Reflux Problems

CH VENKATESH
13021A2536
A tower overhead system consists of a condenser, reflux drum,
and reflux pump.

The condenser, in particular, is subject to a variety of problems related to:

1. Leaking vapor bypass control valve
2. Back-flushing condensers
3. Water velocity
4. Air-cooled condensers
5. Air recirculation
6. Condensed liquid drainage
7. Vapor-bound condensers
Leaking vapor bypass control valve

The purpose of the hot vapor bypass controller is to

pump heat into the reflux drum.
Usually, the rubber-type seat in the hot vapor bypass
butterfly control valve dries out with age and needs to
be renewed.
Eliminate the hot vapor bypass control scheme entirely
and convert the tower to flooded condenser-type
pressure control.
Back-flushing condensers

Condensers must be back-flushed periodically to obtain

peak performance. This is especially true if the water
outlet temperature is higher than design.
Plastic bags are typical of the type of material that
blocks the tube inlets. Mud, grass, crabs, and paper
cups are also common.
The best type of back-flush connection is a nozzle
welded onto the inlet portion of the channel head cover.
The nozzle should be the same size as the cooling water
inlet line.
 Proceed as follows:

1. Block in the cooling water inlet.

2. Blow high-pressure air into the cooling water outlet
line.
3. Fully open the back-flush line.
4. Continue to back-flush for 20 seconds or until the
water clears up.
 Water velocity
The rate of fouling deposits inside the cooling water tubes
can increase exponentially as water velocity decreases.
Water velocity should be at least 3 ft/sec.
To determine water velocity, first approximate the
condensing duty from the observed reflux and distillate
rates. Then measure the water side inlet and outlet
temperatures and calculate the volume of cooling water. If
the calculated velocity is less than 3 ft/sec, decrease the
number of tube side passes by modifying the pass
partitions. As the water side P is constant, this will
increase water flow.
 Air-cooled condensers
The usual problem with air-cooled condensers is insufficient air flow.
Calculate the overhead condenser duty from process side data.
Next, measure the air inlet and outlet temperatures and calculate the volume of air
being moved.
Compare this number against the design value and then measure the amperage
being drawn by the fan motors and compare this number against the design data
sheet.
Check the air-pressure drop across the tubes with a water manometer and compare
with the design value. This data will provide a guide on whether the fan pitch should
be increased to move more air.
Watch the motor amperage rise as the pitch is increased. If the increased fan pitch
does not provide sufficient cooling, you may need to replace the fan (if pitch limits)
or the motor (if amperage limits) or both.
Air recirculation

Locating air coolers too close together or improper

plenum design can cause the air discharging from one
fan to be pulled into the fan of another condenser.
This recirculation can be verified by comparing the
average air inlet temperature to the ambient
temperature.
Condensed liquid drainage
Significant heat-transfer rates in condensing service are
only obtained in the portion of the condenser tubes not
submerged in liquid.
For a shell-and-tube condenser with cooling water on
the tube side, tubes submerged in condensate are being
used to subcool the condensate. These tubes contribute
nothing to condensing the tower overhead vapors.so
about 30% of effective heat transfer surface is wasted.
One way to find the condensate level in a condenser is:

To wait for a warm, humid day. If the cooling water is cold

enough, atmospheric moisture will condense on the outside of
the shell. The wet shell area will roughly correspond to the level
of condensate inside the shell.

A simpler method is to feel along the outside of the shell. You

will be able to locate a 24-inch wide band on the shells
surface with a noticeable temperature gradient. Mark this line,
which is the level of subcooled liquid, and calculate (from the
tube layout drawing) the percent of tubes submerged in
condensate.
Reasons for condensate subcooling:
Condensate subcooling occurs when the distillation
tower overhead product is all liquid. This means the
contents of the reflux drum must be at or below its
bubble point.
Reducing liquid subcooling
Devoting 10% of a condensers surface area to subcooling is about
right when the reflux drum is elevated above the condenser.
If one finds 30% or more of the tubes in subcooling duty,
something is wrong.
Check the pressure drop from the condenser outlet to the reflux
drum inlet.
Subtract the calculated static pressure loss (i.e., the height of
liquid) from the measurement. If the result is more than one-half
psi, consider enlarging the condenser outlet line.
If the contents of the reflux drum are warmer than the condenser
outlet, then vapor is bypassing the condenser.
Vapor-bound condensers
A small amount of really noncondensible gas can effectively
vapor bind a shell-and-tube condenser.
A vent on the top of the condenser shell can be opened,
and condenser capacity is restored.

Ex: In one debutanizer, the ability to condense the

overhead product was lost. Investigation showed that a
nitrogen-purged instrument had been recently installed.
The nitrogen had accumulated in the top of the condenser
shell, and gas blanketed the water-cooled tubes. A vent on
the top of the condenser shell was opened, and condenser
capacity was restored.
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