Sub-cooler Co-location in Steam Condenser Neck

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Solution Overview

Problem

Low-pressure heat exchange devices in steam turbine systems face challenges such as steam flashing and liquid water ingestion due to sensitive equilibrium between steam and water, leading to decreased heat transfer efficiency and wear on components.

Innovation Solution

A heat exchange system with a sub-cooler positioned beneath the first heat exchange device within the same casing, featuring a horizontal sub-cooler housing with a flat topmost surface and anti-flash plates to reduce non-condensed steam accumulation and prevent flashing, along with perforated impingement plates to manage steam flow and prevent liquid water ingestion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a sub-cooling zone is co-located with another heat exchange device in the condenser neck, then heat recovery efficiency is improved and system footprint is reduced, but steam flashing and liquid water ingestion occur due to sensitive pressure equilibrium

Engineering Contradiction:

Improveheat recovery efficiencyVSAvoidsteam-water equilibrium stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The sub-cooler is divided into multiple segments or zones along its length, with each zone having different geometric characteristics (varying cross-sectional areas, spacing between tubes) to control the condensation and sub-cooling process in stages, preventing sudden pressure drops that cause flashing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the sub-cooler have locally optimized properties such as varying tube spacing, different bundle configurations, or varying inlet/outlet positions to create specific flow patterns and pressure gradients that maintain stable steam-water equilibrium while achieving effective sub-cooling

Inventive Principle:

Principle #3Local quality

2Area of stationary object

If a sub-cooling zone is co-located with another heat exchange device in the condenser neck, then system footprint is reduced, but heat transfer efficiency decreases due to steam flashing

Engineering Contradiction:

Improvesystem footprintVSAvoidheat transfer efficiency

Core Design Contradiction:

Area of stationary objectVSLoss of energy

Solution Approach 1:

The sub-cooler employs a horizontal configuration rather than vertical arrangement, allowing it to fit within the limited radial space of the condenser neck while maintaining adequate length for effective heat transfer. This dimensional change enables compact integration without sacrificing performance

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If sub-cooler operates at low pressure around 160 mbar, then it can be integrated with low-pressure steam turbine system, but equilibrium between steam and water becomes very sensitive to pressure fluctuation

Engineering Contradiction:

Improveintegration with low-pressure steam turbineVSAvoidsteam-water equilibrium

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The sub-cooler geometry is specifically designed with parameters (cross-sectional area, tube spacing, bundle arrangement) that create a pressure profile along its length, ensuring pressure remains stable and above the flashing point while still achieving the required sub-cooling effect at the low operating pressure of 160 mbar

Inventive Principle:

Principle #35Parameter changes

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 solution enhances heat recovery efficiency and reduces wear on components by minimizing steam flashing and liquid water ingestion, allowing for efficient co-location of heat exchange devices within the condenser neck, thereby improving system efficiency and footprint reduction.

Implementation Method 1

Steam received within the cavity is condensable via thermal communication with the first heat absorbing fluid to form a first exhaust stream

Methodology Applied

Scientific EffectThermal communication heat transfer: Conduction (thermal)

Implementation Method 2

the first exhaust stream is receivable into thermal communication with the sub-cooler fluid

Methodology Applied

Scientific EffectThermal communication heat transfer: Conduction (thermal)

Data Source

PatentEP3511536B1Heat exchange system having an integrated sub-cooler

Publication Date: 2022.11.30 GENERAL ELECTRIC TECH GMBH

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AI summary

A heat exchange system includes a casing enclosing a cavity therein, and a first heat exchange device configured to channel a first heat absorbing fluid therethrough and extending longitudinally within the cavity. Steam received within the cavity is condensable via thermal communication with the first heat absorbing fluid to form a first exhaust stream. The heat exchange system also includes a sub-cooler configured to channel a sub-cooler fluid therethrough and extending longitudinally within the cavity. The sub-cooler is positioned beneath the first heat exchange device such that the first exhaust stream is receivable into thermal communication with the sub-cooler fluid. In some embodiments, the sub-cooler includes a housing that includes a flat topmost surface. Additionally or alternatively, the heat exchange system includes an anti-flash plate that extends longitudinally within the casing between the upper portion and the lower portion of the cavity.