Condensers: Air Cooled

CONDENSERS
Condensers make use of a condensing medium, such as air or water, that absorbs heat from a vapor. As the vapor loses its
heat to the condensing medium, its temperature falls to the saturation point, and it condenses to a liquid.
(Copyright Alfa Laval, Richmond, VA)
AIR COOLED
Air cooled condensers use air as the cooling medium. They are the most used type of condensers.
(Copyright Dimplex Thermal Solutions, Kalamazoo, MI)
GENERAL INFORMATION
Air cooled condensers use circulating air to cool hot gases. In most large models, a fan is used to either push or pull the
air through the condenser. Smaller models, however, usually depend on gravity to circulate the air.
EQUIPMENT DESIGN
The hot vapor to be condensed travels through a series of finned copper tubes. Fans force air to circulate around the
tubes, and this air removes heat from the vapor. The resulting condensate drips down the tubing into a reservoir or out a
drain.
Condensers can be designed for one or two stages, as shown on the left. While the two-stage condenser is more efficient,
it is also more expensive.
USAGE EXAMPLES
Condensers are used in power plants to condense exhaust steam from turbines. They are also used in refrigeration plants
to condense refrigeration vapors such as ammonia or fluorinated hydrocarbons, and in the petroleum and chemical
industries to condense a variety of chemical vapors. The air cooled condensing unit shown below is a chilling system used
for ice and curling rinks.
(Copyright BERG Chilling Systems Inc.,Toronto, ON)
The condenser shown below has a "V-type" design that is used in refrigeration and air-conditioning installations. This
condenser has alumininum fins and the optimized V shape results in excellent heat transfer with minimized refrigerant
charge.
(Copyright Alfa Laval, Richmond, VA)
ADVANTAGES
Easy to install.
DISADVANTAGES
As water condenses, it has the risk of freezing at
Requires no water.
Condensing medium, air, will not freeze.
low operating temperatures.

Adequate supply of fresh air required.
Fan may be loud in large operations.
Changes in air temperature may cause the
condensing pressures to fluctuate.
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WATER COOLED
This section discusses water cooled condensers, such as the one shown here.
(Copyright BERG Chilling Systems Inc.,

Toronto, ON)
(Picture copyright Alfa Laval,

Richmond, VA)
GENERAL INFORMATION
In most water cooled condensers, the water runs through tubing or coils in a sealed shell. The hot vapor that is to be
condensed is released into this shell (above right).
EQUIPMENT DESIGN
The water cooled chillers shown below use an evaporator to remove heat from the process and then use a water cooled
condenser to remove the heat from the evaporator. Water conducts heat better than air, making water cooled condensers
smaller, cheaper and able to consume less energy per horsepower than air cooled condensers.
(Pictures copyright First Choice Chillers, Markham, Ontario)
USAGE EXAMPLES
Water cooled condensers require an adequate supply of fresh water, and are used in power plants to condense exhaust
steam from turbines, in refrigeration plants to condense refrigeration vapors such as ammonia or fluorinated
hydrocarbons, and in the petroleum and chemical industries to condense a variety of chemical vapors.
ADVANTAGES
Lower condensing pressures than air cooled

condensers.
Better control over condensing pressure.
Since water has excellent heat transfer
characteristics, water cooled condensers are more
compact than air cooled condensers.
DISADVANTAGES
Excessive water velocities or cavitation inside the

condenser tubes can damage condensers.
At low operating temperatures, condensing
medium and condensate may freeze.
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EVAPORATIVE
GENERAL INFORMATION/EQUIPMENT DESIGN
Evaporative condensers are used when the water supply is insufficient to operate a water cooled condenser, or when the
condensing temperature is lower than air cooled condensers can achieve. A water/air mixture, the coolant, is sprayed
into a chamber through which the hot vapor passes. As these substances come in contact with each other, the water
quickly evaporates. The loss of this heat of vaporization causes the vapor feed to condense. This process requires much
less cooling water than water cooled condensers, making evaporative condensers practical for hot, arid regions.
(Image copyright SPX Cooling Technologies, Overland Park, KS)
ADVANTAGES
Water consumption is only a fraction of that in water

cooled condensation.
Condensing temperatures are close to the wet bulb
temperature.
DISADVANTAGES
The water may freeze at low operating temperatures.

Impurities in the vapors may cause corrosion.
A small amount of the cooling water must be
continually purged to prevent the build-up of
contaminants.

Condensers: Air Cooled

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CONDENSERS

(Copyright Alfa Laval, Richmond, VA)

(Copyright Dimplex Thermal Solutions, Kalamazoo, MI)

(Copyright BERG Chilling Systems Inc.,Toronto, ON)

(Copyright Alfa Laval, Richmond, VA)

As water condenses, it has the risk of freezing at

low operating temperatures.

(Copyright BERG Chilling Systems Inc.,

(Picture copyright Alfa Laval,

(Pictures copyright First Choice Chillers, Markham, Ontario)

Lower condensing pressures than air cooled

Excessive water velocities or cavitation inside the

(Image copyright SPX Cooling Technologies, Overland Park, KS)

Water consumption is only a fraction of that in water

The water may freeze at low operating temperatures.

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