CHAPTER TWO

STEAM CONDENSERS

Condensers used in steam power plants to condense exhaust steam from

turbine are known as surface condensers. However, there are many other
applications in which condensers are used, and a wide variety of condenser
types has been developed. A typical surface steam condenser used in steam
cycle is shown in figure 2.1 [2].

It can be seen from figure 2.1 that, the exit steam from turbine entering
the top of the condenser vessel and exit from the bottom of the condenser as
condensate and collected at the hotwell. The cooling water enters the water
box to absorb the heat from the steam through the condenser tubes. [2].

Figu
re 2.1: Surface steam condenser [2].
2.1 Surface Condenser:

Surface condensers (also called Shell-and-tube condensers) are used

extensively in the process industries, typically to condense the overhead vapor
from a turbines or distillation column etc. There are three main types [2].

2.1.1 Cross-flow Shell-side Condenser

The cross-flow condenser is similar to the surface condenser and is

shown in figure 2.2. It consists of a shell containing tubes through which the
coolant flows. The shell-side flow path is designed such that the vapor flows
mainly in cross-flow direction to the tubes. The cross-flow condenser is
typically used for low-pressure applications, in which there is a large volume
flow of vapor and a low-pressure drop is required. The tubes are supported at
intervals by plates to prevent sagging of the tubes and to avoid vibration. The
vapor enters at the top of the shell. Often, more than one nozzle is used to
minimize pressure loss and promote good distribution. It is particularly
important to ensure that the cross-flow condenser is properly vented [2].

Figure 2.2: Cross-flow condenser [2].

2.1.2Baffled Shell-and-tube Condenser

The baffled shell-and-tube heat exchanger, with shell-side

condensation, is the most common type of condenser used in the process
industries and is shown in figure 2.3.

It is most often mounted horizontally. A typical shell-side condenser is

shown in figure 2.3. This is a shell-tube type in which the vapor enters at one
end of the shell and flows to the outlet end, where the condensate and any
uncondensed vapor and non-condensing gases are removed.[2].

Figure 2.3: Baffled shell and tube condenser [2].

 The baffles are normally plates with a single segmental cut. The cut is
usually vertical to allow the condensate to flow along the bottom of the shell
to the outlet. Double segmental baffles may be specified to achieve reduced
pressure drop. The space between the baffles is determined by considerations
such as [ 2 ]:

1. The tubes must be supported to avoid tube vibration;

2. Pressure drop depends on vapor velocity, and hence on baffle spacing;

3. The resistance to heat transfer due to the presence of non-condensing

gases is inversely proportional to the vapor velocity.

4. High vapor velocities can reduce resistance to heat transfer through the
shear effect on the condensate film.

The number of tube passes is determined by the required coolant velocity.

Plain tubes are generally used, though low-finned tubes can be used to obtain
increased heat transfer rates when the condensate resistance to heat transfer
with plain tubes is significantly greater than that of the coolant.

2.2. Air Cooled Condensers

The air cooled condenser is a surface condenser where the air is used as
coolant and a typical forced-draft, air-cooled condenser is depicted
in figure 2.4.

In this type of condensers, the condensation on the tube-side is

preferred when the coolant is a gas, such as air. It may also be preferred if the
condensing fluid is at a higher pressure than the coolant, since it is usually less
expensive to contain a higher pressure inside tubes than inside a shell. An air-
cooled condenser is typical of a tube-side condenser. It consists of a tube
bundle, normally with finned tubes, over which air flows in cross- flow. The
air flow is driven by fans, either in forced- or induced-draft mode [2].

Figure 2.4: Air cooled condenser operating in forced draft mode [2].
2.3 Direct-Contact Condensers

The direct-contact condenser is one in which the coolant is brought into

contact with the vapor, and a typical forced-draft, air-cooled condenser is
depicted in figure 2.5. It has the advantage of low cost and simplicity of
mechanical design, but its use is restricted to those applications in which
mixing of the vapor and coolant is permissible [2].

Figure 2.5: Direct contact condenser [2].

The various types of direct contact condensers are:

2.3.1: Spray Condenser:

In this condenser type, the coolant is sprayed, using nozzles, into a

vessel to which the vapor is supplied. This is shown schematically in figure
2.6. It is important that the spray nozzles and vessel are designed to
produce a fine spray of liquid (to give a large interfacial area for heat
transfer), and a long enough residence time of liquid droplets in the vessel
[2].

2.6: Spray condenser [2].

 2.3.2: The Baffled Column Condenser:

This type is similar to the spray condenser, except that the coolant is
directed to flow over a series of trays in a column. This is shown
schematically in figure 2.7. The vapor is supplied to the bottom of the
column. It has the advantage of countercurrent flow of vapor and coolant,
though care must be taken to avoid flooding. (Flooding is an unstable
condition when the vapor flow is such that the downward flow of
condensate is interrupted and held up [2].

Figure 2.7: Baffled column condenser [2].

2.3.3. The Packed Column Condenser:

 A packed column may consist of tightly-packed metal rings to increase
the interfacial area for heat transfer and this is shown schematically in figure
2.7.. Liquid is supplied to the top of the column and vapor is supplied to the
bottom. The disadvantage of this type of condenser is that the pressure drop is
higher than in other types of direct-contact condenser [2].

Figure 2.8: Packed column condenser [2].

2.3.4 Jet Condenser:

 This is a device in which a jet of liquid is directed into a vapor stream,
usually with the objective of desuperheating the vapor this is shown
schematically in figure 2.10. A jet of liquid is injected into a pipeline carrying
vapor via a small bore pipe and a nozzle located at the center line. The liquid
is usually injected in counter flow to the vapor [2].

Figure 2.9: Jet condenser [2].

2.3.5 The Spurge Pipe Condenser:

 The spurge pipe consists of a pipe with holes for injecting bubbles of
vapor into a pool of liquid this is shown schematically in figure 2.11. .
This is a simple method of condensing a vapor, but there are practical
problems associated with generating a good distribution of bubbles of
small size, which are required for efficient heat transfer [2].

Figure 2.10: Spurge pipe condenser [2].

2.4 Cooling Towers

 A cooling tower is a heat rejection device that rejects waste heat to
the atmosphere through the cooling of a water stream to a lower temperature.
Cooling towers may either use the evaporation of water to remove heat and
cool the working fluid to near the wet-bulb air temperature, or in the case
of closed circuit dry cooling towers, rely only on air to cool the working fluid
to near the dry-bulb air temperature [2].

Figure 2.11: Cooling towers [2]

And there is a 3 type of cooling tower for the power plant station;

2.4.1 -Dry cooling Tower.

Dry cooling Condenser operates by heat transfer through a surface that
separates the working fluid from ambient air, such as in a tube to air heat
exchanger, utilizing convective heat transfer. They do not use evaporation and
operating costs are less. Disadvantage is that there is no fan to crate a forced
air flow.[2]
 Figure 2.12 :dry cooling tower [2]

2.4.2 -Wet Cooling tower.

Operate on the principle of evaporative cooling. The working fluid and

the evaporated fluid (usually water) are one and the same.

Disadvantage is Operating costs are high for operating this, but they are
simple and quick for construction.[2].
 Figure 2.13: wet cooling tower [2].

2.5: Condenser Tube cleaning method

In a steam power plant the condenser used to condense vapor for

long run time in which the steam start to create some sludge inside the
tube and that’s effect the condenser performance by reducing the
surface area of the condenser and lower the power generated from
turbine and even stop it from work when it cant condense the lowest
 amount of water to get in boiler and generate the power . So It is
necessary to removes scale formation of the condenser tubes for proper
heat rejection.

Most of tube cleaning is offline/mechanical method. Great care must be taken

to avoid damaging any tube sheet or tube coatings which may be present;
otherwise the successful removal of fouling deposits may become associated
with new tube leak or increase tube sheet corrosion.

There are generally two types of tube cleaning done as online and offline tube
cleaning.

And the cleaning methods used to cleaning condenser are:

2.5.1: jet Cleaning:

 This is the one of the most effective offline cleaning method, here the
condenser is isolated for cleaning purpose. A high pressure water jet with
discharge pr of 600 to 1000 bar through flexible or rigid hoses with nozzle
(Lancers) is used. The lancers with water jet will be inserted throughout the
entire length of the tube so that the scales are completely removed.[2].
Figures 2.14 a-b : Condenser jet cleaning method [2].
2.5.2: Acid Cleaning

This Method is restricted to condensers suffering from scaling problem

like calcium carbonate and phosphate. Variety of acids, including
Hydrochloric, uric acetic and EDTA are used. Inhibiters like Rhodine-213
are added to the acid to prevent the acid from attacking the metal of the
tubes .After the acid cleaning the acid traces in the condenser is neutralized
with circulating  the alkali caustic soda , Lime  ie NAOH .Then scales
dislodged were removed by water and air jet [2]. 
Figure 2.15 acid cleaning method and acid bottle [2].
2.5.3: Grit Cleaning:

 An alternate to bulleting, this method is known as sinusoidal grit

blasting, it involves blasting graded silica free mineral grit through the
condenser tubes.[2]

Figure 2.16 shows grit blasting [2]

2.5.4: Water Washing

 Tube can be cleaned with a jet of high pressure (around 70 bar).

However before adapting this method, trial must be carried out for
successful result.[2].

Figure 2.17 water washing method for steam condenser [2]

2.5.5:Ball Cleaning Method:

Over sized balls are continuously pressed through the tubes to keep
them clean. Balls are pass on one end of tube and collected at the other
end.
A System consists of a ball vessel into which the balls are introduced. “Ball
recalculating pumps” inject these balls into the inlet water pipe of
condenser. These balls are carried by the circulating water to the condenser
tubes. Since we are using oversized balls, the balls are pressed through the
tubes and thus wiping  and carrying the deposits . After passing through the
first pass of the condenser, the balls are accumulated in the Reverse
Chamber. Then the balls pass through the second pass of the condenser
tubes and reach the outlet water pipe and collected through screens for re-
circulation.

In online ball cleaning system following factors are taken care as:

a) Top up balls periodically.

b) Cleaning the ball collector careen.

c) Ball Circulation Pump Overhauls.

 
 Figure 2.18: Ball cleaning method [2].

2.5.6 Thermal method

This is used to control mussel growth in sea water stations, CW culverts, and
to clean the condenser tubes by drying internal deposits prior to flushing with
water. Heating is achieved by introducing auxiliary steam through the CW
tubes and by reversing the cooling water flow through tubes [2].