Condenser Function

Hot vapors exit the column top containing light hydrocarbons at temperatures typically 30-80°C. The overhead condenser removes heat, converting vapor to liquid condensate. Portion of this liquid returns to the column as reflux controlling separation efficiency. Remaining condensate flows to product storage or further processing. Proper cooling duty maintains column pressure and achieves specified separation between overhead and bottom products.

Condenser Types

Air-cooled condensers use finned tube bundles with forced or induced draft fans, offering operation without water consumption. Shell-and-tube water-cooled units provide compact design with higher heat transfer efficiency where cooling water is available. ERGIL selects configuration based on climate, available utilities, cooling duty requirements typically 0.5 to 25 MMBTU/hr, and site preferences.

Design Configuration

Process vapor flows through tubes or shell side depending on design with cooling medium on opposite side. Complete condensation or partial condensation with vapor-liquid separation depending on application. Materials handle hydrocarbon service including carbon steel, stainless steel, or special alloys for corrosive streams. Design per ASME Section VIII or API 661 standards with appropriate pressure ratings.

System Integration

Condensed liquid collects in reflux accumulator drum providing surge capacity and vapor-liquid separation. Reflux pump returns controlled liquid flow to column top. Level control in accumulator manages reflux rate and net overhead product takeoff. Temperature and pressure monitoring optimizes condenser performance. Back-pressure control on non-condensables maintains column pressure.

Applications

Condensate stabilizer overhead cooling recovering light naphtha product, deethanizer condensers in NGL recovery plants, depropanizer overhead systems producing propane, and debutanizer units separating butane streams. Serves gas processing facilities, refineries, and petrochemical plants across capacities from 500 to 100,000 BPD throughput.

Cooling Methods

Air cooling suits remote locations without water supply or where water conservation is priority. Water cooling provides smaller footprint and consistent performance regardless of ambient temperature. Refrigerated cooling achieves sub-ambient temperatures for light hydrocarbon recovery. ERGIL engineers cooling systems matching site conditions and process requirements.

Performance Features

Efficient heat removal maintains stable column operation. Reliable condensation ensures adequate reflux for separation control. Fouling-resistant designs minimize maintenance. Proven technology with extensive field application. Materials and construction ensure long service life with proper operation.

Operational Benefits

Automated control maintains column pressure and reflux ratio. Minimal operator intervention required. Easy maintenance access for tube cleaning or fan service. Designed for continuous operation with scheduled inspection intervals. Integration with column controls optimizes overall fractionation performance.

ERGIL overhead condensers deliver dependable vapor cooling ensuring effective distillation control and product recovery in hydrocarbon fractionation operations.