CHAPTER 7

STEAM CONDENSERS

1
Steam Condenser
Steam Condenser is a mechanical device
that converts the low-pressure
exhaust steam from the turbine into water.
Or in other words, it is a device that is
used to condense exhaust steam of the
turbine into water. It does so with the help
of cooling water circulated into it from the
cooling tower.

2
Application of Condenser

3
Application of Condenser

4
Application of Condenser

5
 Application of Condenser 6

Schematic representation of the plant energy balance

Thermal losses in air preheaters : 180 kW Flue gas to Stack
4418.9 kW
Flue gas to
cleanup
Energy recovered from ash : 413.4 kW 5855.5 kW losses
Preheated air
Steam
2544.2 kW bleedings Auxiliary power
356.9 kW consumption
Feedwater 1167 kW
1533.7 kW Gross power
Combustion
Full load products
11179 kW
48529.5 kW
Thermal input Total furnace input Net Elec. power
46072.0 kW 48816.2 kW 10012 kW
Furnace losses losses Internal use Mech./Elec.
losses: 311.1 kW
700.1 kW 111.3 kW 113 kW
Net steam production Condenser
41247.1 kW 29757 kW

Thermal losses in air preheaters : 74.2 kW Flue gas to Stack

Flue gas to 2252.38 kW
cleanup
Energy recovered from ash : 180 kW 3244.2 kW losses
Preheated air
Steam Auxiliary power
2102.2 kW bleedings consumption
216.3 kW
Part load  
Combustion 1199 kW
Feedwater

Gross power
690 kW
products
60 % 28998 kW 6357 kW

Thermal input Total furnace input

Net Elec.power
27447 kW 29230.7 kW 5667 kW
Mech./Elec.
Furnace losses losses Internal use Losses : 152.1 kW
420.5 kW 66.5 kW Net Steam production
Condenser
24372.1 kW 17963 kW

6
 Steam Condenser
A steam condenser is a closed vessel in to which the steam is
exhausted, and condensed after doing work in a turbine.
 A condenser is basically steam to water exchanger in which
heat from exhaust steam is transferred to circulating cooling
water.
A steam condenser has the following objectives:
a) To maintain a low pressure (below atmospheric pressure) so
as to obtain maximum possible energy from steam and thus
to secure high efficiency.
b) To condense the exhaust steam from the turbine and reuse it
as pure feed water in the boiler. Thus only make up water is
required to compensate loss of water.
Benefits:
- No feed water treatment is required and hence reduces the cost of the plant
- The formation of deposits in the boiler surface can be prevented with the use of
condensate instead of feed water from outer sources
7
 Steam Condensers
 Let steam be available to a steam turbine at pressure P 1 and
temperature T1.
 If steam is allowed to expand in the steam turbine to obtain
mechanical work and exhausted into the atmosphere, the
final state will be equal to the atmospheric pressure P a and
temperature T2, as figure below.
 Keeping the initial properties the same (state 1), lowering
the final temperature increases the work output.

8
9
 Functions of Condenser:
Itlowers back pressure at turbine exhaust.
Enables recovery and reuse of pure feed water to
boiler.
Enables removal of air and non-condensable gases
from steam.

10
11
12
13
Elements of Condensing Plant:

14
15
16
17
18
19
20
21
 Types of Condensers
Jet condenser:
Water and steam come in direct contact.
Surface condenser:
Water and steam do not come in direct contact.

22
 Types of Jet Condensers:
Low-Level Jet Condenser
1) Counter-flow type
2) Parallel-flow type
High-level jet condenser
Ejector jet condenser

23
Types of Condensers:
1. Direct Contact Condensers (Spray Condenser)
•In this type, the cooling water is sprayed into the steam. Steam by mixing directly
with cold water gets condensed, as shown in Figure (5-1).
•The non-Condensable gases are usually removed with a steam jet air ejector
(SJAE)

Figure (5-1) Direct-Contact Spray Condenser. 24

 

h2-h3 is larger since large latent heat of vaporization where as h3-h5 is much smaller. 25
 Example (1): In a spray condenser, find the ratio of circulating water to steam flow
if the condenser pressure is (0.04 bar), and the cooling tower cools the water to (15
Co). Assume turbine exhaust at (85%) quality.

Solution:

26
 Condenser Efficiency
 The condenser efficiency may be defined as the ratio of temperature
rise of cooling water to the vacuum temperature minus inlet cooling
water temperature.

Where:

To = outlet temperature of cooling water.

Ti = inlet temperature of cooling water

Tv = Vacuum temperature

27
28
 Steam
Condensers
Jet condenser is a mixing type
condenser where exhaust steam is
condensed mix up with cooling
water.

29
30
31
High Level Condenser- (Barometric Condenser)

32
Advantages and Disadvantages of
High Level Jet Condenser:
Advantages:
1. Less floor area
2. Requires only Circulating Pump
Disadvantages:
1. Due to high level, long pipes needed
2. Not readily accessible for maintenance

33
Ejector Condenser

34
 Types of Surface Condensers:
Shelland tube type
◦ Down flow condensers
◦ Central flow condensers
◦ Inverted flow condensers
Evaporative Condensers

35
 2. Surface Condenser
A surface condenser has a great advantages
over the jet condenser, as the condensate does
not mix up with cooling water.
As a result of this whole condensate can be
reused in the boiler.
This type of condenser is essential in ships
which can carry only a limited quantity of
fresh water for the boilers.
Fig . Shows a longitudinal section of a two
pass surface condenser.
36
2. Surface Condenser

37
2. Surface Condensers: It is the most common type used in modern power
plants. It is a shell-and-tube heat exchanger. The saturated steam condenses on
the outside surface of the tubes, and the cooling water circulates inside the tubes,
as shown in figures (5-2) and (5-3)

Figure (5-2) Single-Pass Condenser. Figure (5-3) Two-Pass Condenser.

Number of Passes and divisions: Condensers are designed with 1, 2, or 4 cooling water
passes. The number of passes (N) determines the size and effectiveness of the condenser.

Single-Pass Condenser (N=1):

Two-Pass Condenser (N=2):

38
 Surface- Condenser Calculations
 Heat transfer in a surface condenser is given by the general heat transfer
equation:

39
Thermal Analysis of Surface condenser:
 

 
 

 
Figure (5-4) Temperature profiles
in a Surface Condenser.
40
 

   

41
Condenser thermal performance:
 

42
Given = UAs
43
Example (2): A Two-pass steam Condenser is designed for a full heat load of (293 MW)
at a pressure of (0.05 bar). The inlet and outlet temperature of circulating water is (15 C o)
and (25 Co) respectively. A (2.5 cm) Diameter, (304 Stainless Steel) Condenser tube has
been selected. The water velocity inside the tubes is assumed to be (2.6 m/s). Assume
the following:
 

44
45
 

46
Example (3): Steam is to be condensed by direct injection of cold water. The steam enters
the condenser at the rate of (450 kg/hr) with dryness fraction of (0.9) and pressure (1 bar).
The estimated heat losses from the condenser to the surroundings is (8500 kj/hr). If cold
water enters at (15 Co) and the mixture of condensate and cooling water is to leave at (95 C o).
Determine the required flow of cooling water.
 

47
Example (4): Calculate the condenser pressure for the following condition:
 

48
49
50
51
52
 Advantages of surface
condensers:
High vacuum efficiency, hence suitable for large
power plants.
Pure condensate
Saving in cost of water treatment and cost of fresh
water
No direct contact of water and steam, hence low
quality cooling water can be used
Low power air extraction pump can be used
Controlled condensation

53
 Disadvantages of Surface
Condensers:
Indirect cooling-hence large amount of cooling
water required
High cost (Installation and maintenance)
Large floor area

54
 CIRCULATING WATER
SYSYTEM
 The circulating water system supplies cooling water to the
turbine condenser and thus acts as a medium through which
heat is rejected from the steam cycle to the environment.
 Cooling water can flow through the condenser in two
methods
Once through system
Closed loop system

55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
Closed loop system:-

70
71
72
73
 COOLING TOWERS
 Cools the warm water discharged from the condenser and
feed the cooled water back the condenser. They, thus,
reduces the cooling water demand in the power plant.
 Cooling towers can be classified as :-
 WET COOLING TOWERS
 DRY COOLING TOWERS

74
 WL 320 Cooling Tower Setup
 Wet cooling towers are a proven method of closed-circuit cooling
and heat dissipation. Typical areas of application are: air
conditioning, heavy industry and power plants.
 In wet cooling towers the water to be cooled is sprayed over a
wet deck surface. Water and air come into direct contact in
the counterflow.
 The water is cooled by convection. Some of the water evaporates
and the evaporation heat removed further cools down the water.
 WL 320 examines the main components and principle of a wet
cooling tower with forced ventilation.
 Water is heated in a tank and transported by a pump to an
atomiser. The atomiser sprays the water to be cooled over the
wet deck surface. The water trickles from the top to the
bottom along the wet deck surface whilst air flows from the
bottom to the top. The heat is transferred directly from the
water to the air by convection and evaporation.
 The evaporated water volume is recorded. The air flow is
generated by a fan and adjusted using a throttle valve.
75
Parameters to be determined using Wet cooling
tower Laboratory setup

A. Mass flow rate of the air

B. Volumetric Flow rate of the air
C. Cooling capacity of the air and show
the process on Psychometric chart
D. Heating load of the water
E. Water loss from the cooling tower
F. Show the cooling process of the
water on psychometric chart

76
77
Wet Cooling Tower Exercises

78
79
80
Exercise

81
82
Mixture of Air and Steam

83
WET COOLING TOWERS

84
85
 Assuming an adiabatic process:

86
Approach (A):-
 the difference b/n the exit temperature of cooling water and the
wet bulb temperature of ambient air.

 Warm water from the condenser enters the cooling tower at

temperature Tc1 and is cooled to temperature Tc2, higher than the
minimum value, the wet bulb temperature twb.

87
Cooling range or range (R) :-
 the difference in temperature of the incoming warm water (Tc1) and
the exiting cooled water (Tc2)

 Range varies from 60C to 100C.

 It is the range by which warm water from the condenser is
cooled.
The cooling efficiency
 the ratio of the actual cooling of water to the maximum cooling
possible.

88
 DRY COOLING TOWERS
 A dry-cooling tower is one in which the circulating water flows
through finned tubes over which the cooling air is passed.
 All heat rejection from the circulating water is in the form of sensible
heat to the cooling air.
 A dry-cooling tower can have either mechanical-draft or natural draft.
Advantages:
 They permit plant sitting without regard for large supplies of
cooling water.
 They are less expensive to maintain than wet cooling towers.
 They do not require large amounts of chemical additives and
periodic cleaning as do wet-cooling towers.
 There are two basic dry-cooling tower types:
 Direct dry-cooling tower;
 Indirect dry-cooling tower.

89
 Direct Dry-Cooling Tower
 The condenser tubes are placed inside the tower itself.
 To lower the pressure drop, large diameter tubes are used.

90
 Indirect dry cooling towers
 They are of two general designs:
 Indirect dry-cooling tower with conventional surface condenser.
 Indirect dry-cooling tower with an open-type condenser.

91
92
93
 By energy balance:-

94
 Example-1

 A surface condenser receives 250 t/hr of steam at 40 0C with

12% moisture, the cooling water enters at 32 0C and leaves at
380C. The pressure inside the condenser is found to be 0.078
bar. The velocity of circulating water is 1.8 m/sec. the condenser
tubes are of 25.4 mm OD and 1.25 mm thickness, taking the
overall heat transfer coefficient as 2600 W/m2 K, determine
a) The rate of flow of cooling water
b) The rate of air leakage in to the condenser shell

c) The length of tubes

d) The number tubes

95
 Example-2
 Water at 30 0C flows into a cooling tower at the rate of 1.15 kg
per kg of air. Air enters the towers at the dbt of 200C and a
relative humidity of 60% and leaves it at a dbt of 280C and 90%
relative humidity. Make up water is supplied at 200C.

96
Thank you

97