Integrated Condensate Manifold for Air-Cooled Steam Condensers
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Solution Overview
Problem
Existing air-cooled condensers lack a scalable, integrated condensate manifold that efficiently combines structural support, condensate collection, and storage, leading to inefficiencies and increased material and construction complexity.
Innovation Solution
A single, integrated condensate manifold that integrates condensate collection and storage volumes with structural support, featuring a partitioned design for condensate management and load bearing, reducing the need for separate components and enhancing modularity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate components are used for structural support, condensate collection, and storage, then each component can be optimized independently, but the overall system complexity and material requirements increase
Solution Approach 1:
The patent combines the structural support function, condensate collection function, and condensate storage function into a single integrated manifold component. This merging eliminates the need for separate support structures, collection manifolds, and storage tanks, thereby reducing overall system complexity and material requirements while maintaining the ability to optimize each function within the unified design.
Solution Approach 2:
The integrated condensate manifold is designed to perform multiple functions simultaneously: it provides structural support for the heat exchanging tube bundles, collects condensate from the tubes, and stores the collected condensate. This multi-functionality reduces the total number of components needed in the system while allowing each function to be optimized within the unified structure.
2Reliability
If multiple separate manifolds are used for condensate collection, then condensate can be collected from different tube bundles independently, but the material costs and construction complexity increase
Solution Approach 1:
The patent merges multiple separate condensate collection manifolds into a single integrated manifold structure that serves all tube bundles. This unified structure reduces the total material quantity required compared to having separate manifolds for each tube bundle, while maintaining reliable condensate collection from all regions through its distributed collection points and internal flow paths.
3Strength
If conventional support structures are used below the condenser, then structural stability is provided, but the design flexibility and modularity are reduced
Solution Approach 1:
The integrated condensate manifold serves as both the condensate collection/storage system and the primary structural support element. By eliminating the need for separate support structures, the design achieves greater modularity and adaptability, as the manifold can be configured in different arrangements while maintaining structural stability through its integrated design.
Solution Approach 2:
The patent merges the support function with the condensate manifold, making the manifold itself the load-bearing structure. This integration provides structural stability while enhancing modularity, as the unified component can be more easily adapted to different configurations and requirements compared to fixed separate support structures.
4Strength
If the condenser is positioned close to the support foundation, then structural support is maximized, but air flow for cooling is restricted
Solution Approach 1:
The patent merges the support function with the condensate manifold, allowing the condenser to be positioned optimally for air flow while the integrated manifold provides the necessary structural support. This eliminates the need to compromise air flow rate for the sake of proximity to the foundation, as the manifold itself bears the structural loads.
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 integrated manifold improves efficiency by minimizing sub-cooling and corrosion, reduces material and construction costs, and enhances stability and modularity, while maintaining a closed-loop condensation process.
Implementation Method 1
an air-cooled condenser provides for a cool ambient air flow to allow for thermal transfer of heat from hot steam
Implementation Method 2
the steam is condensed and the condensed liquid, such as water, collected
Implementation Method 3
Cool ambient air is moved over the finned-tube bundles by a fan disposed at a lower portion of the condenser
Implementation Method 4
Steam is drawn from the steam distribution manifold into the tube bundles via a vacuum effect caused by the change in temperature
Implementation Method 5
condensate from the heat exchanging tube bundle to a collection volume within the manifold
Data Source
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AI summary
A steam condensation unit is a V-type induced-draft condenser system having a single, integrated condensate manifold. This integrated manifold combines the functions of conventional lower-region structural support, multiple condensate collection manifolds and a condensate collection tank. The integrated manifold serves as a base assembly to which framing and finned-tube bundles may be attached, and bears all loading from elements of the steam condensation unit disposed above the integrated condensate manifold.