Your LP-Gas cylinder or tank is filled with liquid propane, while your equipment burns vapor. How does this all work?
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LP-Gas (propane, butane, LPG) is transported and stored as a liquid under pressure. In order for your equipment to be able to use the propane1 in your storage vessel (cylinder or tank) it must undergo a phase change (vaporization) from liquid to vapor within the cylinder, before being combusted by your consuming equipment (BBQ, radiant heater, boiler, process burner, etc.). The rate of natural vaporization in your tank is essentially a function of two factors: 1) ambient temperature; 2) tank size and fill level (“wetted” tank surface area). Each piece of propane consuming equipment has its own requirements as to the amount of vapor that it needs to run properly.
Propane, like water, is a “compound” with its own set of chemical properties. At atmospheric pressure, water, a substance that we are all very familiar with, boils — that is to say goes through a phase change from liquid to vapor — at 212 degrees Fahrenheit (100 degrees Celsius). Propane, on the other hand, as a result of its particular set of chemical properties, boils at -44 degrees Fahrenheit (-42 degrees Celsius). Therefore, as long as your propane tank is stored in an area that is at least -44 degrees F. (at sea level), the propane in your tank is undergoing phase change, and the pressure will be great enough to give off at least some vapor pressure.
Now, to complicate things, the phase change of propane, just like that of water, involves the transfer of energy. You cannot boil water without an outside source of heat from, say, the burner on your stove. Further, the more energy applied (the hotter the burner), the faster your water is boiled, and the faster it is expelled into the atmosphere as vapor. Similarly, with propane, a warmer ambient temperature (above -44 F) results in a higher rate of vaporization and greater vapor pressure, allowing you to draw more vapor off the top of your cylinder or tank. Based upon this discussion, it should be fairly evident that ambient temperature has a direct effect on the ability to run your equipment. If your equipment is asking for more vapor pressure than can be provided naturally by ambient heat, it may shut down (or merely provide less heat than you require).
Properties of Hydrocarbons
Saturation Curves
Now that we have briefly discussed the direct effect of temperature (energy) on vaporization, lets now turn to the effects of tank size and fill level. Let’s continue with the water analogy. Say you have two pots of boiling water, one 2 quarts and another 2 gallons. The 2 gallon pot is going to give off more vapor than the 2 quart pot, so long as the heat being applied is held constant. The same is true for propane–the larger and fuller a tank is (the more “wetted” surface it has), the more heat transfer surface area, and the more vapor it is going to give off.
These two factors, heat and heat transfer area (tank size and fill level), directly affect the natural vaporization rate of the propane in your tank. It should be fairly easy to see that if you are relying purely on natural vaporization in order to run your equipment, you are at the mercy of these two factors.
If you’ve ever seen a layer of frost form on your propane tank or bottle, you have seen first hand the limits of natural vaporization. Seeing frost on your tank means that the rate of heat being transferred into the tank to the liquid propane is less than the energy being used to actually convert the liquid to vapor, which results in a pressure reduction thus creating a refrigeration effect. This refrigeration effect continually reduces the rate of vaporization by forming an insulating frost layer on the tank, further causing a loss of vapor pressure. This can have a devastating effect on your ability to run your equipment.
If you notice that your propane consuming equipment isn’t giving off quite as much heat as it should, you should also suspect insufficient natural vaporization–quite simply, the pressure of the vapor reaching the burner has decreased below that which is required for optimal heat output.
If the rate of natural vaporization is a function of two factors–ambient temperature and wetted tank surface–as discussed above, the question becomes: how do you increase your rate of natural vaporization. Unfortunately, you can’t control the outside temperature, so what does that leave you with? Wetted surface area. Simply put, in order to increase your wetted surface area you can either 1) increase your tank size (or add more tanks) or 2) ensure that your tank is always “full.” There are unfortunately, numerous problems associated with these solutions:
In essence, while natural vaporization is often adequate for domestic and light commercial applications, it is typically inadequate for commercial and industrial needs. Larger LPG consuming equipment often requires more vapor than natural vaporization can provide.
An alternate solution to natural vaporization is the addition of artificial heat by using a vaporizer.
Based upon the above information, there are several key benefits associated with using a vaporizer:
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1. While this discussion refers solely to “propane” it is important to point out that LPG mixtures are generally a combination of both propane and butane and vary widely depending on region, source, and other uses. Butane, having its own set of chemical properties, requires a higher temperature to maintain the same pressure (boils at approx 17 F. versus -44 F for propane), and therefore when mixed with propane, reduces the rate of natural vaporization and pressure within a container.
LPG, a clean, efficient, and versatile fuel source, has gained significant importance across industries. LPG is inherently stored as a liquid; however, most appliances utilise it in its gaseous form. Vaporizers bridge this gap by applying heat and converting the liquid LPG into usable gas. Here are two main LPG vaporiser types:
Heated Vaporisers: These are the traditional vaporisers, using electricity, water baths, or steam to heat the LPG and facilitate vaporisation.
Heater less Vaporisers: These innovative devices utilise the principles of thermodynamics to achieve vaporisation without any external heat source.
Heaterless Vapouriser Working Principle
Heaterless Vaporizers, also known as ambient air vaporisers, stand out for their innovative operation principle and eco-friendly profile. LPG from the cylinder manifold system enters a flashing valve. This valve rapidly reduces the pressure of the liquid, causing a drop in temperature due to a phenomenon called adiabatic expansion.
The depressurised and cooled LPG then passes through a shell-and-tube heat exchanger. This exchanger uses ambient-temperature air or water (usually above 15°C) to further vaporise the LPG through heat transfer. Heavier hydrocarbon components with higher boiling points settle down in a liquid trap within the vaporiser and vapour is then released for utility.
Why choose Heater less Vapouriser over traditional Vapouriser
Check out the comparison table highlighting the key differences between heaterless vaporisers and traditional vaporisers for industrial applications.
Factor Heater less Vapouriser Traditional Vapouriser Operational Cost HLVs use ambient air to vaporize fluids, adding no extra energy cost; this is especially beneficial in India where energy conservation is critical due to high demand and occasional shortages. Traditional Vapourisers use electricity or gas, which can be costly. The industrial electricity tariffs in India can exceed, affecting operational costs negatively. Maintenance and Longevity Typically requires less maintenance due to fewer moving parts and no combustion residues or scaling from water, potentially extending its lifespan. Requires more frequent maintenance to manage wear and tear on heating elements, controls, and to clean combustion by-products. This can reduce the lifespan and increase overall maintenance costs. Carbon Footprint Zero direct emissions as no fossil fuels are burned and no electricity is used, making it a green solution. Higher carbon footprint due to consumption of electricity or burning of fossil fuels. The emissions depend on the energy source but can significantly contribute to greenhouse gas emissions Safety Higher safety due to the absence of combustion or electric heating elements, reducing risks of fire or electrical hazards. Increased safety risks associated with the combustion of fuels or electrical faults. Flexibility Highly flexible and can be installed in remote or off-grid locations. May require proximity to energy supplies (electricity, natural gas lines).Heater less vapouriser offers a blend of safety, cost-effectiveness, and eco-friendly efficient energy solution not only represents the significant developmental advancement in LPG industry but also is a greener alternative in industrial operations.
It is also important to comply to IS guidelines and safety protocols while during installation. While talking about safety standards who does that better than SUPERGAS.
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