Rental Solutions Maximize Summertime Distillation Column Condenser Performance

Seasonal weather changes hurt summertime production rates in the refining and petrochemicals industry. Efficient condenser cooling is essential for maximizing throughput and for maintaining product purities.

However, the hotter it is outside, the more challenging the heat removal process becomes.  During the summer months in North America, the ambient air and cooling water temperatures increase anywhere from 10-50℉, dramatically reducing condenser capacity. In response, Operators raise column pressure to restore the hot-cold temperature difference.

Unfortunately, this makes separation less efficient, reducing column capacity; consequently, plants are forced to reduce throughput, hurting profits: production losses of 3-6% relative to winter rates are pretty common.  Since product demands and margins are highest in the summer, this causes huge economic losses.

So what can you do to maintain steady production all year round rather than suffering losses caused by warmer weather?

Cool the overhead reflux stream 

Direct cooling of the reflux stream can lower the cooling burden on the condensers.  Cooling the external reflux stream increases the efficiency of separation by maximizing internal reflux.  However, there are limits on the extent to which external reflux can be cooled.

Improve Condenser Cooling

Additional heat exchangers, usually in parallel to the existing units, have improved condensing capacity significantly.  We have also provided dedicated cooling towers that deliver cooling water that is 10 to 15°F cooler than normal plant cooling water.

Alternatively, we use closed-circuit refrigerated chillers to optimize the condenser’s temperature driving force.  This technique has enabled notable column capacity increases and efficiency improvements from increased reflux flow and reduced tower pressure.

In vacuum distillation columns, Aggreko has helped clients maximize profits dramatically by using chilled water in the overhead condensers to: (a) improve the flash zone vacuum, (b) maximize unit throughput and VGO feed rate to the FCC, and (c) improve vacuum tower bottoms (asphalt) quality.

Cool a pumparound stream

Supplemental cooling of the pumparound stream on the uppermost trays can offload the condenser while increasing internal reflux flows, boosting the overall separation efficiency of the column.

Augment the plant cooling water system

Another option is to improve the existing cooling capability of the entire plant.  Rental cooling towers can be brought in during the warmer months to provide additional cooling when needed most.  For maximum flexibility, look for a partner who has a well-established track record of providing highly efficient, modular cooling tower solutions.  You can easily add or remove units as your needs change.

Choose the right partner

If you want to overcome your condenser cooling limitations and maximize your productivity, choosing the right partner to support you is crucial. Aggreko has decades of industry-leading engineering expertise and experience in providing these solutions to plants around the world.

Debottlenecking distillation column overhead condenser limitations can present technical challenges, but our knowledge and track record are unmatched: we help you find the right solution for your unique configuration.

All our equipment is modular; therefore, we can configure and then engineer the perfect setup for you, no matter how large or small your operations are. And, as you grow, you can quickly expand your cooling systems to keep up with demand, using rental solutions with a benefit/cost ratio of at least 5:1, avoiding the CAPEX route entirely.

Our huge fleet of rental equipment is readily available at strategic hubs in the USA, and we can have your plant running more efficiently in days or at most a few weeks. 

Our field-proven solutions maximize summertime production rates consistently, increase productivity all year round, and help you achieve dramatic uplifts in unit profitability.

Learn more about our solutions for the petrochemical and refining sector

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