Field-Erected Air Cooled Condenser Panel with Central Manifold
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Solution Overview
Problem
Large scale field erected air cooled industrial steam condensers lack an efficient means to remove non-condensable gases, leading to reduced thermal efficiency and increased pressure drop, particularly at winter conditions, and existing variations either compromise on tube length or require costly field welding.
Innovation Solution
The design incorporates an integral secondary condenser section within the heat exchanger panel, flanked by primary condenser sections, allowing for counter-current and co-current condensing operations, with a centralized steam distribution manifold and flexible panel orientations to enhance gas removal and airflow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If standard prior art ACC arrangement with separate primary and secondary condenser bundles is used, then non-condensable gases can be removed, but device complexity and field welding requirements increase
Solution Approach 1:
The patent combines the primary and secondary condenser bundles into a single integrated heat exchanger panel. The tube bundle includes both primary condenser tubes and secondary condenser tubes arranged in the same panel structure, eliminating the need for separate bundle assemblies and complex field welding operations while maintaining the two-stage condensing function for effective non-condensable gas removal
2Ease of manufacture
If tube length is reduced to accommodate manifold in shipping container, then manufacturing and shipping cost decrease, but steam-side pressure drop increases
Solution Approach 1:
The patent distributes multiple steam distribution manifolds along the length of the heat exchanger panel rather than using a single manifold at one end. This multi-dimensional arrangement of steam entry points allows for shorter tube lengths that can be accommodated in standard shipping containers while maintaining adequate steam pressure distribution and minimizing pressure drop across the condenser
3Use of energy by moving object
If 1st stage condenser bundles are arranged horizontally, then thermal efficiency improves, but difficulty of detecting and measuring performance increases
Solution Approach 1:
The patent arranges the primary condenser tubes and secondary condenser tubes in distinct vertical zones within the same panel, with primary tubes in the upper portion and secondary tubes in the lower portion. This localized arrangement maintains the thermal efficiency benefits of horizontal-style condensing while enabling easier performance measurement and detection through clear spatial separation of the two condensing stages
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
This configuration improves thermal efficiency by effectively removing non-condensable gases and reducing pressure drop, while allowing for modular assembly and reduced material usage, thus enhancing overall performance and cost-effectiveness.
Implementation Method 1
the 1st stage of condensing occurs in counter-current operation... In this arrangement the 2nd stage of condensing occurs in co-current operation
Implementation Method 2
heat exchanger panels are constructed with an integral secondary condenser section positioned in the center of the heat exchanger panel, flanked by primary condenser sections
Implementation Method 3
a bottom bonnet runs along the bottom length of the heat exchanger panel, connected to the bottom side of the bottom tube sheet, for delivering steam to the bottom end of the primary condenser tubes
Implementation Method 4
The tops of the tubes are connected to a top tube sheet, which in turn is connected on its top side to a top bonnet. Uncondensed steam and non-condensables flow into the top bonnet from the primary condenser tubes
Implementation Method 5
a plenum section having a single fan or multiple fans drawing air through a plurality of heat exchanger panels
Data Source
AI summary
Large scale field erected air cooled industrial steam condenser having heat exchanger panels independently loaded into and supported in a heat exchange frame section. A bottom bonnet runs along the bottom length of each heat exchanger panel for delivering steam to the bottom end of condenser tubes in the heat exchange panel and for receiving condensate formed in those same tubes. The tops of the tubes are connected to a top bonnet. Uncondensed steam and non-condensables are drawn into the top bonnet from the condenser tubes. A steam distribution manifold is suspended from the heat exchange section frame perpendicular to the longitudinal axis of the heat exchange panels and beneath a center point of the heat exchange panels and delivers steam to each heat exchange panel via a single steam inlet located at a center point of each bottom bonnet.