1. Evaporative Condenser Introduction

An evaporative condenser is a high-performance heat exchange unit that integrates efficient condensation with significant water and energy savings. By ingeniously combining the latent heat of water evaporation with forced air convection, it achieves far superior heat transfer efficiency compared to traditional air-cooled or water-cooled condensers.

The core working principle is as follows: high-temperature, high-pressure refrigerant vapor from the refrigeration system enters the coil circuit. Simultaneously, a recirculating water pump sprays water evenly over the external surface of the coil, creating a thin film. An axial fan then draws air upwards through the unit, causing it to pass at high velocity over the wet coil surface. During this process, a portion of the water evaporates instantly, absorbing a vast amount of latent heat of vaporization, which efficiently removes heat from the refrigerant inside the coils, causing it to condense rapidly into a liquid. The unevaporated water falls back into the bottom sump for reuse.

2. Evaporative Condenser Application

• Metallurgical Industry

The evaporative condenser can be used in the soft water cooling and sealing cycle of the iron-making blast furnace; the cooling water of the steel-making heating furnace, crystallizer, and oxygen lance; the cooling water system of steel rolling and coking; the Cooling water of the blower, motor, and other equipment.

• Power industry

Evaporative condenser is mainly used in the power industry as an auxiliary cooling system for the main air cooling system, for condensing exhaust steam from small steam turbines, and replacing or retrofitting traditional water cooling systems.

• Chemical industry

Evaporative condensers are mainly used in the chemical industry for condensation in distillation and distillation systems, cooling and condensation in reaction vessels, condensation in vacuum systems, cooling and condensation of process gases, and recovery of steam condensate water.

• Coal chemical industry

  Evaporative condensers are used in the coal chemical industry for methanol production, such as cooling and condensation in methanol distillation, synthesis, and compression sections, and cooling in synthetic ammonia production, such as compression and synthesis sections; Condensation in ammonia synthesis systems, cooling condensation in urea production and downstream chemical product production processes such as dimethyl ether, olefins, etc

3. Evaporative condenser type

• 3.1 Header type evaporative condenser

Header type evaporative condenser includes plug header-box type evaporative condenser and remove-cover plate evaporative condenser.

Advantages :

1. Easy to repair: The plugs at both ends of the pipe box can be disassembled
2. Moderate price: The price is lower than that of a removable box-type evaporative condenser
3. Good sealing and reliability

Disadvantage :

1. The threaded connection between the plug and the pipe box is a potential leakage point
2. Generally not applicable to ultra-high-pressure working conditions.

• 3.2 Coil Coil-type evaporative condenser 
  Coil-type evaporative condensers are divided into Coil Type Cross-flow evaporative condenser and Coil Type Counter-flow type evaporative condenser.

(1) Coil-type cross-flow evaporative condenser

Advantages 

1. Using PVC fill to replace part of the heat exchange coil, the heat transfer efficiency is higher than the counter type
2. Light weight, small initial investment

Disadvantage

1. Fill is prone to blockage and needs to be cleaned every 2 years, replacedevery  3~5 years.
2. Large installation area

(2)Coil-type counter-flow evaporative condenser

Advantages 

1. Without fill, long service life.
2. Cheaper than box-type evaporative
3. Fully welded and sealed, not easy to leak

Disadvantage

1. Hard to find the leak point and maintain when leaking due to being fully welded.
2. The serpentine tube structure has large wind resistance.
3. Many takeovers and complicated pipelines