Power Plant Condenser Plasma Coating for Renewable Hydrophobic Surfaces
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Solution Overview
Problem
Thin, hydrophobic surface coatings in power plant condensers have a short service life due to chemomechanical stress, leading to efficiency losses as they are prone to damage from turbine steam and water retention effects, necessitating a cost-effective, renewable, and repairable solution.
Innovation Solution
A device with electrodes and a gas inlet for generating a plasma within the circulatory system, allowing for the coating of inner surfaces using precursor and reaction gases, where electrodes within the system are used to ignite a plasma for coating the condensation surfaces of power plant condensers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thin hydrophobic surface coatings are applied to condensation surfaces, then heat transfer efficiency is improved by avoiding film condensation, but service life is reduced due to chemomechanical stress from turbine steam and water ingress
Solution Approach 1:
The patent applies plasma treatment to modify the surface parameters of the condensation surface, creating a hydrophobic microstructure that maintains water repellency while being more resistant to chemomechanical stress. The plasma process changes the surface energy and topography parameters without significantly altering the bulk coating thickness, thereby maintaining heat transfer efficiency while improving durability.
Solution Approach 2:
The invention creates a composite surface structure by combining the base coating material with plasma-induced surface modifications. This results in a hierarchical structure where the underlying coating provides mechanical integrity and the plasma-treated surface layer provides enhanced hydrophobicity and chemical resistance, effectively combining the benefits of both thin coating and durability.
2Reliability
If expensive corrosion-resistant materials are used for condensation surfaces, then durability is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies a cost-effective plasma treatment process to standard condensation surfaces, avoiding the need for expensive corrosion-resistant materials. The plasma modification provides sufficient corrosion and chemical resistance for the intended application lifecycle at a fraction of the cost of alternative materials like titanium alloys or stainless steel.
Solution Approach 2:
The invention replaces the mechanical/chemical approach of using expensive corrosion-resistant materials with a plasma-based surface modification process. This substitution achieves comparable or superior corrosion resistance through controlled surface chemistry changes rather than relying on inherent material properties, significantly reducing manufacturing costs.
3Loss of substance
If the condensation surface area is reduced to save materials, then manufacturing cost is reduced, but heat transfer efficiency decreases unless coating efficiency is maximized
Solution Approach 1:
The patent applies plasma treatment selectively to the condensation surfaces to create localized hydrophobic properties where they are most needed for heat transfer efficiency. This localized modification ensures optimal performance on the condensation surfaces without requiring expensive materials throughout the entire condenser structure, achieving material savings while maintaining energy efficiency.
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 plasma-based coating method extends the service life of the coatings, maintaining efficiency by renewing or repairing the surface without extensive equipment changes, ensuring optimal heat transfer and reducing thermal conduction losses.
Implementation Method 1
at least one internal surface in the interior space of the device can be used as an electrode for generating a plasma by contacting it, and at least one of the internal surfaces of the device can be coated by the plasma
Data Source
AI summary
The invention relates to a device for operating a circulation system, to a coating method and to the use of generator and/or turbine blades and/or condenser tube sheets of a power plant condenser for producing plasma. The invention specifically relates to a multifunctional power plant condenser, especially one having coated condenser surfaces. The interior of a power plant condenser is used to produce and/or ignite plasma by contacting electrodes and introducing plasma gases. Said plasma can be used to produce a coating on the interior surfaces or a part of the interior surfaces, for example the condenser surfaces of the power plant condenser.