Direct Contact Principle

Hot vapor enters vessel bottom. Cool water sprays downward from multiple nozzle levels. Vapor contacts cold water droplets condensing on liquid surfaces. Heat transfers directly without tube barriers. Non-condensable gases cool while condensable components liquefy.

Condenser Design

Vertical tower with vapor inlet at bottom, multiple spray headers at different heights distributing cooling water, liquid collection sump at bottom, cooled gas outlet at top, recirculation pump, cooling water supply and makeup. Height provides contact time for target condensation.

Operating Advantages

Direct contact more efficient than shell-tube exchangers for dirty or fouling services. No tube surfaces to foul. Handles particulates and contaminants. Lower capital cost than surface condensers. Compact design saves space.

Cooling Water

Recirculates through spray system with makeup replacing evaporation and blowdown. Heat absorbed from vapor heats water. External cooler or cooling tower maintains water temperature. Water quality important preventing spray nozzle plugging.

Material Selection

Carbon steel for hydrocarbon service. Stainless steel for corrosive applications or high-purity requirements. Spray nozzles resist plugging and erosion. Materials handle thermal cycling during operation.

Applications

Vacuum system vapor condensing, vent gas cooling before compression, thermal oxidizer quench, geothermal steam condensing, atmospheric tower overhead cooling, and any vapor service where direct contact condensation acceptable.

Temperature Control

Spray water flow rate controls outlet gas temperature. More water increases cooling. Automated valve modulation responds to temperature changes maintaining setpoint. Balance between cooling duty and water consumption.

Vapor Loading

Design handles vapor flow rate and heat duty. Adequate spray coverage ensures complete vapor contact. Sufficient tower height provides residence time. Gas velocity prevents liquid entrainment in outlet.

Liquid-Vapor Separation

Mist eliminators at top capture entrained water droplets preventing carryover. Proper gas velocity through separator prevents flooding. Clean gas exits meeting downstream requirements.

Performance Benefits

Efficient vapor cooling and condensation. Handles fouling services without tube cleaning. Lower cost than surface condensers. Simple operation with minimal maintenance.

Water Treatment

Makeup water treatment prevents scaling and corrosion. Chemical injection controls pH and inhibits fouling. Blowdown removes concentrated contaminants. Proper water management maintains spray system performance.

Construction Standards

Design per applicable pressure vessel codes. Spray system design for uniform distribution. Materials for process conditions. Complete documentation with thermal and hydraulic calculations.

ERGIL spray condenser DC units provide efficient direct contact vapor cooling serving refining and chemical process applications.