sensible heat exchange with the air flow. The water temperature is approximately the wet bulb temperature of the air, and then collected in the water tank at the bottom to complete a cycle. It is then pumped to the upper water distributor by the circulating water pump for spraying, so that the spray water continuously flows through the tubes of the cooling (condensing) heat exchanger. The air flow introduced by the axial flow fan for exhaust heat and humidity flows through the wetted tubes of the cooling (condensing) heat exchanger simultaneously with the spray water in a countercurrent or crossflow manner. Under certain heat load and inlet air volume conditions, the water temperature of the spray water reaches an equilibrium temperature during the circulation process. If the operating conditions remain unchanged, the equilibrium temperature will also remain unchanged. During the entire process, the spray water in the water tank is neither heated nor cooled. To maintain a stable water level in the water tank, the evaporated part of the spray water needs to be continuously replenished. The make-up water flows into the water tank controlled by a float valve. A water separator is installed at the upper part of the spray device to prevent water droplets from being carried away by the air.

Technical Features

Axial Flow Fan

A draft-type axial flow fan specially designed for exhausting hot and humid air. It is an improved cooling tower fan with propeller blade type aluminum alloy material, whose noise is 5-10 decibels lower than that of similar ordinary fans. It has the advantages of large air volume and appropriate air pressure, and the blade angle can be adjusted to change the air volume and air pressure. The fan extracts hot and humid air, forming negative pressure in the lower space, accelerating the evaporation of the water film on the outer surface of the tubes, and improving the evaporative cooling efficiency.

Water Collector

A PVC filler layer arranged in a sinusoidal wave cross-staggered pattern, which makes the saturated humid air turn three times and twist twice in a staggered manner, effectively separating water from the humid air and preventing water drift. The air resistance is lower than that of conventional M-wave and S-wave fillers.

Spray System

Adopts stainless steel spiral nozzles with a solid cone spray shape and a spray angle of 90-120°. The droplet size can be changed with the water pressure and flow rate. The nozzles can be easily maintained, cleaned and replaced during operation. With a diameter larger than 10mm, the nozzles will not be blocked by rust or impurities in the water.

Coil Heat Exchange Elements

Adopt a fully welded structure, which can withstand high operating temperature and pressure. The straight tube header type allows individual replacement of each heat exchange straight tube, suitable for harsh working environments. The material of the heat exchange elements can be stainless steel tubes, brass tubes, red copper tubes, etc., and the type can be coil type.

The evaporative condenser integrates the condenser heat exchange coil of the water-cooled condenser-cooling tower system directly into the cooling tower cabinet, combining the cooling and condensation process of the process fluid with the circulating water cooling process into one, realizing direct cooling and efficient heat dissipation. It mainly uses the heat absorbed during water evaporation to condense the refrigerant vapor in the tubes, and has the advantages of water saving, energy saving and small floor space.

The "high-efficiency and energy-saving evaporative condenser" technology has the following key innovations:

1.Adopts alternating curved corrugated tubes of high-efficiency enhanced heat transfer tubes;

2.Applies nano-hydrophilic coating treatment to the coil tubes;

3.Optimizes and controls the air volume and water volume of the evaporative condenser all year round according to different outdoor air and circulating water conditions;

4.Low initial investment and operating cost.

Application Fields

It is used in the fields of petrochemical industry, energy, environment, equipment and mechatronics. At present, it has been initially promoted and applied in industrial and civil buildings, such as condensation and cooling of various top tower oil and gas, cooling of oil products, and interstage cooling of compressors in the oil refining and chemical industry; closed-circuit circulation cooling of cooling water, steam, refrigerants and other process fluids in the power, metallurgy, refrigeration and other industries. Especially for the condensation and cooling of media below 80℃, it has incomparable advantages compared with other cooling equipment. The evaporative condenser can be effectively, safely and stably applied to compressor coolers of ice machine systems in chemical fertilizer plants and chemical factories, ketone-benzene dewaxing (deoiling) units, gas fractionation units, propane (butane) deasphalting units, alkylation units, alkylbenzene units, furfural units, reforming units, aromatic extraction units, dry gas desulfurization units, hydrogen production units, gasoline isomerization units, gasoline etherification units, n-hexane units, gasoline and diesel hydrotreating units, jet fuel hydrotreating units, jet fuel sweetening units, atmospheric and vacuum distillation units, catalytic units in kerosene and chemical factories, as well as natural gas light hydrocarbon recovery units and metallurgical industry, etc. The evaporative condenser effectively integrates the functions of a cooling tower and a heat exchanger into a single piece of equipment, which can cool the cooled fluid temperature to a level quite close to the air humidity.