Gas Condenser: The Ultimate FAQ Guide

In this guide, you will find all information you’re looking for about gas condensers.

Among the key aspects, you will learn include applications, benefits, limitations, quality certifications, cleaning, and maintenance, amongst others.

Keep reading to learn more.

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What is Gas Condenser?

A gas condenser is a highly efficient system that you can use to recover sensitive and latent heat from polluted gasses.

It has different components including pillow plates at the core which help in getting rid of heat from the polluted gas.

Gas condenser system

 Gas condenser system

What are the Main Applications of the Gas Condenser?

You will use the gas condenser to in various industrial applications.

Here are some of the industrial applications where gas condensers come in handy.

· Chemical Industry

The gas condenser will help in the elimination or recovery of latent and sensitive heat from different chemical gases.

· Heat Recovery Industry

Just from the name, you will note that the gas condenser comes in handy in the recovery of heat from different gases.

· Process Therm

You will use the gas condenser in process therms to recover energy from smoke or gas streams with high humidity.

· Oil and Gas Industry

You will also use the gas condenser in the purification process of gases in the oil and gas industry.

Apart from the above applications, you can use the gas condensers in the following industrial applications.

  • Pulp and Paper Industry
  • Mining Industry
  • Agricultural Industry in the production of fertilizer
  • Food and Beverage Processing Industry
  • Pharmaceutical Industry
  • Textile Industry

What are the Benefits of Using the Gas Condenser?

There are numerous benefits that come with the use of gas condensers in different industrial applications.

Here are some of the benefits that you will realize when you use the gas condensers.

· High Heat Exchange Efficiency

Gas exchangers has various components such as pillow plates which increase the efficiencies of heat transfer.

It assists in making the process of heat elimination simpler and faster thus increasing the overall production efficiency.

· Reduction in Pressure Drops

You will also save a lot of cost by using the gas condensers due to the fact that they reduce the pressure drops.

You will save on the investment capital as well as the cost of operation when you use the gas condensers.

· Easy Cleaning Process

Gas exchangers clean different types of gases in a very easy and simple cleaning process.

It does not spend a lot of energy in the whole process of eliminating heat from gases.

· Design Flexibility

You have the freedom of coming up with different and unique designs for your gas condenser.

The flexible designs are flexible for both new installations as well as retrofit situations.

· Wide Range of Operation

You can use the gas exchanger in a wide range of applications capable of handling different pressure and temperature conditions.

Apart from that, it also has a wide range of heat-transfer capacities capable of eliminating wide range of heat capacities.

Are there Limitations of Using the Gas Condensers?

Yes, unfortunately, there are limitations to the use if the gas condenser.

Here are some of the limitations that you will experience by using the gas condensers.

 Condensing boiler

 Condensing boiler

· System Complexity

You might experience situations where the gas condensers shut down especially in very cold conditions.

This is due to the fact that the external connecting pipes have a high susceptibility to freezing weather conditions.

· Expensive to Maintain

You should prepare to spend a considerable amount of money in the cleaning and maintenance process of the gas condensers.

It has a complex system that will require a lot of resources to clean and maintain well.

What are the Main Components of a Gas Condenser?

Gas condensers depend on various parts that work in conjunction with one another to eliminate heat from gas.

Here are the main parts of the gas condenser system that help in the overall function.

· Condenser Coil

This is the part that performs the entire condensation process and helps in the elimination of heat from the system.

It is made of different types of materials such as copper tubings and aluminum fins which help in rapid heat elimination.

· Fans

Gas condensers have fans that help in propelling the gas through the gas condenser system for other parts to take action.

You will determine the size of the fan according to the size of the gas condenser you are building.

· Pillow Plates

These are two spaced thin steel sheets that are welded to one another that deform in order to cool a circulation medium.

It helps the gas condenser in the process of eliminating heat from the gases flowing through the pillow plates.

· Control Unit

The control unit is the panel that allows you to control all the operations of the gas condenser from a standing point.

You will be able to program the machine and also monitor all the operations taking place within the gas condensers.

· Electric or Power Unit

This is the system that provides the power which the gas condenser needs to properly get rid of excess heat.

It has capacitors among other electric installations which control the quantity of energy flowing to the gas condenser.

· Transport System

You will depend on the transport system to assist in the movement of gas from one point of the gas exchanger to the next.

It consists of pipes and tubes which begin from the inlet of the gas condenser all the way to the outlet.

How Does a Gas Condenser Work?

Gas condenser system

Gas condenser system

Gas condensers have special designs that operate according to your own working specifications.

It employs the different parts that work in conjunction with one another to eliminate heat from gases.

The process begins with the production of gas that has excess heat in the industrial application such as biomass production.

You can refer to the gas as the combustion gas since it is a product of combustion and also has a lot of heat.

The combustion gas will flow in an external direction through the inlet of the gas condensers.

Once inside the gas condenser, the gas will flow through the pillow plates.

Apart from the action of the pillow plates, we have water flowing throughout the gas condensers.

The circulating water in pipes is in constant circulation from the industrial zones.

The water alongside the action of the pillow plates will create pressure systems and relative humidity within the gas condensers.

The humidity and pressure will lead to condensation of the heated gas thus proper recovery of heat.

You can modify the pillow plates within the gas condensers to work at maximum just from the control panel.

As soon as the gas condenser recovers heat from flowing gas, it will proceed to eliminate the gas through the outlet.

You can also use gas condensers to clean and get rid of debris from flowing gas through the same process.

Which Factors Must You Consider When Selecting a Gas Condenser?

There are quite a number of factors that you need to place under proper consideration before you select a gas condenser.

Here are the main factors that you need to look at when selecting the gas condensers.

· Construction Materials

You have a whole list of materials that you can use in the process of manufacturing a gas condenser.

It is important to choose materials such as copper and aluminum which will help in rapid heat elimination.

· Cost of the Equipment

You must also have a proper budget that will cover the purchase, installation, and running of the gas condensers.

It is important to know the type of gas condenser that will fit your application requirements as your budget.

· Working Capacity

In this case, you will look at how much gas the gas condensers can condense comfortably without stressing the system.

You will look at factors such as the industrial application requirements when determining gas condenser working capacity.

How Does the Gas Condenser Achieve an Efficiency Exceeding 100%?

You can use the gas condenser to achieve condensation efficiency that exceeds 100%.

Implying that the gas condenser will work towards achieving heat recovery that will exceed the lower heating value of input fuel.

In that case, you will assume that the combustion products are not condensed when performing the usual efficiency calculations.

It will be implicit especially when you will be basing your calculations on the lower heating values of the gas condenser.

Alternatively, you can base your efficiency calculations on the higher heating values which will result in efficiencies less than 100%.

Which Materials Do You Use to Manufacture the Gas Condensers?

The main materials that you will use in the process of manufacturing gas condensers are stainless-steel.

You will use different grades of stainless-steel which include:

  • Austenitic Stainless-steel (AISI 304, AISI 316L, AISI 316Ti, AISI 317, AISI 321, others)
  • Ferritic Stainless-steel (AISI 430)
  • Special Stainless-steel (SMO 254, AISI 904L, others)
  • Duplex Stainless-steel (SAF 2205, SAF 2307, LDX 2101)
  • High Nickel alloys (Hastelloy)

Apart from the main materials which is stainless-steel, you can use copper and aluminum materials.

These materials have very high heat conduction rates that help in the elimination of heat at rapid rates.

What are the main Quality Certifications for the Gas Condensers?

You must make sure that your gas condensers are of very high quality.

It is the reason why we have quality specifications that dictate the quality requirements of the gas condensers.

Here are the main quality certifications that you have to pay close attention to.

  • Pressure Equipment Directives Quality Certifications such as PED 2014/68/EU
  • ASME U-STAMP Quality Certifications
  • AD2000 Quality Certifications

How Does a Gas Combi Condenser Compare to a Gas Condensing Condensers?

Just from the name, you will realize that the gas combi condenser is a combination of different types of capabilities.

Implying that you can use the gas combi condenser to eliminate heat while providing the heat for other purposes.

It can use the heat for heating water and then transfer the hot water for other industrial applications.

On the other hand, gas condensing condensers are responsible for the elimination of heat and other debris from flowing gas.

In many cases, the gas condensing condensers usually get rid of the heat from the system instead of recycling.

Why Do You Need a Gas Condenser?

You need the gas condenser in your industrial applications to help in the elimination of heat from gasses.

It will help in making gas cooler before you inject the gas into other applications.

Apart from that, you will need the gas condensers to help you in getting rid of dirt and debris in the gas.

It will help you in cleaning the gas and preparing them for other purposes after eliminating the debris.

What Makes the Gas Condenser Safe?

Gas condensers are usually safer due to a number of safety features on them.

One of the safety features is proper heat insulation which will insulate the heat from escaping into the environment.

You can, therefore, work in a perfectly cool environment where the gas condenser is installed.

Apart from that, it has sensors that will help in detecting any malfunction on the system.

It will either warn you of the malfunction or pending danger or automatically shut down if the risk is great.

It also disposes of the heat via pipes which direct the heat outside and eliminates it in a safe mode.

What are the Common Problems that You are Likely to Face with the Gas Condenser?

Modern gas condensation systems are one of the most reliable machines that you can use in any application.

Despite the technological advancements to make them safe and reliable, you might experience a few problems.

Gas condensers usually use a lot of water which often drains into the water reservoirs.

You should consider having your industry next to a large water body which will provide plenty of water for use.

In the cold season, the machine may automatically stop working due to frozen gas condensate pipes.

There are technical advances that re looking into the situation to make the gas condensers more reliable in the cold seasons.

You can also prevent the problem by housing the outlet in an area that you can warm during the cold winter seasons.

How Many Sizes of Gas Condensers Do You Supply?

There are a couple of factors that you must consider when choosing the right size of the gas condenser.

In this case, you will look at the size of the industrial application and how much gas you intend to cool and clean.

Apart from that, you will also look at other issues such as the availability of inputs such as water.

These inputs are responsible for sustaining the operations of the gas condenser through every step.

In a nutshell, there are various sizes of gas condensers that you can choose from as long as you can support them.

How Much Does the Gas Condenser Cost?

Gas condensers are available for you to purchase at varying prices ranging between 1000 to 200000 US Dollars.

There is a very huge price gap between the simplest type of gas condenser and the complex types of gas condensers.

In that case, the price variation is as a result of the type of gas condenser and quality of gas condenser.

You will realize that the high-quality gas condensers cost a lot more than the low-quality gas condensers.

In addition to that, the more gas condensers you purchase, the higher the cost unless you get a discount.

Which Flow Directions Do Gas Condensers Follow?

In the gas condensers, there are different types of fluids that flow within the tubes.

On the other hand, we also have fluids that flow outside the tubes in different directions.

Here are the main directions of fluid flow that takes place within the gas condenser.

Boiler condense

 Boiler condenser

· Parallel Flow

This is a situation where the cold and hot fluids flow in and outside the tubes in one direction.

· Counterflow

In this case, the cold and hot fluids will flow within and outside the tubes in opposite directions.

· Cross Flow

Here is a situation where the hot and cold fluids flow outside and in the tubes in perpendicular directions.

What is Tub Resistance in Gas Condensers?

Tub resistance is the opposition to the transfer of heat from one fluid to the other.

In the gas condensers’ heat elimination process, there are barriers between different fluids.

The barriers can be in the form of metal tubs that will cause a certain degree of resistance.

This form of resistance is the tub resistance which creates opposition to the flow of heat through fluids.

How Do You Clean and Maintain the Gas Condenser?

You should clean and maintain the gas condenser on a regular basis to get rid of dust and dirt.

Regular cleaning and maintenance of the gas condensers eliminate debris that might clog the system.

It is the same reason why you should consider inspecting the machine regularly to identify faults.

Here is a step by step process that you can follow when cleaning and maintaining the gas condensers.

Shutting Down the Machine

First, you will have to shut down the machine before you embark on the cleaning and maintenance process.

Allow the machine to cool down to prevent cases of being burned especially when you touch the machine.

After that, you will refer to the cleaning and inspection schedule to identify the parts that require special attention.

Cleaning the Machine

You will proceed with the cleaning process which involves getting rid of the debris and dust that clog the systems.

You will use different types of cleaning materials such as water, and special detergents that get rid of the stains.

Apart from that, you will also make sure that you clean the pipes which may harbor molds and other toxic substances.

Maintenance of the Machine

This is the point where you take care of the gas condenser systems by replacing the broken parts of the machine.

Apart from that, you will lubricate all the moving parts of the machine and refill the fluid reservoirs.

As soon as you complete this process, you will inspect the whole machine again after putting things together.

You will finish by testing the machine and marking the dates for the next cleaning and maintenance date on your schedule.

What is the Difference Between Condensing and Non-Condensing Gas Condensers?

Well, in the application of the gas condensers, you can choose the condensing or non-condensing gas condensers.

Here is a comparison between the two types that will influence your choices.

· Condensing Gas Condensers

It consists of one or more than one gas condensation chambers that operate at lower combustion temperatures.

It recycles the exhaust gas through the gas condenser systems thus reducing pollution through CO2 elimination reduction.

It is often quite costly to purchase but you will realize its efficiency in cost savings as you operate it continuously.

· Non-Condensing Gas Condensers

 Non condensing gas system

F Non condensing gas system

It consists of a single unit of gas condensers and operates with high-temperature combustion products reaching 180 degrees.

It directs almost 70% of the gases for heat elimination and allows 30% to be wasted thus causing environmental pollution.

In addition to that, it has a very high carbon footprint which also contributes to the pollution of the environment.

The initial cost of purchase is low, but the cost usually increases as you operate the machine.

In short, there are many factors to consider when importing gas condenser systems.

The best part, the FilSon Filters team will help you find the best Gas Condenser systems.

Contact us today for all your gas condenser needs.

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