P. O.

BOX 1, KYAMBOGO-KAMPALA, UGANDA

Tel: +256-41-285272/041287341, www. Kyambogo.ac.ug
Mob +256(0) 772-872439/706332576; E-mail: pascalmusaazi@gmail.com
Environmental Engineer (Senior Lecturer) Kyambogo University

FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING

SECTION OF ENVIRONMENT AND REFRIGERATION

CHAPTER ONE: CONDENSERS AND CONDENSATION PROCESS

Prepared by Eng. Musaazi Pascal Ssenkindu (Senior Lecturer)

MIIE; UNARA; MSc (Env. Eng; PgD-RAC; Higher/Ordinary Dipl (Mech. Eng.)

Date: 10thSeptember 2015

Chapter 4
4.0 CONDENSERS AND CONDENSATION PROCESS
4.1 Condensers Loads
Work of Condenser involves the overcoming of the following heat inflows:
 Refrigeration Load  R h11  h4 in.W
Q .O  m

 Actual Compression work Load Pel  h2  h1

 Suction line losses Q Losses  h1  h11

 Ambient Heat flow Q E

  = Ambient heat flow;

Where Q. Q O = Refrigeration load;
E

Pel = Compression Work; Q Losses = heat loss

Q C  Q O  P el Q Losses
Q ON

Q O  PMOT
M

Q C
Semi-Hermetic
Evaporator Compressor

Fig.1. Fundamentals of Condenser Water Cooled

Condenser

The Condenser removes the condensation heat from the refrigerant vapour, Evaporator and from R-
Compressor and supplies it to the coolant say, water. Then more or less superheated refrigerant vapour
comes from R-Compressor being heated, condensed and lastly sub-cools due to more or less condenser
surface area.
As the condensation heat is absorbed from the refrigerant, the condenser must give off this heat to the
coolant. Every condenser consists of three zones. In the first zone (heating rejecting zone), the
superheated refrigerant vapour forming is being removed from the superheating temperature to the
condensing temperature (tC).
There after the refrigerant is being condensed in the second zone. Temperature and pressure remains
constant. In the last zone the sub-cooled refrigerant heat is being removed from sub-cooled refrigerant, it is
cooled from under the condensation temperature to sub-cooling temperature.
2
 The fundamental Coolant Methods include the following:
(i) Air cooled Condensers
(ii) Water Cooled Condensers and
(iii) Evaporative Condensers.
Definition: Condenser is where heat is transferred from the hot compressed refrigerant vapour to a cooling
medium usually water or Air, and the refrigerant is then being liquidified. This is done so that the same
refrigerant may be returned to the evaporator and used again, the cycle of evaporation, compressed and
condensation being repeated indefinitely.

4.2 The Principle function of the refrigerant-side of the Condenser

Coolant
t2 =+50OC  PC =8.0bar

End of Heat rejecting

zone tC = +33OC
 PC =8.0bar
+25OC
Coolant Temp.

End of Condensation
zone tC = +33OC
 PC =8.0bar

End of Sub-Cooling
R12 Zone at tC = +32OC
 PC =8.0bar

Fig.2 Illustration principles of Refrigerant in Condensers

The effective sub-cooling temperature reaches after the Refrigerant Receiver.

The energy process in the condenser flows from state 2 until state 3 and state 4 inclusive. From state 2 to
2’, the necessary Heat rejection enthalpy is being removed from the refrigerant and supplied to the coolant.

3
 The temperature of the refrigerant sinks from superheating temperature to condensation temperature.
From state 2’ to 3’ condensation of refrigerant begins under constant pressure and temperature. From
state 3’ to 3 begins end of sub cooling of the liquid refrigerant.

This is then the first separation, when the refrigerant temperature lies at least at 1K on condensation outlet
under the condensation temperature. Further sub-cooling begins in addition to the Heat exchanger behind
the Receiver.
4.3 Energy Process in the Condensers
Over Superheated
h31 Refrigerant Vapour h21 h2 t2
Coolant

tW2

R-Receiver

tW1
Coolant

t3
Sub-Cooled
Liquid Refrigerant Heat
Condensation Rejection
Liquid h2
Minimal Sub-Cooling Refrigera
t2
nt
h31 tC h21
tW2
t3 h3

Heat flow in Condenser

tW1
Fig. 3. Energy Process in the Condenser

This change of state is found practically by constant pressure (the condensation pressure) and constant
temperature (the condensation temperature) between the stretches 2 to 3.
Important: “The pressure remains constant, because the volume of the condensation part gets ca. 90% of
the condensation volume and also the volume working changes continues”.

4
4.3 Heat flow in the Condensing Zones
Parts in the condensing zone reject heat flow differently. It is interesting,
Heat flow in the Condensation zones for different Refrigerants; is acquired from dry saturated vapour
refrigerant by isentropic compression and an evaporation temperature from –10OC.

Table 1.
Condensing Superheating Su-Cooling Heat Condensation Sub-Cooling Specific
Temp. tC Temp.t2 Temp.t3 Rejection Part Part Condensation
in OC in OC in OC Part in % in % In % Enthalpy
Refrigerant R 12
+30 +40 +25 4.8 91.9 3.3 148.28
+36 +45 +30 4.53 92 3.45 144.08
+40 +50 +35 5.19 91.28 3.53 142.40
+46 +55 +40 5.95 90.62 4.44 138.89
+50 +60 +45 5.72 90.45 3.83 135.95
Refrigerant R 22
+30 +55 +25 9.95 87 3.05 203.21
+36 +65 +30 12.1 84.2 3.7 202.38
+40 +70 +35 13.14 83.68 3.17 198.33
+46 +75 +40 13.70 82.34 3.96 193.09
+50 +85 +45 16.97 79.68 3.34 193.36
Refrigerant R 502
+30 +40 +25 3.36 91.99 4.65 132.57
+36 +45 +30 2.94 91.15 5.91 127.39
+40 +50 +35 3.94 91.00 5.15 123.22
+46 +55 +40 3.53 89.84 6.63 117.40
+50 +60 +45 4.80 89.35 5.85 112.83
Refrigerant R 717
+30 +40 +25 12.52 85.71 1.77 1337.94
+36 +45 +30 14.55 83.32 2.13 1345.49
+40 +50 +35 16.03 82.18 1.79 1342.69
+46 +55 +40 17.36 80.46 2.18 1337.25
+50 +60 +45 18.13 80.02 1.85 1320.91

5
4.4 Types of Condensers
Fundamentally, there are different application purposes between Air-, Water-cooled and Evaporative-
Condensers.

Air-cooled Condensers Water-Cooled Condensers

 Static Air flow Condensers  Through flow Condensers
 Forced Air flow Condensers  Evaporative Condensers

 Plate Condensers  Bare Coil Immerse able; Evaporative

 Fin-tube Condensers  Counter flow -Double tube; Condensers
 Wire-tube Condensers for  Counter flow Shell-and tube; with Radial fans
Household and Commercial use  Co-axial-tube;
 Fin-tube Condenser with Axial  Plain tube coil;
and/or Radial fans
 Shell-and U-tube from plain tube;
Table 2 Types of Condensers

There are several condensers to be considered when making a selection for installation.
They are air cooled, water-cooled, and shell and tube, shell and coil, tube within a tube, and
evaporative condensers. Each type of condenser has its own unique application. Some determining
factors include the size and the weight of the unit, weather conditions, location (city or rural),
availability of electricity, and availability of water. A wide variety of condenser configurations are
employed in the process industry. Selection of condenser type is not easy and depends on the
following criteria:
(i) condenser heat capacity,
(ii) condensing temperature and pressure,
(iii) the flow rates of refrigerant and coolant,
(iv) design temperature for water and/or air,
(v) operation period, and
(vi) climatic conditions;
The type of condenser selected depends largely on the following considerations:
(i) size of the cooling load,
(ii) refrigeration used,
(iii) quality and temperature of available cooling water (if any), and
(iv) amount of water that can be circulated, if water use is acceptable;

6
4.5 Air-and Water Cooled Condensers

Fig. 4 (a) Fin-Tube type Condenser

Domestic refrigerators commonly use the four types of condensers including Finned-tube static (Natural
convection), Finned-tube forced convection (fan driven air), Wire-tube static condensers, Plate-plate static
condensers and Plate-tube condensers. Static means that air circulation through the condenser tubing and
fins is by natural convection; that is, warm air tends to rise. As the air in contact with the fins and tubes
becomes heated, it rises and cooler air takes its place. The tubes and fins are usually made of copper or
steel.

7
For a forced convection fin-tube type of condenser, whenever the compressor is operating, the motor-
driven fan forces air through the condenser. Shown above fig.4 (b) is a Wire-tube type of condenser, which
uses small metal wires brazed, or spot-welded to the condenser tubing. It is usually of the static type.
The plate type of condensers tubes are soldered or brazed to a flat metal surface. This is a very common
type of condenser construction. It is used on many Chest-type freezers. The condenser tubes are attached
to the inside (insulation side) of the freezers’ outer shell. This type of condenser is very easy to keep clean.
It is only necessary to off the surface of the cabinet shell. To get proper removal of heat from the refrigerant
vapour, always keep the condensers area clean.
Commercial systems use three types of condensers including Finned-tube static air-cooled, Finned-tube
forced convection air cooled, and shell-tube Water-cooled and Tube-in-tube water-cooled. The finned-tube
static and the finned-tube forced convection condensers are built much the same as the domestic
condensers, except that they are larger.
Forced convection finned condensers are used on many commercial refrigeration installations. Water-
cooled condensers usually consist of two tubes, one within the other. Water circulates through the inside
tube. Hot compressed vapour circulates through the space between the tubes.
These condensers are usually called tube-within-tube condensers. They are very efficient. With the rapid
development of commercial refrigeration and Air-conditioning, many communities have differently in
supplying enough water for water-cooled condensers.

4.6 Cooling Towers

Thus, more and more forced convection air-cooled condensers and “Cooling towers are being used in
connection with water-cooled condensers and illustrations of cooling towers are shown in figure 6 to follow.
Fig.7 shows a large, three-fan, roof mounted air-cooled condenser installations.

8
Different types of cooling towers, A,B, and C show three different air flow patterns.
D, E, and F show different methods to vaporize some of the water for cooling.
9
In some areas, water contains chemicals making it unsuitable as a coolant. In other localities, water may
be very scarce, expensive, or its use may be limited by law.
To permit use of a water-cooled mechanism and to save on water consumption, water-cooling towers are
used. These towers serve the same purpose as the spray towers used in large industrial refrigeration
systems. A variety of cooling tower designs are shown in fig. 6 (a-to f). Since they can be located away
from noise-sensitive areas such as offices, restaurants, and living quarters.
One system connects the water lines of the condenser to a water coil in an enclosure.
Water is drawn from the sump/basin/reservoir of the cooling tower and circulated throughout the condenser
circuitry before returning to the cooling tower distributor. The distributor is located toward the top of the
cooling tower and enables the water to be evenly sprayed over the fill which increases the water surface
area for the air flow to evaporate and cool the water. The cooled water then collects in the
sump/basin/reservoir for recirculation.
As water evaporates, air draws heat from the body of the water. The larger the surface area of the water
the more heat can be rejected.

A _ An industrial cross-flow cooling tower. B- Diagram of the cooling tower, indicating

the flow of air and its operation. (Baltimore Air coil Company)

10
Water Pumps:
Water pumps are mechanical devices, generally centrifugal type, used to circulate water through pipes and
equipment such as water cooled condensers, cooling towers evaporative condensers, water chillers,
cooling coils, boilers and hot water coils.
Water Treatment:
Water treatment is usually carried out by specialists to comply with the Public Health Act.
Chemical treatment and water filtration are required to reduce/control the build up of bacteria, solids, algae
etc. The water must not be acidic or alkaline; i.e. it must be neutralized, to aid in the prevention of system
corrosion.
A pump forces the water through the condenser and then through the coil in the tower. The tower coil is
pierced with holes, and the water is sprayed into the enclosure.
Air, rushing through the sprayed water, evaporates some of it. Evaporation cools the remaining water to
the outdoor temperature or even lowers it (wet bulb temperature).
In some systems, motor-driven fans control air flow through the cooling tower. Some recent cooling tower
designs use of water at a high enough pressure (15 to 60psig.) to eliminate the need for an air flow fan.
The water spray at these high pressures induces the air flow to accomplish the required cooling.
Cooled water collects in the bottom of the enclosure and passes through a screen that removes or other
foreign material. Then it is recalculated through the condenser. A float-controlled valve in the lower water
pan adds more water as needed. This float operates like a refrigerant low side float mechanism.

11
A drain continually bleeds some water out of the water pan to keep water hardness to a minimum.
Chemicals may be added to retard rust formation, algae fungus growth, and that like.

Typical cooling tower application. Recalculated water is cooled several

degrees in tower. Water is then circulated through refrigerant condenser to
cool it.
The Chilled Water

Chilled water application with water-cooled condenser and cooling tower.

12
 The flow of water from a cooling tower to the condenser of a chillers cooling system
The compression-type chillers use the compressor to create a pressure difference between the high side
and the low side. The pressure difference causes the refrigerant to boil and condense by lowering the
evaporator pressure. Common types of compression chillers include those with centrifugal, scroll, screw,
and reciprocating compressors.
5.0 Air- Cooled Condensers
Air- cooled condensers are quite common in commercial systems. Cooling water may be too expensive or
corrosive. Smaller units use static condensers with thermal air flow. Larger condensers may be cooled by a
big fan built onto the motor or into the compressor flywheel on external drive units. Larger hermetic units
use separate motors to drive the fans.
The efficiency of the fan on air-cooled condenser may be increased by placing a metal shroud around it.
These condensers have fins and frequently use a double or triple row of tubes. Many fin arrangements and
constructions have been used. To cool the compressor head and valves, a double air-cooled condenser is
sometimes used. Refrigerant leaves the compressor and passes through one condenser.
Then it is back through the motor compressor to help cool it. From there it goes into the second condenser,
where it is condensed (cooled) into liquid.

13
 Extended surface fin arrangements used in air cooled condensers.
A-Fin is part of tubing. B-Fin pressed on the tubing. C-Fin fastened by crimped tubing.
D- Fin flange pressed on tubing. E-Coiled wire used as fin. F- Circular fin.
G - Crimped circular fin. H-Large multiple tubing fin.

The air-cooled condensers find applications in domestic, commercial, and industrial refrigerating, chilling,
freezing, and air-conditioning systems with a common capacity of 20−120 tons. The centrifugal fan air-
cooled condensers (with a capacity of 3−100 tons) are particularly used for heat recovery and auxiliary
ventilation applications. In fact, they employ outside air as the cooling medium. Fans draw air past the
refrigerant coil and the latent heat of the refrigerant is removed as sensible heat by the air stream.
The advantages of air-cooled condensers are the following:
(i) no water requirement,
(ii) standard outdoor installation,
(iii) elimination of freezing, scaling, and corrosion problems,

14
 (iv) elimination of water piping, circulation pumps, and water treatment,
(v) low installation cost, and
(vi) low maintenance and service requirement;
On the other hand, they have some disadvantages as given below:
(i) high condensing temperatures,
(ii) high refrigerant cost because of long piping runs,
(iii) high power requirements per kW of cooling,
(iv) high noise intensity, and
(v) multiple units required for large-capacity systems;

Pipe work Installation

Danfoss has introduced a new range of compressors and condensing units for commercial refrigeration,
designed for the ozone-neutral refrigerant R 404A. The new introduction offers a product to meet the

15
phase-out dates set out in the Montreal Protocol, as well as special national schemes to phase out CFCs
and HCFCs.
The R 404A range is a supermarket to the commercial R 34a range. It replaces the range of compressors
and condensing units for R502 and supplements the R22 range.

Refrigerant R 404A
R 404A was introduced by DuPont in 1993 under the trading name. Suva HP62
Today, this refrigerant is marked by all leading refrigerant manufacturers and is considered to be the most
interesting of the known replacement refrigerants for R 502 and to some extent R 22, particularly at low
evaporating temperatures.
R404A is a virtually azeotropic refrigerant with a temperature glide below 1°C. It is non-toxic and
nonflammable. P 404A consists of R 143afR 125/P 134a in the ratio 52%/44%/4% (% by weight) and is
primarily used in refrigerating appliances operating at relatively low evaporating temperatures but will also
be used in the MBP evaporating temperature range.
Full Range
The full R 404A range was presented at the IKK fair in October 1994. The range covers both compressors
and condensing units and will be far more extensive than the present ranges for P O2 and R 22, since in
addition to SC compressors it also includes P 404A compressors based on the well-known TL and FR
types.

16
17
 Condensers provide the surface area to allow heat rejection to take place from the
refrigerant to the cooling medium. High pressure refrigerant vapour is condensed
to a liquid. The vapour temperature is firstly reduced to the condensing
temperature. The saturated vapour then condenses into a liquid without a change
in temperature. The two processes that basically take place are:
 Removal of sensible heat
 Removal of latent heat of condensation

5.0.1 Finned-tube Condensers with Axial fan

WL =1.5m/s 2.0m/s 2.5m/s
From Q C =220W 270W 295W
12kW 14kW
to Q C = 9.8kW

NB: 1. Tube distance apart = 25/22mm

2. Fin distance apart = from 2.5mm to 4.2mm
3. Tube diameter = 10mm.
There also Circular fin-tube; Crimped circular-tube constructions and large multiple fin-tubing.
5.1 Water-Cooled Condensers

ELT AMC SCH/SCS

SST VSE
tube in tube ammonia Coaxial
shell and tube shell and coil
application
Various water-cooled condensers (Courtesy of Standard Refrigeration Company).
Many large commercial refrigerating units use Water-cooled type condensers. This condenser is built in
three styles:
1. Shell and tube-Opposite Fin-tube condenser;
2. Shell and coil;
3. Tube-within-a tube.
In the first type, the refrigerant vapour goes directly from the compressor into a tank or shell while the water
travels through the tank or shell in straight tubes finned for better heat transfer. The second type also uses
a shell but the water travels through the shell in coils of tubing.
The third type uses two pipes or tubes-one inside the other. The refrigerant passes one way through the
outer pipe or tube, while the condenser water flows in the opposite direction through the inner tube.
18
 Water-cooled condensers are of many different types. The most common condensers are generally shell
and tube type heat exchangers with refrigerant flow through the shell and water (as coolant) flow through
the tubes. The lower portion of the shell acts as a liquid receiver. These condensers are widely used in
large heat capacity refrigerating and chilling applications. If a water-cooled condenser is used, the following
criteria must be examined:
(i) requirement of cooling water for heat rejection,
(ii) utilization of a cooling tower if inexpensive cooling water is available,
(iii) requirement of auxiliary pumps and piping for re-circulating cooling water,
(iv) requirement of water treatment in water recirculation systems,
(v) space requirements,
(vi) maintenance and service situations, and
(vii) provision of freeze protection substances and tools for winter operation;
5.1.1 Tube-within-tube water-Cooled Condensers
The tube-within-a tube water cooled condenser is popular because it is easy to make. Water passing
through the inside tube cools the refrigerant in the outer tube. The outside tubing is also cooled by air in the
room. Double cooling improves efficiency in a cylindrical, spiral or rectangular style. To increase heat
transfer, the inner tube is grooved by 6-lead and an 8-lead tube work.
Water enters the condenser at the point where hot vapour from the compressor enters the condenser. This
is called counter flow design. The warmest water is adjacent to the warmest refrigerant, and the coolest
refrigerant to the chilled water.

Tube in tube: have a small tube inside a larger tube. The water flows through the smaller tube whilst the
refrigerant flows in the outer / larger tube. Some heat rejection will be to the surrounding air. They need to be
cleaned chemically

19
 Water velocity should be at least 7fps (feet per second) but no more than 10fps. If flow is too fast, water
may remove the oxide coating causing pitting. If the water velocity drops to 3fps, scaring will occur. Water-
cooled compressors are sometimes used with water-cooled condensers. The water flow, then through the
cylinder head, and finally into the drain water flow may be regulated by an automatic water valve.

Refrigerant Receiver-OUB
A liquid line filter-drier with sight glass
and moisture indicator. This filter-drier is
compatible with all CFC, HCFC, and
HFC refrigerants.

Two common types of liquid receivers. Note the liquid line

service valve at O. It allows easy charging of refrigerant.
20
5.1.2 Shell-and Coil water-Cooled Condensers
The shell and coil condenser is very much like the shell and tube water-cooled condenser. It has a coil of
water tubing inside the shell rather than a straight tube. It is often used in smaller commercial units.
While the shell and coil condenser is less costly to manufacture, it cannot be mechanically cleaned.
The water tube is only chemically cleaned.

Shell and coil: generally have a coil of tube fitted inside a casing/shell. The water flows through the coil whilst
the refrigerant is contained in the casing/ shell. This type of condenser can act as a liquid receiver. They need
to be cleaned chemically.
5.1.3 Shell-tube water-Cooled Condensers
The shell and tube is a cylinder usually made of steel with copper tubes inside. Water circulates through
the tubes condensing hot vapours in the cylinder into a liquid. The bottom part of the shell serves as the
liquid receiver.

21
The shell and tube condenser has some advantages. It is compact, needs no fans, and combines the
condenser and receiver in one.
It uses a number of straight tubes inside the receiver with a water manifold on both ends. When these
manifold ends are removed, the water can easily be cleaned of deposits. This type is sometimes called a
shell and pipe condenser.

Diagrammatic Layout of Baffling and Water Pass Arrangements

22
5.1.4 Evaporative water-Cooled Condensers
The evaporative condenser system carries the refrigerant into a condenser which is in an enclosure much
like a cooling tower. In this system, as the word “evaporative “indicates, water is sprayed or drops over the
condenser. This cools it. The water cycle is in the condenser cabinet only.
Usually, the evaporative condenser is mounted outdoors. However, it may be used indoors if air ducts are
provided to the outside. Some systems pump water to a trough above the condenser. The water then drips
over coils as air is forced through them. A thermostat can be used to control the water flow. A fan blows air
over the condenser when ever the condensing unit is opening.
The condenser is cooled by air alone until the condenser temperature reaches 27OC or more. Water
cooling is then turned on by a thermostat. Some units sub cool the refrigerant leaving the receiver by piping
the receiver outlet (liquid line) into and out of the evaporative condenser.
Temperature of the refrigerant can be dropped 6OC by sub-cooling. When the temperature reaches 7OC or
lower, the water is shut off. However, the condenser can still carry the load as air-cooled condensers.
Some have water reservoirs inside the building. For protection from freezing weather the reservoir
must be large enough to hold all the water in the system. Fan dampers are sometimes used to
decrease air flow as outside temperature drops.
Evaporative condensers are used in medium to large capacity systems. These are normally cheaper
compared to water cooled condensers, which require a separate cooling tower. Evaporative
condensers are used in places where water is scarce. Since water is used in a closed loop, only a
small part of the water evaporates. Make-up water is supplied to take care of the evaporative loss. The
water consumption is typically very low, about 5 percent of an equivalent water cooled condenser with
a cooling tower. However, since condenser has to be kept outside, this type of condenser requires a
longer length of refrigerant tubing, which calls for larger refrigerant inventory and higher pressure
drops. Since the condenser is kept outside, to prevent the water from freezing, when outside
temperatures are very low, a heater is placed in the water tank. When outside temperatures are very
low it is possible to switch-off the water pump and run only the blowers, so that the condenser acts as
an air cooled condenser.
Another simple form of condenser used normally in older type cold storages is called as atmospheric
condenser. The principle of the atmospheric condenser is similar to evaporative condenser, with a
difference that the air flow over the condenser takes place by natural means as no fans or blowers are
used. A spray system sprays water over condenser tubes. Heat transfer outside the tubes takes by
both sensible cooling and evaporation, as a result the external heat transfer coefficient is relatively
large. The condenser pipes are normally large, and they can be either horizontal or vertical. Though
these condensers are effective and economical they are being replaced with other types of condensers

23
due to the problems such as algae formation on condenser tubes, uncertainty due to external air
circulation etc.

Another evaporative condenser design. Note air and water flow.

Water make-up is controlled by float valve.

24
 Air Out Air Out

Air Blowers
Blower
Motor

Drift Eliminator

Air Spray

Refrigerant in

Refrigerant out

Air in
Make up Water

Air in

Water Sump

Water Pump
Schematic of Evaporative Condensers

EVAPORATIVE CONDENSERS
 Water cooled
 Air cooled
These condensers consist of metal tube coils where the discharge vapour passes
through. Water is sprayed through the spray nozzles above the coils. The water then
absorbs the heat from the discharge vapour in the coils, evaporates and thus dissipates

25
the heat into the atmosphere. A fan is used to move air over the coil thereby increasing
the evaporative effect. The water is circulated over the coils by means of a pump.

26
5.2 Evaporative water-Cooled Condensers connecting possibilities
Manometer with
Motor Manometer cock (0-1.5bar)
Adjustmen
t

Air Gate
Entrance
Protection
Valve to adjust pressure
Ceiling 0.5bar on entrance

Foundation
Base
Water loss line

Adjustable
Valve At least 40mm

Fresh Water
Overflow
Water Filter Evacuation

Air Cooled Vs Water Cooled Condensers:

The Salient features of air cooled and water cooled condensers are shown below.
The advantages and disadvantages of each type are discussed below.
Parameter Air cooled Water cooled
Temperature difference, TC – Tcoolant o
6 to 22 C 6 to 12OC

Volume flow rate of coolant per TR 12 to 20 m3/.min 0.007 to 0.02m3/min

Heat transfer area per TR 10 to 15m2 0.5 to 1.0m2
Face Velocity 2.5 to 6 m/s 2 to 3 m/s
Fan or pump power per TR 75 to 100 W negligible

27
 Advantages and disadvantages:
Air-cooled condensers are simple in construction since no pipes are required for air. Further, the disposal of
warm air is not a problem and it is available in plenty. The fouling of condenser is small and maintenance
cost is low. However, since the specific heat of air is one fourth of that of water and density is one
thousandth of that of water, volume flow rates required are very large. The thermal conductivity is small;
hence heat transfer coefficient is also very small. Also, air is available at dry-bulb temperature while water
o
is available at a lower temperature, which is 2 to 3 C above the wet-bulb temperature. The temperature
rise of air is much larger than that of water, therefore the condenser temperature becomes large and COP
reduces. Its use is normally restricted to 10 TR although blower power goes up beyond 5 TR. In systems up
to 3 TR with open compressors it is mounted on the same chassis as the compressor and the compressor
motor drives the condenser fan also. In middle-east countries where is shortage of fresh water these are
used up to 100 TR or more.
The air-cooled condensers cost two to three times more than water-cooled condensers. The water-cooled
condenser requires cooling tower since water is scarce in municipality areas and has to be recycled. Water
from lakes and rivers cannot be thrown back in warm state since it affects the marine life adversely.
Increased first cost and maintenance cost of cooling tower offsets the cost advantage of water-cooled
condenser. Fouling of heat exchange surface is a big problem in use of water.

6.0 Heat Passage Coefficient (Refrigerant-Condenser K in W/m2K)

Water-Cooled Condenser
1.
Immersed Coil R717 230
2.
Opposite flow-Double tube R717 700-800
3.
Opposite-Fin-tube R717 700-800
4.
Co-axial tube R 1750-2300
5.
Coiled tube R 350-580
6.
Shell-Plain tube R717 870-1400
7.
Integral Shell-finned tube R717 520-800
8.
Tower-condenser R717 870-1750
Water Saving Condenser
1. Spray condensers R717 1160-
2. evaporative condenser R717,R 350-700
Air –Cooled Free Convection
1. Chimney condenser R 8-14
2. Finned tube R 6-12
3. Wire-tube R 10-14
4. Forced Air-cooled R717, R 17-35
1. The bigger the condensing cooling surface areas, so also the bigger is the condensing power;
2. The bigger the k-Value of a condenser, so the bigger is the power;
3. The bigger the temperature difference between cool- and refrigerant, so the bigger is its power.

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6.1 Working Example 1
Condensation K-Value
The bigger is the condensation power, the higher is the condensation temperature rises over the coolant
temperature.
Q C  AxKxTm in kW From the evaporation performance plus the electrical clamp power gives the
condensation power of 6kW. The k-Value is 20W/m2K. Find middle mean temperature by cooling surface
area of 12m2.
Middle mean temperature = 6000/20x12 = 25K
6.2 Working Example 2
An Air-cooled condenser with radial fan measures as in picture has condensation temperature +45 OC, k-
Value by 30W/m2K, its cooling surface area 79m2. The ambient temperature of +30OC being assumed.
How big are the condensation power, when the outlet air temperature apart from that condenser is +35 OC,
+40OC?
tL2 = +35OC; +40OC

+45OC T1e

Refrigerant
T1S T2

T2e
T1 +35OC
Air flow
O
T2S +30 C tC = +45OC

tL1=t Amb = +30OC

Solution 1 Solution 2
TS1 = 318-303 =15K; TS1 = 318-303 =15K
TS2 = 318-308 =10K TS2 = 318-313 =5K
Using same flow formula Using same flow formula
T1s  T2 S   T1e  T2e  T1s  T2 S   T1e  T2e 
Tm  Tm 
T  T2 S  T  T2 S 
In 1s In 1s
T1e  T2 S  T1e  T2 S 
Tm = 12.33K; Tm = 9.1K
Q C  AxKxTm in kW

Q C  79 x30 x12.33.  .29222W Q C  79 x30 x9.1.  .21567W

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 t C in OC t Amb = tL1 in OC tL2 in OC Tm in K Q C in W

+45 +30 +35 12.33 29222

+45 +30 +40 9.1 21567
NB:
1. The smaller the condensation cooling surface area is, the bigger must be the temperature difference,
and the demanded power should remain constant.
2. Small-cooling surface area demands big temperature difference while big cooling surface area demands
small temperature difference.
To keep Condensation Power low will be promoted by:
Air Cooled
(i) Keep Straight fins by plastic comb;
(ii) Circulate high fresh air;
(iii) Clear condensing unit out of rubbish blockage;
Water Cooled
(i) Treat water to avoid infections;
(ii) De-scale condenser tubes (water hardness if any);
(iii) Supply constant clean water using water regulating valve;

Installation and servicing of home air conditioners is one of the many careers open to a
person with knowledge and hands –on training in refrigeration and air conditioning.

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 HOT AND COLD AIR WAVES FLOW PATTERNS IN EVAPORATORS AND CONDENSERS

A serviceable commercial system with air-cooled condenser, thermostatic expansion valve and V-type
compressor. Note size of compressor. (Carrier Corp., Subsidiary of United Technologies Corp.)

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 TEMPERATURE AND RELATIVE HUMIDITY BY THE REFRIGERTION STORAGE
COMPILED TOGETHER FROM REFRIGERATION TECHNOLOGY RESEARCH
INSTITUTE KOPENHAGEN
Some of Storage RH Storage Some of Storage RH Storage
Trade Ware Temp. % Time Trade Ware Temp. % Time
O O
C D= Days; C D= Days;
W=Weeks; W= Weeks;
M=Months M= Months
Green Pineapples +10-+16 85-90 2-4W Maize -0.5 -+1.5 80-85 1-4M
Orange 0-+1.2 85-90 8-10W Malt +1.7 65 6M
Banana +11.7 2W Margarine +0.5 80 6M
Beer 0-+5 85 6W Melon +2- +7 80-90 1-8W
Flowers +1.1 85-90 2W Melon +2 -+4 75-85 2-3W
Cauliflower 0-+2 85-90 2-3W Milk 0 +2 80-85 1W
Blood -3.9 75 1W Milk Powder 0 +1.5 75-80 1-6M
Green Beans +1-+7.5 85-90 8-10D Non-Green Carrot 0 +1 80-95 2-5
Dry Beans +0.7 70 6M Bundled Carrot 0 85-90 1-2W
Butter -10 - -1 75-80 6M Nuts 0- +2 65-75 8-12M
Butter Milk 0 85 1M Frozen Fruits -23- -15 80-90 6-12M
Eggs -1- -0.5 80-85 8M Dry Fruits 0- +5 70 6-18M
Frozen Eggs -18 12M Fruit Juice -15 - -23 80-90 2-8M
Dry Eggs +2 Small 6M Cooking Oil -15 - +12 6-12M
Ice -4 80 Grape fruit 0-+10 85-90 3-12W
Ice cream -30 - -20 85 2-12W Sweet Pepper +7- +10 85-90 1-3W
Green Pea 0 80-90 1-3W Dry Pepper 0-+10 70-75 6-9M
Dry Pea +0.5 75 6M Plant +1 85 2W
Strawberry -0.5-+1.5 75-85 7-10D Rice 0- +1 85-95 2W
Fat +0.5 80 6M Beef 0- +1.5 88-92 1-6W
Fat -18 90 12M Frozen Beef -24 - -18 85-95 3-12M
Fresh Fish -0.5-+4 90-95 1-2W Cream 0- +2 80 1W
Frozen Fish -20- -12 90-95 8-10M Salads 0 -+1 85-90 1-2W
Salty Fish -2- +1 80-90 4-8M Grain seed -10- -2 70 3-12M
Smoked Fish +4- +10 50-60 6-8M Ham 0- +1 85-90 7-12M
Dried Fish 0- -9 75-80 3M Frozen ham -24- -18 90-95 6-8M
Fresh Chicken 0 80 1W Salty ham +15- +18 75-80 12M
Frozen Chicken -30- -10 80 3-12M Smoked ham -10- -2 70 3M
Frozen Vegetables -24- -18 6-12M Chocolate +4.5 75 6M
Cucumber +2-+7 75-85 10-14D Pork 0- +1 80-90 3-10D
Yeast 0 75 2W Frozen pork -24 - -18 85-95 2-8M
Mutton 0 80 10D Syrup (Dose) +1 80 6W
Frozen Mutton -12 - -18 80-85 3-8M Fresh Bacon -23- -10 90-95 4-6M
Dried Mutton -12- -18 80-85 3-8M Smoked bacon +15 - +18 60-65
Pumpkin 0 75 2W Spinat 0-+1 90 10-14D
Honey +1 75 6M Bale Tobacco +1 75 6M
Lamb Meat 0- +1 90 5-10D Green Tomatoes +10- +20 85-90 3-4W
Frozen Lamb meat -24- -12 80-90 6M Ripe Tomatoes +1 +5 80-90 1-3W
Irish Potatoes +3-+6 85-90 6M Wine +10 85 6M
Cherry +0.5-+1 80 1-3W Fresh Sausage +4 -+5 85-90 1-3W
Cabbage 0-+1 75-80 6-8M Smoked Sausage +4 -+5 85-95 3M
Pumpkin 0-+3 80-85 2-3M Sugar +7- +10 <60 1-3Yr
Cheese +1 -+1.5 65-75 3-10M Onion +1.5 80 3M
Liver -24 - -18 90-95 3-4M Apple -1 -+1 85-90 2-7M
Lemons +5- +10 80-90 2M

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