Power Plant steam condensers

Chapter Five
Steam Condensers
1-Introduction:
The functions of condensers in steam power plants are to condense the
exhaust steam from the steam turbine. The recovery of exhaust steam in the
condenser reduces the high quality (demineralized water) makeup feed water
that must be added to the system from 100% when exhausting to
atmosphere, to about 1 to 5%. The condenser also maintains exhaust
vacuum pressure (about 25 mm of Hg absolute) and thereby increasing the
work done by the prime mover and improving the cycle efficiency.
The condenser and other available heat exchanger including feed water
heaters are merely heat transfer equipments which have no mechanical
complexity, however it play important role in steam cycle
ّٛ‫خ ػبن‬ٚ‫بد يبء انزغز‬ًٛ‫ٍ ٔاعزؼبدِ ك‬ٛ‫غزخذو يكضف انجخبس ألصانّ انؾشاسح يٍ انجخبس انًغبدس نهزٕسث‬ٚ:‫المقذمت‬
%011 ٍ‫ط ي‬ٕٚ‫بِ انزؼ‬ٛ‫بد ي‬ًٛ‫قهم ْزا األعهٕة ك‬ٚ ‫ش‬ٛ‫ؽ‬,‫ ٔإسعبػٓب يشِ أخشٖ نًٕنذ انجخبس‬demi-water‫خ‬ٛ‫انُٕػ‬
‫عب ثبنؾفبظ ػهٗ ظغػ انزخهخم انعشٔس٘ نشفغ كفبءح انذٔسح‬ٚ‫قٕو انًكضف أ‬ٚ . %5 ٗ‫ إن‬0 ٍ‫قشة ي‬ٚ ‫إنٗ يب‬
‫ دٔسِ انجخبس يضم‬ٙ‫خ األخشٖ ف‬ٚ‫ انًجبدالد انؾشاس‬ٙ‫رؼزجش انًكضفبد ٔثبق‬.ٍٛ‫بدح شغم انزٕسث‬ٚ‫ق ص‬ٚ‫خ ػٍ غش‬ٚ‫انؾشاس‬
‫ ٔػهٗ انشغى يٍ رنك فئَٓب رهؼت‬,‫ذ انٗ ؽذ يب‬ٛ‫ّ يٍ انزؼق‬ٛ‫ خبن‬ْٙٔ ‫خ يؼذاد الَزقبل انؾشاسح فقػ‬ٚ‫يغخُبد يبء انزغز‬
‫ أداء دٔسِ انجخبس‬ٙ‫ب ف‬ٛ‫دٔسا أعبع‬

1
Power Plant steam condensers

2-The requirements for an efficient steam condenser

1. Maximum amount of steam condensed per unit of heat transfer area.
2. Minimum quantity of circulating coolant required.
3. Minimum heat transfer surface required per kW capacity
4. Minimum power drawn by the auxiliaries.

3-Elements of a condenser plant are:

1. Condenser body in which the steam is condensed.
.‫ف انجخبس‬ٛ‫خ ركض‬ٛ‫ّ ػًه‬ٛ‫ ثذٌ انًكضف انز٘ رؾصم ف‬-0
2. A supply of cooling water. ‫ذ‬ٚ‫بِ انزجش‬ًٛ‫ يصذس ن‬-2
3. Air extraction system: used to remove air and other non-condensable
gases from the condenser.
‫ف‬ٛ‫ش قبثهخ نهزكض‬ٛ‫ انغبصاد انغ‬ٙ‫ انًُظٕيخ انًخزصخ ثُضع انٕٓاء ٔثبق‬ْٙٔ : ‫ يُظٕيخ َضع انٕٓاء‬-3
.‫نهؾفبظ ػهٗ ظغػ انزخهخم‬
4. Condensate extraction pump.
ٕ‫ رقٕو ثشفغ ظغػ انًبء انًكضف إنٗ ظغػ انغ‬ٙ‫ انًعخخ انز‬ْٙٔ :‫ يعخخ َضع انًبء انًكضف‬-4
.ٍ‫ٔرغهى انًبء إنٗ انًغزٕدع انغبخ‬
5. Various water circulation pumps which vary according to the unit type.
.‫ّ انٕؽذح‬ٛ‫ش انًبء ٔرخزهف ؽغت َٕػ‬ٚٔ‫ يخزهف انًعخبد نزذ‬-5
6. A hot well in which the condensed steam is discharged by the condensate
extraction pump.
.‫غ انًبء انًكضف‬ًٛ‫ّ رغ‬ٛ‫زى ف‬ٚ ٘‫ ْٕٔ انؾٕض انز‬:ٍ‫ انًغزٕدع انغبخ‬-6
7. Cooling Towers: This is used for re-cooling the cooling water (when a
closed cooling cycle is used).
.‫ذ انًغهقخ‬ٚ‫ دٔساد انزجش‬ٙ‫ ٔرغزخذو ف‬,‫ذ‬ٚ‫ذ يبء انزجش‬ٚ‫ رقٕو ثزجش‬ٙ‫ انًُظٕيخ انز‬ْٙٔ ‫ذ‬ٚ‫ أثشاط انزجش‬-7
8-Various pumps which vary according to its function for example:

2
Power Plant steam condensers

 Feed water pump: this is used to supply the boiler with feed water and
it receive the water from hot well.
 Make-up water: This is used to supply the compensated water.
:‫فخ يضم‬ٛ‫ رخزهف ؽغت انٕظ‬ٙ‫ يخزهف يعخبد انًبء انز‬-8
.ٍ‫خ ٔرغزهى انًبء يٍ انًغزٕدع انغبخ‬ٚ‫ش رضٔد انًشعم ثًبء انزغز‬ٛ‫ ؽ‬: ‫خ‬ٚ‫ يعخخ يبء انزغز‬
.‫ط‬ٕٚ‫ذ انذٔسح ثًبء انزؼ‬ٚٔ‫ٔرقٕو ثزض‬: ‫ط‬ٕٚ‫ يعخخ يبء انزؼ‬
4-Types of condensers:
1- Direct contact condensers. 2- Evaporative condensers.
3- Surface condenser.
:‫تىقسم المكثفاث إلى ثالثت أوىاع رئيسيه وهي‬
‫ّ ٔانًكضفبد راد انغطٕػ‬ٚ‫ش‬ٛ‫يكضفبد انزًبط انًجبشش ٔانًكضفبد انزجخ‬
4-1-Direct contact condenser:
This is the oldest type of condensers and also it called the mixing
condensers. These types are not recommended for modern steam power
plants due to feed water contamination. This type is sub-dived into three
types:
‫ يؾطتبد‬ٙ‫تب فت‬ٛ‫عب ٔال رغتزخذو ْتزِ انًكضفتبد ؽبن‬ٚ‫ أقذو إَٔاع انًكضفبد ٔرغًٗ يكضفبد انًضط أ‬ْٙٔ
‫ ر تبثّ ْتزِ انًكضفتبد‬.‫تذ‬ٚ‫خ يتٍ عتشاء يضعتّ يتغ يتبء انزجش‬ٚ‫ت يبء انزغز‬ٛ‫ص‬ٚ ٘‫انقذسح ثغجت انزهٕس انز‬
‫خ انًفزٕؽخ‬ٚ‫ثؼًهٓب يغخُبد يبء انزغز‬open FWH.
A- Low level spray condensers:
This is either counter flow or parallel flow.
 Parallel Flow Type: Here the steam and cooling water enter at the
top of the condenser and flow downwards in parallel. The coldest water
is thus in contact with hot steam and, therefore, it is less efficient.
 Counter Flow Type: Here, the steam flows upwards through the
condenser, meeting the cooling water which flows downwards from the
top. The air is removed at the top. In this type, since the hottest steam is

3
Power Plant steam condensers

in contact with the hottest cooling water, it is thermodynamically the

most efficient.

Spray condenser –counter flow Spray condenser-parallel flow type

B- High level barometric condenser:

If the bottom of the condenser is not less than, say, 10.5 m above the level of
the water in collection tank (hot well), condensate extraction pump is not
needed and the condenser is self-discharged to atmospheric pressure.
‫ ْزا انُٕع يٍ انًكضفبد يٍ انًًكٍ اخزضال يعخخ انًبء‬ٙ‫ف‬:ٖٕ‫ّ انًغز‬ٛ‫خ ػبن‬ٚ‫انًكضفبد انجبسٔيزش‬
‫ يزش‬01.5 ٗ‫صم اسرفبع ْزا انُٕع ان‬ٚ ٌ‫ش يٍ انًًكٍ ا‬ٛ‫ؽ‬,‫انًزكضف ٔرنك ثبعزخذاو ػًٕد انًبء‬
C- Low level ejector condenser:
.ٖٕ‫ّ ٔاغئّ انًغز‬ٛ‫انًكضفبد انُفض‬
In this condenser, the height could be reduced by designing the condenser
body as ejector. This condenser thus acts as a pump as well as a condenser.

4
Power Plant steam condensers

Low level ejector condenser High level barometric condenser

4-2- Evaporative Condensers: In this condenser, the steam flows through a

set of finned piping. Cooling water is sprayed from the top over the pipes.
As it drips from one pipe to the other, it forms a thin film over the pipes. Air
blowing across the pipes (by induced draught fans) rapidly evaporates the
water film resulting in condensing of the steam flowing through the pipes.
Several eliminators are placed at the top to save the cooling water. This type
is considered as a combination of a surface condenser and cooling tower. It
is very suitable for low capacity power plants and for desert climate where
water is expensive or a small quantity of pure water is available.
ٕ‫ذ فت‬ٚ‫زى سػ يبء انزجش‬ٚ ‫ش‬ٛ‫ّ ؽ‬ٚ‫ش‬ٛ‫ٕظؼ ان كم أدَبِ يجذأ ػًم انًكضفبد انزجخ‬ٚ: ‫المكثفاث التبخيريه‬
‫تت‬ٛ‫تزى إيتشاس انٓتٕاء ػهتٗ األَبث‬ٚ ‫ٍ ٔثتُفظ انٕقتذ‬ٛ‫ رؾًتم انجختبس انًغتبدس نهزتٕسث‬ٙ‫ت انز‬ٛ‫أعطؼ األَبث‬
‫قتٕو ثتذٔسِ ثغتؾت‬ٚ ٘‫تش انًتبء انًششتٕػ انتز‬ٛ‫قٕو انٕٓاء ثزجخ‬ٛ‫انًجزهخ ثٕاعطخ يشأػ نغؾت انٕٓاء ف‬
ِ‫انؾشاسح يٍ انٕٓاء ٔانجخبس ٔثزنك رُخفط دسعّ ؽشاسح انٕٓاء ٔانجخبس (ْٕٔ َفظ يجذأ ػًتم يجتشد‬

5
Power Plant steam condensers

‫فزٓتب‬ٛ‫ذ يششؾبد أػهٗ انًششتؾبد ٔظ‬ٛ‫زى رضج‬ٚ ‫ّ انًبء انًششٕشخ‬ًٛ‫ّ) ٔنهؾفبظ ػهٗ ك‬ٚ‫ش‬ٛ‫انٕٓاء انزجخ‬
‫ٍ انًكضفتبد راد انغتطٕػ ٔأثتشاط‬ٛ‫تّ ؽبنتّ ديتظ ثت‬ٚ‫ش‬ٛ‫ رًضم انًكضفتبد انزجخ‬.‫أػبدِ قطشاد انًبء انؼبنقخ‬
‫تش‬ٛ‫خ انغبفتخ ؽ‬ٚٔ‫ األيتبكٍ انصتؾشا‬ٙ‫هتّ انغتؼّ ٔفت‬ٛ‫فعتم اعتزخذايٓب نًؾطتبد أنقتذسِ قه‬ٚٔ ‫ذ يؼتب‬ٚ‫انزجش‬
.‫كٌٕ يؾزٕٖ انشغٕثخ ٔاغئ‬ٚ

4-
3- Surface Condenser
This type is preferred to use in modern power plants. The usual
construction of this type is that there is a cast iron or steel shell fitted with a
tube bundle fitted at each end. The usual flow pattern is that water flows
through the tubes and the steam is condensed in the shell. The steam leaving
the low pressure turbine enters the condenser at the top of the shell. The
steam after being condensed leaves the condenser through a hole at the
bottom of the shell. The surface condensers may be single pass or two pass.
ِ‫تب ٔرزكتٌٕ يتٍ ق تش‬ٛ‫ يؾطتبد أنقتذسِ ؽبن‬ٙ‫خ ان بئؼخ االعزخذاو ف‬ٛ‫ انُٕػ‬ْٙٔ:‫المكثفاث راث السطىح‬
‫خ‬ٛ‫خبسع‬shell ٍ‫ ٔرخزشقٓب يغًٕػّ ْبئهخ ي‬.‫ٓب انجخبس يٍ االػهٗ انٗ االعفم‬ٛ‫غش٘ ف‬ٚٔ ٌ‫ركٌٕ انجذ‬

6
Power Plant steam condensers

‫تتت‬ٛ‫تتبٌ انًكضفتتبد راد انق تتشح ٔاألَبث‬ٛ‫ ثؼتتط األؽ‬ٙ‫تتذ ٔنتتزنك رغتتًٗ فتت‬ٚ‫ٓتتب يتتبء انزجش‬ٛ‫غتتش٘ ف‬ٚ ‫تتت‬ٛ‫األَبث‬
shell and tubes condensers .ٍٚ‫ٍ راد يًشس ٔاؽذ ٔأخشٖ راد يًش‬ٛ‫ٔركٌٕ ػهٗ َٕػ‬

Steam inlet
Discharge
water outlet

Condenser Water Box

Shell

Tubes

Air-Vapor outlet

Water Box
Condensate outlet Cold Water inlet

Down flow surface condenser -one pass

Steam inlet Discharge

water outlet

Condenser
Shell

Air-Vapor outlet

Water Box
Condensate outlet
Cold Water inlet

Down flow surface condenser- two pass

7
Power Plant steam condensers

5-Types of cooling water cycles:

There are two types of cooling water cycles which are open and closed. In
the open cycle, cooling water is drawn from the source (river or lake). The
cooling water is pre-treated before sending to the condenser's tubes. After
receiving the condenser heat, the cooling water is circulated in long channel
around the plants. This will eliminate the "thermal pollution" which is
caused by high cooling water temperature. For the closed cooling cycle, the
cooling water is re-circulated and re-cooled using the cooling towers. The
cooling towers are classified into two types: wet and dry. In the wet type, air
cools the water via direct contact while in the dry type air does not mix with
the cooling water.
‫أوىاع دوراث التبريذ‬
ٖ‫ دٔسِ يفزٕؽتتخ ٔأختتش‬,ِ‫ يؾطتتبد أنقتتذس‬ٙ‫تتب فتت‬ٛ‫تتذ انًغتتزخذيخ ؽبن‬ٚ‫تتبِ انزجش‬ٛ‫ٍ يتتٍ دٔساد ي‬ٛ‫ُْتتب َتتٕػ‬
ّ‫تتب ألصانتت‬ٛ‫تتذ يتتٍ انُٓتتش انًغتتبٔس ٔرتتزى يؼبنغزتتّ أٔن‬ٚ‫تتبِ انزجش‬ٛ‫ انتتذٔسح انًفزٕؽتتخ عتتؾت ي‬ٙ‫تتزى فتت‬ٚ .ّ‫يغهقتت‬
‫ ٔثؼتذ‬.‫ رخزتش انق تشح‬ٙ‫تذ انزت‬ٚ‫تبِ انزجش‬ٛ‫تت ي‬ٛ‫هٕنخ دٌٔ اَغتذاد أَبث‬ٛ‫خ انؼبنقخ نهؾ‬ٛ‫بٌ ٔانُجبربد انًبئ‬ٛ‫األغ‬
ِ‫م ظتبْش‬ٛ‫هخ قجم إػبدرّ إنٗ انُٓش انًغبٔس نزقه‬ٕٚ‫ يغبس٘ غ‬ٙ‫شِ ف‬ٚٔ‫زى رذ‬ٚ ‫ذ نهًكضف‬ٚ‫يغبدسِ يبء انزجش‬
‫ذ ثٕاعطخ أثشاط‬ٚ‫بِ انزجش‬ٛ‫ذ ي‬ٚ‫زى رجش‬ٛ‫ انذٔسح انًغهقخ ف‬ٙ‫أيب ف‬. thermal pollution ٘‫انزهٕس انؾشاس‬
ّ‫تّ عبفت‬ٛ‫ٍ َٕػ‬ٛ‫تذ ػهتٗ َتٕػ‬ٚ‫ ٔركٌٕ أثشاط انزجش‬.‫ذ‬ٚ‫بِ انزجش‬ٛ‫ ؽبنّ َذسِ ي‬ٙ‫خ ف‬ُٛ‫ذ ٔرغزخذو ْزِ انزق‬ٚ‫رجش‬
‫تخ‬ٛ‫ انُٕػ‬ٙ‫تق انزًتبط انًجبشتش أيتب فت‬ٚ‫ذ ػتٍ غش‬ٚ‫ذ يبء انزجش‬ٚ‫خ انشغجخ رجش‬ٛ‫ انُٕػ‬ٙ‫زى ف‬ٚ .ّ‫ّ سغج‬ٛ‫َٕٔػ‬
.‫ذ‬ٚ‫ٍ انٕٓاء ٔيبء انزجش‬ٛ‫ٕعذ رًبط يجبشش ث‬ٚ ‫انغبفخ فال‬
6-The Air Ejector:
The removing of leaked air into the steam cycle is called "Deaeratotion".
To perform this task, a special designing pump is used which is called
"Steam jet ejector". This special pump is mounted on the condenser. In
general, the deaeration process is performed using open feed water heater in
which the steam jet is mounted.

8
Power Plant steam condensers

ٙ‫ (ٔانزت‬non-condensable gases ‫تف‬ٛ‫تش قبثهتّ نهزكض‬ٛ‫تّ أصانتّ انغتبصاد غ‬ٛ‫وازع الهوىا رتذػٗ ػًه‬
‫ نهًكضف أظبفّ إنتٗ ثؼتط‬ٙ‫ر ًم ثبنذسعخ األعبط انٕٓاء انًزغشة إنٗ انذٔسح ثغجت انعغػ أنخٕائ‬
‫ انًؾطتخ) رتذػٗ ة‬ٙ‫ يخزهف َتٕاؽ‬ٙ‫انغبصاد انُبرغخ يٍ رؾهم انًبء ٔرفبػهّ يغ انؼُبصش األخشٖ ف‬
‫ َبصع انٕٓاء رٔ انُفش‬ْٙ ‫ّ انطشد ْزِ ثٕاعطخ يؼذِ خبصخ‬ٛ‫ٔرزى ػًه‬, ‫ أ٘ َضع انٕٓاء‬deaeration
‫ّ َضع انٕٓاء ثٕاعطخ‬ٛ‫ب رزى ػًه‬ٛ‫ ٔؽبن‬. ‫ضجذ ػهٗ انًكضف‬ٚ ٘‫ ٔانز‬steam jet air ejector ٘‫انجخبس‬
‫ّ يفزٕػ‬ٚ‫ ْٕٔ ػجبسح ػٍ يغخٍ يبء رغز‬deaerator ‫يؼذِ اكجش (يٍ ظًُٓب َبصع انٕٓاء) رغًٗ ة‬
.‫ّ َبصع انٕٓاء‬ٛ‫ٔيضجذ ػه‬

High
pressure
motive
steam

Non –condensable gases in

Steam jet ejector

7-The side effects of air and non-condensable gases:

1- The pressure of air in the condenser lowers the partial pressure of steam,
which means steam, will condense at a lower temperature and that will
require greater amount of cooling water.
2- Results in an increase in the condenser pressure which limits the useful
work output from the turbine and thereby lowering the thermal efficiency.
3- It reduces the rate of condensation and boiling, because air having poor
thermal conductivity impairs the overall heat transfer.
4- Some elements have chemical side effects. Foe example, oxygen causes
corrosion especially in boiler. Also, hydrogen tends to extract carbon from
the pipe material and causes material brittleness.

9
‫‪Power Plant‬‬ ‫‪steam condensers‬‬

‫التوويثيراث الناوبيووت لءهووىا وال ووازاث ال يوور مكثفووه‪:‬ر تتزًم انزتتاص‪ٛ‬شاد انغبَج‪ٛ‬تتخ نهٓتتٕاء انًزغتتشة إنتتٗ‬
‫انذٔسح ػهٗ‪:‬‬
‫‪ٚ.-0‬قهم يٍ ظغػ انجخبس ٔثبنزبن‪ ٙ‬رضداد انؾشاسح انكبيُخ نهزكض‪ٛ‬تف‪ٔ latent heat‬ثبنزتبن‪ ٙ‬ركتٌٕ ُْتب‬
‫ؽبعّ يبء رجش‪ٚ‬ذ ثًؼذل اكجش‪.‬‬
‫‪ٚ .2‬ؤد٘ إنٗ سفغ ظغػ انًكضف ٔثبنزبن‪ٚ ٙ‬قهم شغم انزٕسث‪ ٍٛ‬يؤد‪ٚ‬ب إنٗ رقه‪ٛ‬م انكفبءح انؾشاس‪ٚ‬خ‪.‬‬
‫‪.3‬رقهتتم يتتٍ يؼتتذل اَزقتتبل انؾتتشاسح فتت‪ ٙ‬انًكضتتف أٔ انًشعتتم نزكٕ‪ُٓٚ‬تتب غجقتتّ ػبصن تّ‪ insulation‬ػهتتٗ‬
‫عذساٌ األَبث‪ٛ‬ت ٔثبنزبن‪ ٙ‬رقهم كفبءح انًشعم ٔانًكضف ٔكبفّ يغخُبد يبء انزغز‪ٚ‬خ انًغهقخ ؽ‪ٛ‬ش رغش٘‬
‫ػًه‪ٛ‬بد انزجبدل انؾشاس٘‪.‬‬
‫‪. 4‬نتتجؼط انؼُبصتتش رتتاص‪ٛ‬شاد ك‪ًٛٛ‬بئ‪ٛ‬تتّ عبَج‪ٛ‬تتّ ‪,‬فًتتضال األٔكغتتغ‪ٚ ٍٛ‬غتتجت انزهكتتم ٔخبصتتخ فتت‪ٔ ٙ‬ؽتتذِ‬
‫انًشعم أيب انٓ‪ٛ‬ذسٔع‪ ٍٛ‬ف‪ٛ‬قٕو ثغؾت انكشثٌٕ يٍ انًؼبدٌ ٔ‪ٚ‬غجت ظبْشِ ْ بشخ انًؼذٌ ‪material‬‬
‫‪brittleness‬‬

‫‪Dry cooling Tower‬‬

‫‪10‬‬
Power Plant steam condensers

The wet cooling tower

Open cycle condensing system

11
Power Plant steam condensers

Closed cycle condensing unit with cooling tower

8-Deaerator
The deaerator is an open feed water heater with steam jet ejector. This
device is widely used for the removal of non-condensable gases from the
feed water to steam-generating boilers. It is usually mounted directly before
the steam generator and has three types:
1. spray type deaerator
2.tray type deaerator
3.combined spray –tray deaerator

12
‫‪Power Plant‬‬ ‫‪steam condensers‬‬

‫مسخه وازع الهىا إٌ يغخٍ َبصع انٕٓاء ْٕ ػجبسح ػٍ يغخٍ يبء رغز‪ ّٚ‬يفزٕػ ‪open feed‬‬
‫‪ٚ water heater‬قٕو ػالٔح ػهٗ رغخ‪ ٍٛ‬يبء انزغز‪ٚ‬خ ثُضع انٕٓاء انًزغشة إنٗ انذٔسح‪ٚ .‬قغ يغخٍ‬
‫َبصع انٕٓاء قجم انًشعم ٔرزجؼّ يجبششِ يعخخ يبء انزغز‪ٚ‬خ ‪ . feed water pump‬رؾزٕ٘ كم‬
‫يؾطبد انجخبس أنؾذ‪ٚ‬ضّ ػهٗ يغخٍ َبصع انٕٓاء‪ٚ.‬كٌٕ يغخٍ َبصع انٕٓاء ػهٗ صالصخ إَٔاع‪.‬‬

‫‪13‬‬
Power Plant steam condensers

9-Steam condenser performance analysis:

In this section, the surface condenser will be analyzed. This includes;
1- The amount of leaked air into the condenser shell.
2- The vacuum efficiency.
3- The condenser efficiency.
4- The amount of heat energy transferred from the steam to the cooling
water and the rise in cooling water temperature.
surface condenser‫زى انزطش إنٗ أداء انًكضفبد راد انغطٕػ‬ٚ ‫عٕف‬:‫تحءيل أدا مكثفاث البخار‬
:ٙ‫ه‬ٚ ‫م انؾصٕل ػهٗ يؼهٕيبد رخص يب‬ٛ‫ ًم انزؾه‬ٚٔ .‫ االعزخذاو‬ٙ‫ٕػب ف‬ٛ‫كَٕٓب األكضش ش‬
.‫كفبءح انزخهم‬-2 .‫ض‬ٛ‫ انؾ‬ٙ‫ ر بس انجخبس ف‬ٙ‫ ق شِ انًكضف ٔانز‬ٙ‫خ انٕٓاء انًؾزٕاح ف‬ًٛ‫ك‬-0
ٙ‫ذ ٔاالسرفبع انؾبصم ف‬ٚ‫بِ انزجش‬ٛ‫ّ انؾشاسح انًُزقهخ يٍ انجخبس إنٗ ي‬ًٛ‫ ك‬-4 ‫ كفبءح انًكضف‬-3
.‫ذ‬ٚ‫دسعّ ؽشاسح يبء انزجش‬
10-Dalton law of partial pressure
According to Dalton's law of partial pressures the pressure exerted by a
mixture of two gases or a gas and a vapor is equal to the sum of the
pressures which each fluid would exert if occupying the same space alone.
So, for the condenser shell, the pressure exerted by the condenser ( Pc ) is the
sum of the partial pressure of air and steam and air:
‫ظ‬ٚ‫ نًض‬ٙ‫خ ػهٗ أٌ انعغػ انكه‬ٛ‫ُص قبٌَٕ دانزٌٕ نهعغٕغ انغضئ‬ٚ ‫قاوىن دالتىن لءض ىط النسئيه‬
‫ رنك‬ٙ‫خ نهغبصاد انًؾزٕاح ف‬ٛ‫غبٔ٘ يغًٕع انعغٕغ انغضئ‬ٚ ٍٛ‫ ؽغى يؼ‬ٙ‫يٍ انغبصاد انًؾزٕاح ف‬
‫ٍ أٌ ظغػ انًكضف‬ٛ‫ج‬ٚ ‫ق ْزا انقبٌَٕ ػهٗ انًكضف‬ٛ‫ ٔرطج‬.‫ غم كبيم انؾغى‬ٚ ‫انؾغى ػهًب إٌ كم غبص‬
‫ٕعذ فشاؽ‬ٚ ‫ش ال‬ٛ‫ انق شح (ؽ‬ٙ‫ ف‬ٙ‫كٌٕ يغبٔ٘ إنٗ يغًٕع ظغػ انٕٓاء انًزجق‬ٚ )ٕ‫(األقم يٍ انغ‬
‫ انجئش‬ٙ‫يطهق) ٔظغػ انجخبس انًغبٔ٘ إنٗ ظغػ انز جغ انًقبثم إنٗ دسعّ ؽشاسح انًبء انًكضف ف‬
)‫ذ فبئق‬ٚ‫ٕعذ رجش‬ٚ ‫ (إرا نى‬hot well ٍ‫انغبخ‬

14
Power Plant steam condensers

pc  p a  p s

Where:
pc : The condenser pressure. p a : The air partial pressure.
p s : The steam partial pressure which is equal to the saturation pressure at
the steam temperature (steam tables).

If a manometer is used to measure the condenser pressure, then:

pc  patm  gH

h Condenser
shell
H

Where ( H ) is the vacuum reading.

(  ) liquid density in the manometer.
( Patm ) :is the atmospheric pressure which is usually measured by a
barometer.
patm  gh

Where ( h ) is the barometer reading.

If we use the same liquid in the manometer and barometer then it can be
written:
pc  g (h  H )

15
Power Plant steam condensers

By assuming that the condenser volume is ( V ), then this volume is

occupied by the leaked air and steam. So:
ms ma ma  s
V  ms s   ma a   
s a ms  a
Where ( ,  , m ) are the specific volume , density and mass respectively.
Since air can be considered as a perfect gas, then the mass of leaked air per
unit volume of condenser shell is:
1 ma p
a    a
a V Ra Ta
For the steam, the mass of per unit volume of condenser shell is:
1 ms p
s    s
s V Rs Ts

16
Power Plant steam condensers

11-Vacuum efficiency:
The vacuum reading ( H ) refer to how much the vacuum inside the
condenser is efficient. The present of air inside the condenser will affect the
vacuum reading. Vacuum efficiency depends upon the amount of air present
in the condenser. If there is no air present in the condenser, partial pressure
of steam will be the same as the condenser pressure and the vacuum reading
will be maximum (ideal):
ideal vacuum patm  p s

The actual vacuum is the usual case where air is present:

actual vacuum patm  pc

The vacuum efficiency is the ratio between the actual to the ideal vacuum
reading:
actual vacuum p atm  pc
 vacuum  
ideal vacuum p atm  p s
ِ‫تش‬ٛ‫ًتخ كج‬ٛ‫ دالنتّ ػهتٗ كفتبءح انزخهختم فكهًتب كبَتذ ْتزِ انق‬H ‫ قشاءِ انزخهختم‬ٙ‫ رؼط‬: ‫كفا ة التخءخل‬
ٍ‫قهتم يت‬ٚ ٌ‫ إٌ ٔعتٕد انٓتٕاء داختم ق تشِ انًكضتف يتٍ شتاَّ أ‬.‫ذا داخم انًكضتف‬ٛ‫كهًب كبٌ انزخهخم ع‬
‫ٓتب نتٕ كبَتذ كزهتّ انٓتٕاء‬ٛ‫تخ نقتشاءح انزخهختم عتٕف َؾصتم ػه‬ٛ‫ًتخ انًضبن‬ٛ‫ّ فبٌ انق‬ٛ‫قشاءِ انزخهخم ٔػه‬
‫ٓتب كًشعتغ‬ٛ‫ًكتٍ االػزًتبد ػه‬ٚ ٍ‫ٓتب يطهقتب ٔنكت‬ٛ‫ًكتٍ انٕصتٕل إن‬ٚ ‫صفش داخم انق تشح ْٔتزِ انؾبنتخ ال‬
‫خ إنتتٗ ظتتغػ انغتتٕ َبقصتتب‬ٚٔ‫تتخ نقتتشاءح انزخهختتم يغتتب‬ٛ‫ًتتخ انًضبن‬ٛ‫ إرٌ ركتتٌٕ انق‬.‫نؾغتتبة كفتتبءح انزخهختتم‬
)‫كٌٕ ظغػ انٕٓاء صفش (أ٘ ظغػ انجخبس فقػ‬ٚ ‫ظغػ انًكضف ػُذيب‬

17
 Power Plant steam condensers

12-Condenser efficiency
The condenser efficiency is defined as:

Actual rise in temperature of cooling water

 co 
Maximum rise in the temperature of cooling water

The temperature of condensate is equal to the saturation temperature of

steam corresponding if there is no sub-cool. Ideally, the maximum outlet
temperature of the cooling water is steam saturation temperature
( Two  Tsat ). This situation could not be attained due to thermal resistance.

Two  Twi
 condenser 
Tsat  Twi
‫تش إرا‬ٛ‫كتٌٕ يصتطهؼ انكفتبءح يؾ‬ٚٔ , ‫كفا ة المكثف إٌ انًكضف ػجبسح ػٍ يؼذِ الَزقبل انؾتشاسح فقتػ‬
ٌ‫تف نُتب أ‬ٛ‫ فك‬,‫تذ‬ٚ‫غبٔ٘ يؼذل اَزقبل انؾشاسح إنٗ يبء انزجش‬ٚ ‫ػشفُب إٌ يؼذل اَزقبل انؾشاسح يٍ انجخبس‬
‫تش دسعتّ انؾتشاسح نكتم يتٍ انجختبس ٔيتبء‬ٛ‫ش يُبعت نكفبءح انًكضتف نتٕ أيؼُتب انُظتش إنتٗ رغ‬ٛ‫َعغ رؼج‬
‫تزى أصانتّ عتضء انؾتشاسح‬ٚ ‫تش‬ٛ‫ (ؽ‬Tsat ‫ دسعتّ انؾتشاسح‬ٙ‫تش فت‬ٛ‫ يتٍ رغ‬َٙ‫ؼتب‬ٚ ‫ذ َالؽع أٌ انجختبس ال‬ٚ‫انزجش‬
ٙ‫تبدح فت‬ٚ‫ يتٍ ص‬َٙ‫ؼتب‬ٛ‫تذ ف‬ٚ‫ أيتب يتبء انزجش‬sub-cool ‫تذ انفتبئق‬ٚ‫ ؽبنتّ انزجش‬ٙ‫ ) إال ف‬latent heat‫انكبيُخ‬
thermal ‫تخ‬ٚ‫ ثغتجت انًقبٔيتخ انؾشاس‬Tsat ٍ‫ ركٌٕ اقتم يت‬Two ًّٛ‫ ٔاٌ ق‬Twi  Two ‫دسعّ انؾشاسح‬
ّ‫شفغ دسعّ ؽشاسح انًبء إنٗ دسع‬ٚ ٌ‫غ أ‬ٛ‫غزط‬ٚ ٘‫ذ ْٕ رنك انًكضف انز‬ٛ‫ ٔاٌ انًكضف انغ‬resistance
‫ؼ رنتك‬ٛ‫ًكتٍ رٕظت‬ٚٔ .‫تخ دائًتب يٕعتٕدح‬ٚ‫ّ كٌٕ انًقبٔيتخ انؾشاس‬ٛ‫ ؽبنّ يضبن‬ْٙٔ ‫ؽشاسح انز جغ نهجخبس‬
.ِ‫ثبنشعٕيبد أدَب‬

Tsat Tsat
Two  Tsat
Two

Twi Twi

18
Power Plant steam condensers

13-Energy balance for the condenser:

By assuming the condenser shell is isolated, then the heat energy rejected by
the steam is equal to the heat energy received by the cooling water.
Qout  m
 cw Cpw (Two  Twi )  m  s [(h f  x h fg )  hw ]
Where : m s , m cw are the mass flow rates of steam and cooling water.
( x ): the dryness fraction of steam entering the condenser.
( hw ) is the condensate enthalpy which is equal to ( 4.18 * Tw ). Keeping in

mind that the condensate temperature must be in degree ( oC ).

For the case where there is no under cooling, the balance equation will be:
Qout  m
 w Cp w (Two  Twi )  m
 s x h fg
This heat energy could be calculated using the heat transfer correlation:
Qout  U i Ai TLMTD  U o Ao TLMTD

Where: U i ,U o are the inside and outside overall heat transfer coefficients.
Ai , Ao : are the inside and outside surface areas. These are equal for thin tubes

and not equal for thick tubes.

Ai  2 ri L n
Ao  2 ro L n

‫خ‬ٚٔ‫ش يزغب‬ٛ‫ ٔغ‬thin ‫فخ‬ٛ‫ت انُؾ‬ٛ‫خ نألَبث‬ٚٔ‫خ ركٌٕ يزغب‬ٛ‫خ ٔانخبسع‬ٛ‫يغبؽبد اَزقبل انؾشاسح انذاخه‬
thick ‫كخ‬ًٛ‫ت انغ‬ٛ‫نألَبث‬

n : The number of tubes.

ro , ri : The outside and inside.
L : Tube length.
The overall heat transfer coefficient are give in terms of thermal resistance:
1
U i Ai  U o Ao 
Rtotal

19
Power Plant steam condensers

The thermal resistance is given by:

ri
ln
1 ro 1
Rtotal   
hi Ai 2kL ho Ao
Where: h is the heat transfer coefficient.
k : The conductivity of the pipe.
The above thermal resistance equation is for the new condenser. For old
condenser the fouling factors must be included.
r
R fi ln i
1 ro R fo 1
Rtotal     
hi Ai Ai 2kL Ao ho Ao

Where: R f is the fouling factors.

The term TLMTD refer to the log mean temperature difference.

Where: Tinlet , Texit are temperature difference between the cooling water
and steam at the inlet and outlet of the condenser. These will depend on the
type of flow.
There are three types of flow:
1- Parallel flow. 2- Counter flow. 3- Cross flow

20
 Power Plant steam condensers

Hot out Hot out

Cold
out
cold in cold in Cold out

Hot in Hot in

Counter flow Parallel flow

21
Power Plant steam condensers

Tinlet  Tsat  Twi

For the parallel flow:
Texit  Tsat  Two

Tinlet  Tsat  Two

For the counter flow:
Texit  Tsat  Twi

For the cross flow, the counter flow is assumed with correction factor.
‫ ػهٗ يؼبدنخ اَزقبل‬F ‫ؼ‬ٛ‫ف يؼبيم رصؾ‬ٛ‫بٌ يزؼبكظ َٔع‬ٚ‫بٌ انًزقبغغ فُؼزجش إٌ انغش‬ٚ‫ايب انغش‬
:ٌٕ‫ك‬ٛ‫انؾشاسح ف‬
Qout  U i Ai F TLMTD

Remark:
It can be shown that the condenser efficiency for the case of no under-
cooling is given by:
:‫ذ فبئق‬ٚ‫ ؽبنخ ػذو ٔعٕد رجش‬ٙ‫ّ فقػ ف‬ٛ‫يٍ انًًكٍ اصجبد اٌ كفبءح انًكضف رؼطٗ ثبنًؼبدنخ االر‬
U i Ai U o Ao
 condenser  1  Exp( )  1  Exp( )
m w Cp w m w Cp w

22
Power Plant steam condensers

Example 1:
The following observations were recorded during a test on a steam
condenser of counter flow:
Barometer reading 765 mmHg

Vacuum reading 710 mmHg

Steam and air temperature 35 oC

Condensate temperature 28 oC

Condensate collected per hour 2 tons

Cooling water collected per hour 60 tons

Inlet cooling water temperature 10 oC

Exit cooling water temperature 25 oC

Cooling water tubes specification Thin tubes D=2 cm ,L=5 m ,n=350,

Determine:
1. The vacuum efficiency. 2. The condenser efficiency. 3. Quality of steam
x entering the condenser. 4. The overall heat transfer coefficient 5.Mass of
air per m3 of condenser volume.
Solution:
vacuum reading 710
1.vacuum    98.23%
patm  ps 765  42.2

where ps  0.05622 bar  42.2mmHg at Ts  35

Two  Twi 25  10
2. con    60%
Ts  Twi 35  10

23
Power Plant steam condensers

3.
Q  m wCp w (Two  Twi )  m s (h f  xh fg  Cp wTw )
 60 * 4.2 * (25  10)  2(146 .6  x * 2418 .8  4.2 * 28)
 x  0.769
4.
Q  UATLMTD
60000 18
* 4.2 * 1000 * (25  10)  U * ( * 0.02 * 5 * 350 ) * [(18  10) /(ln )]
3600 10

U  701.6W / m 2 .K

5.
pc  Barometer reading  Vacuumreading  765  710  55mHg
 pc  p s  p a
p a  55  42.2  12.8 mmHg
 12.8 *10 3 * 9.81 *13.6 *1000  1707 .73 Pa
ma p 1707 .73
  a   0.01932 kg / m 3
V RTa 287 * (35  273 )

24
Power Plant steam condensers

Example 2:
The following data relate to a two-pass surface condenser:
Steam condensed = 1540 kg/hr
Temperature of cooling water when it enters the condenser = 15º C
Temperature of cooling water when it leaves the condenser = 30 º C
Vacuum in the condenser = 675 mm of Hg
Barometer reading = 750 mm of Hg
Temperature of condensate = 32 º C
Quality of exhaust steam = 0.92
Water velocity in tubes = 2.6 m/s
Outside diameter of tubes = 2.8 cm
Thickness of tubes = 0.03 cm
Heat Transfer coefficient = 3.35 kJ/h/cm2
Determine
(i) Area of the tube surface required
(ii) No. of tubes
(iii) Length of tubes

Solution:

25
Power Plant steam condensers

Tinlet  Texit
TLMTD 
Tinlet
ln
Texit

26
Power Plant steam condensers

27
Power Plant steam condensers

28
Power Plant steam condensers

Power Plant Engineering TUTORIAL SHEET ‐ 5 ‫الجامعه المستنصريه – كليه الهندسه‬

Steam Condenser ‫قسم الهندسه الميكانيكيه‬

1- In a surface condenser, the pressure of steam is 12 kPa and the cooling

water flow rate is 40 kg/kg of steam condensed. The condensate leaves at
44º C and the rise in temperature of circulating water is 14º C. Determine the
dryness fraction of steam entering into the condenser.
Answers: [x = 0.9738]

2- In a condenser test, the following observations were made:

Vacuum reading = 715 mm of mercury
Barometer reading = 765 mm of mercury
Mean temperature of steam = 34°C
Hot well temperature = 29°C
Inlet temperature of cooling water = 15°C
Outlet temperature of cooling water = 25°C
Determine:
1. Vacuum efficiency. 2- Condenser efficiency.

3- The following observations were recorded during a test of a surface

condenser:
Condenser vacuum reading = 69.85 cmHg
Barometer reading = 76.33 cmHg
Steam and air temperature = 35 oC
Condensation rate = 16 kg/min
Cooling water flow rate = 610 kg/min
Cooling water temperature rise = 12 oC

29
Power Plant steam condensers

Assuming no under cooling for the condensate, calculate:

1. The mass of air per m3 of condenser volume.
2. The dryness fraction of steam entering the condenser.
Answer: (0.0342 kg/m3 ,0.79)

4- The following reading were taken during a test on a surface condenser:

Mean condenser temperature = 35ºC
Hot well temperature = 30ºC
Condenser vacuum = 69 cm Hg
Barometer reading = 76cmHg
Condensation rate = 16 kg/min
Cooling water temperature inter = 20 oC
Cooling water temperature outlet = 32.5 oC
Flow rate being = 37500 kg/h
Calculate:
(a) mass of air present per cubic meter of condenser
(b) quality of steam at condenser inlet
(c) vacuum efficiency
(d) condenser efficiency
Answer: (ma= 0.042 kg/m3, x = 0.836, Vacuum efficiency=96.1%,
Condenser efficiency = 83.33% )

5- Steam enters the condenser at 35ºC. The condenser vacuum is 70 cm of

mercury when the barometer reads 75.5 cm of Hg.
Determine the vacuum efficiency. Estimate the mass of air present in the
condenser per kg of steam.

Answer: (Vacuum efficiency=98.29%, ma= 0.467 kg air/ kg steam)

30