Modular Air Cooled Condenser Design for Uniform Steam Distribution

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Solution Overview

Problem

Current mechanical draft cooling towers face challenges in uniform steam distribution, leading to inefficiencies in heat transfer and increased turbine back pressure, and are labor-intensive and costly to assemble due to non-uniform ducting and large surface area requirements.

Innovation Solution

A modular mechanical draft cooling tower design featuring a vertical arrangement of condenser bundles with steam manifolds and condensate headers, allowing for efficient steam distribution and reduced pressure drop, along with pre-assembled modules for reduced on-site assembly time and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a large surface area is provided in the condenser, then heat dissipation efficiency is improved, but steam side pressure drop increases thus increasing turbine back pressure and reducing power plant efficiency

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidturbine back pressure

Core Design Contradiction:

Loss of energyVSStress or pressure

Solution Approach 1:

The condenser is divided into multiple modular bundles, each with its own steam distribution manifold. This segmentation allows steam to be distributed more efficiently across the large surface area without creating excessive pressure drop, as each module can be optimized independently for flow distribution.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The steam distribution system is designed with local optimization, where each modular bundle has strategically placed ducting and condenser surfaces tailored to its specific position and steam flow requirements. This ensures uniform steam distribution across the entire large surface area while minimizing pressure drop in each local region.

Inventive Principle:

Principle #3Local quality

2Loss of energy

If a large surface area is provided in the condenser, then heat dissipation efficiency is improved, but uniform steam distribution becomes difficult to achieve due to non-uniformity in delivery caused by system ducting pressure losses and velocity distribution

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidsteam distribution uniformity

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

By dividing the condenser into multiple modular bundles with individual steam manifolds, the system achieves uniform steam distribution across a large surface area. Each module can be designed and optimized independently, ensuring consistent steam flow patterns throughout the entire condenser surface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The steam distribution manifolds are designed and pre-configured within each modular bundle to establish uniform steam distribution from the outset. This preliminary design of the distribution system ensures that steam is evenly delivered to all condenser surfaces before the condensation process begins, avoiding the non-uniformity problems that would otherwise require complex corrections.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If current air cooled condenser towers are assembled at the job site, then installation flexibility is maintained, but assembly is labor intensive requiring a large amount of time and therefore can be costly

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidassembly time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The condenser modules are pre-assembled at the manufacturing plant with all internal components, ducting, and condenser surfaces installed and configured before shipping to the installation site. This preliminary assembly significantly reduces on-site assembly time and labor requirements while maintaining the modular design's installation flexibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Multiple condenser bundles are combined into integrated modular assemblies that include steam manifolds, ducting, and support structures as unified units. This merging of components into pre-assembled modules reduces the number of separate assembly operations required at the installation site, thereby reducing overall assembly time and labor costs.

Inventive Principle:

Principle #5Merging (Combining)

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 modular design ensures uniform steam distribution, reduces turbine back pressure, and decreases assembly time and cost by allowing for efficient heat exchange and pre-fabrication of components, enhancing overall cooling tower efficiency and cost-effectiveness.

Implementation Method 1

Dry cooling towers dissipate heat by conduction and convection

Methodology Applied

Scientific EffectConduction (thermal): Conduction (thermal)

Implementation Method 2

Dry cooling towers dissipate heat by conduction and convection

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

mechanical draft cooling tower that utilizes air cooled condenser modules. The aforementioned cooling tower operates by mechanical draft and achieves the exchange of heat between two fluids such as atmospheric air

Methodology Applied

Scientific EffectMechanical draft:

Data Source

PatentUS9551532B2Modular air cooled condenser apparatus and method

Publication Date: 2017.01.24 SPX DRY COOLING USA LLC

AI summary

A mechanical draft cooling tower employs air cooled condenser modules and operates by mechanical draft to exchange heat between atmospheric air and steam. The cooling tower utilizes a modular air cooled condenser with heat exchange deltas having tube bundles that are manufactured and assembled prior to being shipped to the tower site.