Air-Cooled Condenser Air-Flow Diffuser Design
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Solution Overview
Problem
Air-cooled condensers require large fans with high electrical power consumption to circulate sufficient air for steam condensation, leading to increased energy costs.
Innovation Solution
Incorporating an air-flow diffuser with a specific design that increases the cross-sectional area from the inlet to the outlet, reducing dynamic pressure and transforming it into static pressure, which is then used to reduce the total pressure drop and subsequently the power consumption of the fan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large fans are used to circulate sufficient air for steam condensation, then the condensation efficiency is improved, but the electrical power consumption increases
Solution Approach 1:
An air-flow diffuser is introduced as an intermediary component between the fan and the heat exchanger panels. The diffuser has a gradually expanding cross-sectional area that transforms the high-velocity air flow from the fan into a lower-velocity, higher-pressure flow that distributes more efficiently across the heat exchanger panels, reducing the power needed to achieve the same condensation rate
Solution Approach 2:
The diffuser changes the parameters of the air flow by transforming kinetic energy (high velocity) into potential energy (high pressure) through its expanding geometry. This parameter transformation allows the air to penetrate and distribute across the heat exchanger panels more effectively, improving condensation efficiency while reducing fan power consumption
2Stress or pressure
If the cross-sectional area of the air flow passage is increased, then the pressure drop is reduced, but the device height increases
Solution Approach 1:
Instead of increasing the vertical height to reduce pressure drop, the diffuser expands the air flow passage in the horizontal plane. The cross-sectional area increases by expanding radially outward from the fan inlet, transforming the pressure profile without significantly increasing the overall device height
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The air-flow diffuser design reduces fan power consumption by 12% compared to prior art systems, achieving efficient air distribution and condensation while minimizing the height of the air-cooled condenser structure.
Implementation Method 1
increases the cross-sectional area from the inlet to the outlet, reducing dynamic pressure and transforming it into static pressure
Implementation Method 2
The tubes of the heat exchanger panels are in contact with the ambient air and when steam passes through the tubes, the steam gives off heat and is eventually condensed
Implementation Method 3
when steam passes through the tubes, the steam gives off heat and is eventually condensed
Implementation Method 4
ducted fans are used to generate an air-flow through these large heat exchanger panels. Each ducted fan comprises a rotatable fan that is located below the roof-shaped heat exchanger assembly so that, when in operation, an air draft is forced from the space below the fan towards the plenum space
Data Source
AI summary
The present invention relates to an air-cooled condenser (1) for condensing steam. The air-cooled condenser comprises one or more roof-shaped heat exchanger assemblies (51,52,53,54,55,56).A plenum space (60) is located between a top boundary delineated by the one or more roof-shaped heat exchanger assemblies (13,14) and a bottom boundary delineated by a deck cover (17). A ducted fan (5) is provided for generating an air-flow. The air-cooled condenser according to the invention comprises an air-flow diffuser (8) having an air inlet side connected to an upper side of the cylindrical duct (7) of the ducted fan and an air outlet side coupled with the deck cover such that, when in operation, an air-flow generated by the fan is flowing through the air-flow diffuser before entering the plenum space via a deck opening (18) in the deck cover. The cross sectional area and the height of the air-flow diffuser are optimized to reduce the electrical power consumption of the fan.