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Surface Condenser and Cooling Tower Guide

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0% found this document useful (0 votes)
8 views7 pages

Surface Condenser and Cooling Tower Guide

Uploaded by

Abhinav Kumar
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd

surface condenser is a crucial component in many power plants, particularly in

steam power plants, where it serves to condense exhaust steam from the turbine back into liquid water
for reuse in the boiler. Here's how it works:

1. Steam Inlet: High-pressure steam, having performed its work in driving the turbine, enters the surface
condenser. This steam is typically at a lower pressure and temperature compared to its state when it
entered the turbine.

2. Cooling Tubes: Inside the surface condenser are numerous tubes or pipes through which cold water
flows. These tubes are designed to maximize the surface area available for heat exchange between the
steam and the cooling water.

3. Heat Exchange: As the steam comes into contact with the cool surfaces of the tubes, heat is
transferred from the steam to the water flowing through the tubes. This causes the steam to lose
thermal energy and begin to condense back into liquid water.

4. Condensate Collection: The condensed steam, now in the form of water droplets, collects at the
bottom of the surface condenser. This liquid condensate is then pumped out of the condenser and sent
back to the boiler to be reheated and reused in the steam cycle.

5. Non-condensable Removal: Any non-condensable gases, such as air and other vapors, that may have
accompanied the steam are also removed from the surface condenser. This is typically achieved by
vacuum pumps that maintain a low pressure inside the condenser, facilitating the removal of these
gases.

6. Cooling Water Circulation: The cooling water that absorbs heat from the steam inside the condenser
undergoes a temperature increase. This heated water is then circulated to a cooling tower or another
heat rejection system where it releases the absorbed heat to the environment, typically through
evaporative or convective cooling processes.

COOLING TOWER
By efficiently condensing the exhaust steam from the turbine back into liquid water, the surface
condenser helps maximize the efficiency of the power plant's steam cycle. This allows for the effective
reuse of water and ensures optimal performance of the overall power generation process.
The primary function of a cooling tower in a power plant is to remove excess heat generated during the
electricity generation process. When power plants burn fuel or use nuclear reactions to generate
electricity, a significant amount of heat is produced. This heat needs to be dissipated to prevent
equipment from overheating and to maintain efficient operation.

Here's how a cooling tower works:

Heat Transfer: Hot water from the power plant's condenser, which has absorbed heat from the steam
turbine, is pumped into the cooling tower. This hot water is distributed over the tower's fill material,
which increases the surface area available for heat transfer.

Airflow: As the hot water cascades over the fill material, it comes into contact with a flow of ambient air.
This air is either drawn through the tower naturally or forced by fans. The contact between the hot water
and the air causes evaporation and heat exchange.

Evaporation: As the hot water flows over the fill material, a portion of it evaporates due to the difference
in temperature with the cooler ambient air. This process of evaporation absorbs heat from the remaining
water, effectively cooling it down.

Cooling: The cooled water collects at the bottom of the cooling tower and is either recirculated back to
the power plant's condenser to absorb more heat or discharged into a nearby water body, depending on
the plant's design and environmental regulations.

By utilizing the principle of evaporative cooling, cooling towers can efficiently dissipate large amounts of
heat from the power plant's processes. This allows the power plant to operate at optimal temperatures,
ensuring the reliability and efficiency of its equipment while minimizing environmental impacts.

In the context of boilers, "mountings" and "accessories" refer to the various components and devices
that are installed on a boiler to ensure its safe and efficient operation.

1. **Boiler Mountings:**
- Mountings are those essential fittings which are necessary for the safe and satisfactory operation of
the boiler. They primarily ensure the safety of the boiler and its personnel. Some common boiler
mountings include:

- Safety valves: These are pressure relief valves that release excess steam when the pressure inside
the boiler exceeds a certain limit, preventing explosions.

- Water level indicators: Devices to indicate the water level inside the boiler, ensuring it does not run
dry or overflow.

- Pressure gauge: Instrumentation to measure and display the pressure of steam inside the boiler.
- Steam stop valve: A valve used to regulate the flow of steam from the boiler to the steam
distribution system.

- Fusible plug: A safety device that melts and releases steam in the event of excessive boiler
temperature, preventing boiler damage.

- Blowdown valve: Used to remove impurities and sludge from the boiler by periodically draining a
portion of the boiler water.

- Feed check valve: A non-return valve that allows water to enter the boiler but prevents backflow.

2. **Boiler Accessories:**
- Boiler accessories are optional components that may be installed to enhance the efficiency or
convenience of boiler operation. They are not essential for the basic functioning of the boiler but can
improve its performance or serve specific purposes. Some common boiler accessories include:

- Economizer: A heat exchanger that preheats the feedwater using waste heat from the boiler exhaust
gases, improving boiler efficiency.

- Superheater: A device that increases the temperature of steam produced by the boiler to achieve
higher energy content and efficiency.

- Air preheater: A heat exchanger that preheats combustion air using waste heat from the boiler
exhaust gases, improving combustion efficiency.

- Water softener: A device used to remove minerals and impurities from feedwater to prevent scale
formation and improve boiler lifespan.

- Boiler feed pump: A pump used to deliver feedwater to the boiler at the required pressure and flow
rate.

- Fuel feeding system: Equipment for delivering fuel (such as coal, oil, or biomass) to the boiler
combustion chamber.

Overall, mountings and accessories play complementary roles in ensuring the safe and efficient
operation of boilers in various industrial and commercial applications.

The regenerative steam power cycle is a modification of the traditional


Rankine cycle used in steam power plants. It aims to improve the overall thermal efficiency of the power
plant by utilizing extraction steam from the turbine to preheat the feedwater before it enters the boiler.
This preheating process reduces the amount of fuel needed to heat the feedwater to the desired
temperature, thereby increasing the cycle's efficiency. Here's how the regenerative steam power cycle
works:

1. **Boiler:** The cycle begins with the boiler, where water is heated to produce high-pressure steam.
This steam is then used to drive the turbine.

2. **Turbine:** The high-pressure steam expands through the turbine, performing work and generating
electricity.

3. **Extraction:** Before the steam reaches the end of the turbine, a portion of it is extracted at an
intermediate pressure. This extraction steam still contains a significant amount of thermal energy.

4. **Feedwater Heater:** The extracted steam is directed to one or more feedwater heaters, where it
transfers its thermal energy to the feedwater coming from the condenser. The feedwater heaters
typically consist of heat exchangers that allow the extracted steam to heat the feedwater without mixing
the two streams.

5. **Condenser:** After passing through the turbine, the steam is condensed back into liquid water in
the condenser, releasing its latent heat of vaporization. The resulting condensate is then pumped back to
the boiler to be reheated and reused in the steam cycle.

6. **Feedwater Pump:** The feedwater pump pressurizes the feedwater and sends it to the boiler.
Because the feedwater has been preheated in the feedwater heaters, less energy is required to raise its
temperature to the level needed for boiler operation.

7. **Reheat (Optional):** In some regenerative steam power cycles, a reheat stage may be included
after the initial expansion of steam in the turbine. This involves reheating the steam before it enters
subsequent stages of the turbine, which can further improve cycle efficiency.

By using extraction steam to preheat the feedwater, the regenerative steam power cycle reduces the
temperature difference between the boiler and the condenser, thereby increasing the thermal efficiency
of the cycle. This improvement in efficiency translates to reduced fuel consumption and lower operating
costs for the power plant.
Let's break down each of these terms related to psychrometrics, which is the study of the physical and
thermodynamic properties of gas-vapor mixtures:

1. **Dry Bulb Temperature (DBT):** This is the temperature of the


air measured by a standard thermometer, usually referred to as just "temperature." It indicates the
thermal energy of the air without considering the moisture content.

2. ** Dew Point Temperature (DPT):** The dew point temperature is


the temperature at which air becomes saturated with moisture, leading to condensation (dew or fog
formation) if cooled further without adding or removing moisture. It's a measure of the absolute
humidity of the air.

3. **Specific Humidity:** Specific humidity is the mass of water vapor per unit mass
of dry air in a mixture. It is expressed in units of kg/kg or grams of water vapor per kilogram of dry air.
Specific humidity gives a measure of the actual amount of moisture present in the air.

4. ** Relative Humidity (RH):** Relative humidity is the ratio of the partial pressure of water
vapor in the air to the saturation pressure at the same temperature, expressed as a percentage. It
indicates how close the air is to saturation with moisture. Higher relative humidity means the air
contains more moisture relative to its capacity at that temperature.

5. ** Degree of Saturation of Air :** This term is often used interchangeably with relative
humidity. It refers to how close the air is to being saturated with moisture at a given temperature. A
degree of saturation of 100% means the air is fully saturated (RH is 100%) and any further addition of
moisture will lead to condensation.

6. **Enthalpy of Mixture :** Enthalpy is a measure of the total energy of a system,


including both its internal energy and the energy associated with pressure and volume changes. In the
context of air-water vapor mixtures, the enthalpy of the mixture is the total heat content per unit mass
of the mixture. It takes into account the sensible heat (related to the temperature) and the latent heat
(related to the phase change of water vapor). Enthalpy is often expressed in units of kJ/kg or Btu/lb.
1. **Ideal Vacuum . In an ideal vacuum, there is no gas, liquid, or solid matter, and therefore, no
pressure exerted by particles. It's an abstraction used in physics and engineering for theoretical
calculations.

2. **Actual Vacuum **:. In practical terms, it's a space where the pressure is lower than
atmospheric pressure but not necessarily zero

3. **Vacuum Efficiency **: This term refers to how effectively a vacuum system removes
particles and reduces pressure within a given space. It's typically expressed as a ratio or percentage
comparing the achieved vacuum level to the theoretical ideal vacuum

Steam turbines are often compounded to improve their overall efficiency and performance.
Compounding involves dividing the expansion of steam across multiple stages, each stage extracting
energy from the steam to drive the turbine. There are several methods of compounding, each with its
own benefits:

1. **Velocity Compounding**: In velocity compounding, the turbine stages are arranged such that the
steam expands through a series of moving blades. As the steam expands, its velocity decreases, and the
energy is extracted from the steam. The blades of each stage are designed to increase in size, which
allows them to extract more energy from the steam as it expands. Velocity compounding is effective at
lower pressure differentials and is often used in smaller turbines.

2. **Pressure Compounding**: Pressure compounding involves dividing the expansion of steam into
multiple chambers or stages, each operating at successively lower pressures. The steam passes through a
series of stationary nozzles and then expands through a series of moving blades. Each stage extracts
energy from the steam as it expands, resulting in higher overall efficiency compared to a single-stage
turbine. Pressure compounding is commonly used in medium-sized turbines.

3. **Velocity-Pressure Compounding (Curtis Stage)**: This method combines elements of both velocity
and pressure compounding. In a Curtis stage turbine, the steam first expands through a series of fixed
nozzles, which increases its velocity. The high-velocity steam then enters a set of moving blades, where it
expands further and its pressure decreases. The combination of velocity and pressure compounding
allows for greater energy extraction from the steam and is often used in large turbines.
4. **Reheat Compounding**: Reheat compounding involves reheating the steam between stages to
maintain its temperature and pressure. After the steam expands through one set of turbine stages, it is
passed through a reheater where its temperature is increased before entering the next set of stages.
Reheat compounding helps to maintain high steam quality and can improve the overall efficiency of the
turbine.

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