Enerquip’s stainless steel custom vapor condensers are designed and manufactured with the utmost care and attention to detail. We use state-of-the-art technology and techniques to produce durable, efficient condensers that meet all of your heating and cooling needs.
Our engineers have the expertise, ASME Code and TEMA knowledge, and industry experience to design condensers for even the toughest applications, process requirements, and size limitations. Whatever your requirements for a vapor condenser may be, we have a solution that fits your needs.
Vapor Condensers: What are they and how are they used?
Vapor condensers work by cooling a vapor to the point where it condenses back into a liquid. This is achieved by passing the vapor through a heat exchanger, where it comes into contact with a cooler surface, typically a tube or a series of tubes. The cooler surface causes the vapor to lose heat, and as a result, it begins to condense back into a liquid.
The condensed liquid then flows out of the heat exchanger and is collected in a separate container, while any remaining vapor is released into the atmosphere or directed back into the process from which it originated.
Vapor condensers are used in a wide range of industries, such as power generation, renewable fuel, chemical processing, refrigeration, cannabis, food and beverage, and pharmaceuticals, to recover valuable products or to reduce emissions of harmful gases into the atmosphere.
Types of Vapor Condensers
There are different types of vapor condensers, but the most common shell-and-tube condensers include the following.
Solvent Recovery Condensers
In solvent recovery systems, vapor condensers play a vital role in controlling emissions and recovering valuable solvents. They function by condensing vapors, allowing the condensed liquid to be collected and reused or safely disposed of. These condensers can operate under both vacuum and pressure conditions, ensuring efficient solvent recovery and emission control.
Reflux Condensers
In reflux systems, vapor condensers are crucial for condensing vapors and returning the condensate back to the process. Typically mounted directly on a tank or reactor vent flange, they cool the rising vapors, causing them to condense and drip back into the tank. This efficient vapor condensation and reflux action improve process control and efficiency. Reflux condensers can also be designed as stand-alone units, mounted vertically or horizontally.
Knock-back Condensers / Cold Trap Condensers
In knock-back and cold trap systems, vapor condensers are essential for capturing and condensing vapors. Designed as vertical U-tube units with a removable tube bundle, they allow vapors to contact the cooled tubes and condense. The condensate then drains out the bottom of the shell, ensuring efficient vapor condensation and removal. These condensers can include an extended shell section to collect condensate away from the tube bundle.
Pharmaceutical Condensers
In pharmaceutical processes, vapor condensers ensure the purity of product streams during condensation. Featuring polished product contact surfaces and sanitary tri-clamp connections designed to ASME-BPE standards, they maintain the highest levels of hygiene. These condensers typically condense vapors on the tube side of the exchanger, available in single and double tube sheet designs. Electro-polished tube-side finishes and various materials, including 304L or 316L SS and Hastelloy, are available.
Terpene & Oil Condensers
In the essential oils and CBD processing industries, vapor condensers ensure product quality and safety under extreme temperature and pressure conditions. With a focus on sanitary design and ASME certifications, these condensers maintain the integrity of the product stream while meeting all safety requirements. They efficiently condense vapors, allowing the collection of high-purity essential oils and CBD extracts.
Emissions Abatement Condensers
Vapor condensers play a crucial role in emissions abatement by capturing and condensing volatile organic compounds (VOCs) and other hazardous vapors emitted during industrial processes. These vapors are cooled in the condenser, transitioning from gas to liquid. The condensed liquids are then collected for safe disposal or recycling, reducing the amount of harmful emissions released into the atmosphere. By removing VOCs and other pollutants from the exhaust stream, vapor condensers improve air quality and ensure compliance with environmental regulations.
Vacuum Systems Condensers
In vacuum systems, vapor condensers are essential for creating and maintaining efficient vacuum conditions. They lower the pressure by removing condensable vapors from the system, preventing potential damage to vacuum pumps and reducing efficiency losses. This vapor removal reduces the load on vacuum pumps, leading to lower energy consumption and operational costs. Additionally, vapor condensers maintain stable vacuum levels, which is critical for processes requiring precise pressure control, such as chemical reactions and material processing.
Customizing Your Vapor Condenser
At Enerquip, customization is almost endless.
Technical Specifications & Options:
Sizes: Up to 48” diameter (or larger depending on weight)
Styles: U-tube, straight tube, single-pass or multi-pass configurations
Materials: 304 SS, 316L SS, Duplex, Hastelloy & AL6XN
Standards: TEMA, ASME, 3-A, PED and CRN
Additional Design Options: Electropolished tube side surfaces, passivation of tube side surfaces, sight glasses, level gauge ports, CIP spray ball assemblies, condensate collection sumps/chamber, etc.
Contact Us
Enerquip’s engineers bring extensive ASME Code and TEMA knowledge, coupled with vast industry experience. Utilizing state-of-the-art technology and techniques, we produce durable, efficient condensers tailored to meet our customer’s unique needs.
Contact us today for a quote or to learn more about our products and services.