AIR-COOLED STEAM CONDENSER WITH IMPROVED SECOND STAGE CONDENSER

Abstract

Large scale field erected air cooled industrial steam condenser having heat exchanger panels with primary and secondary condenser sections, in which the secondary condenser section comprises 10% or less of the total heat exchanger, and in which the tubes of the primary condenser sections have narrowed outlet orifices having an area that is 50% or less than the cross-sectional area of a corresponding tube. The invention permits the reduction of secondary condenser tubes while reducing the outlet header pressure sufficiently to minimize backflow, sweep non-condensables and prevent the formation of dead zones.

Claims

1. A large scale field erected air cooled industrial steam condenser connected to an industrial steam producing facility, comprising: a condenser street comprising a row of condenser modules, each condenser module comprising a plenum section having a single fan or multiple fans drawing air through a plurality of heat exchanger panels supported in a heat exchanger section, and each heat exchanger panel having a longitudinal axis and a transverse axis perpendicular to its longitudinal axis; each heat exchanger panel comprising a plurality of tubes, a top bonnet connected to and in fluid communication with a top end of each of said plurality of tubes, a bottom bonnet connected to and in fluid communication with a bottom end of at least a subset of said plurality of tubes, said bottom bonnet having a single steam inlet; said condenser street further comprising a steam distribution manifold beneath said heat exchanger section and arranged along an axis that is perpendicular to longitudinal axes of said heat exchanger panels at midpoints of said heat exchanger panels and extending a length of said condenser street beneath said plurality of heat exchanger panels, said steam distribution manifold having at its top surface a plurality of connections, each of said plurality of connections adapted to connect to a corresponding said single steam inlet; wherein each heat exchanger panel comprises a primary condenser section, a secondary condenser section, and a top bonnet connected to and in fluid communication with a top end of each tube in said secondary condenser section and said primary condenser section, and each said top end of said primary condenser section comprises an outlet flow orifice having a narrower area than a cross-sectional area of a corresponding tube in said primary condenser section, said bottom bonnet connected to and in fluid communication with a bottom end of each tube in said primary condenser section, each heat exchange panel further comprising an internal secondary chamber inside the bottom bonnet connected to and in fluid communication with a bottom end of each tube in said secondary condenser section.

2. The large scale field erected air cooled industrial steam condenser according to claim 1, wherein each said outlet flow orifice has an area that is 50% or less of the cross-sectional area of said corresponding tube.

3. The large scale field erected air cooled industrial steam condenser according to claim 1, wherein the amount of said primary condenser tubes is greater than 90% of the total heat exchanger section and the amount of said secondary condenser tubes is less than 10% of the total heat exchanger section of the ACC

4. A large scale field erected air cooled industrial steam condenser according to claim 1, wherein the secondary condenser section is centrally located along said heat exchange panel and flanked at each end by primary condenser sections.

5. A large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have a cross-sectional width of 5.2-7 mm.

6. A large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have a cross-sectional width of 6.0 mm.

7. A large scale field erected air cooled industrial steam condenser according to claim 1, wherein said plurality of tubes in said heat exchanger panels have fins attached to flat sides of said tubes, said fins having a height of 9 to 10 mm, and spaced at 5 to 12 fins per inch.

8. A large scale field erected air cooled industrial steam condenser according to claim 1, wherein said plurality of tubes in said heat exchanger panels have fins attached to flat sides of said tubes, said fins having a height of 18 mm to 20 mm spanning a space between adjacent tubes and contacting adjacent tubes, said fins spaced at 5 to 12 fins per inch.

9. A method for reducing the amount of secondary condenser tubes in an ACC while reducing the outlet header pressure to minimize backflow, sweep non-condensable gases and prevent the formation of dead zones in primary condenser tubes, comprising replacing standard primary condenser tubes with condenser tubes having an outlet orifice having an area that is 50% or less of the cross-sectional area of corresponding primary condenser tubes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1A is side elevation view of a two stage heat exchanger panel according to a preferred embodiment of the invention.

[0014] FIG. 1B is representation of flow patterns in Detail A of FIG. 1A.

[0015] FIG. 2 is a topside down view of primary condenser tubes along Section B-B of FIG. 1A.

[0016] FIG. 3 is a side view of a two stage heat exchanger panel according to an embodiment of the invention.

[0017] FIG. 4 is a top view of the heat exchanger panel shown in FIG. 3.

[0018] FIG. 5 is a bottom view of the heat exchanger panel shown in FIG. 3.

[0019] FIG. 6 is a cross-sectional view of the heat exchanger panel shown in FIG. 3, along line C-C.

[0020] FIG. 7 is a cross-sectional view of the heat exchanger panel shown in FIG. 3, along line D-D.

[0021] FIG. 8 is a cross-sectional view of the heat exchanger panel shown in FIG. 3, along line E-E.

[0022] FIG. 9 is a side elevation view of a two stage heat exchanger panel and upper steam distribution manifold according to an alternate embodiment of the invention.

[0023] FIG. 10A is a Section view along line A-A of FIG. 9.

[0024] FIG. 10B is alternative embodiment to the embodiment shown in FIG. 10A.

[0025] FIG. 11 is a cross-sectional view of a bottom bonnet of the type shown in FIG. 9 with a flat shield plate according to an embodiment of the invention.

[0026] FIG. 12 is a cross-sectional view of a bottom bonnet of the type shown in FIG. 9 with a bended shield plate according to an embodiment of the invention.

[0027] FIG. 13 is a plan view of a large scale field erected air cooled industrial steam condenser according to an embodiment of the invention.

[0028] FIG. 14 is a closeup side view of one cell of the large scale field erected air cooled industrial steam condenser shown in FIGS. 13.

[0029] FIG. 15 is an elevation view of the steam distribution manifold and its connections to the heat exchanger panels, including optional condensate piping from the secondary bottom bonnet according to an embodiment of the invention.

[0030] FIG. 16 is a further closeup side view of one cell of the large scale field erected air cooled industrial steam condenser shown in FIG. 14, showing an end view of two pairs of heat exchanger panels.

[0031] FIG. 17 is side view of a large scale field erected air cooled industrial steam condenser according to an embodiment of the invention in which the steam distribution manifolds are directly connected to an elevated turbine steam duct.

[0032] FIG. 18 is side view of a large scale field erected air cooled industrial steam condenser according to an alternate embodiment of the invention in which the steam distribution manifolds are directly connected to an elevated turbine steam duct.

[0033] FIG. 19 is an end view of the embodiment shown in FIG. 18.

[0034] FIG. 20 is a plan view of a large scale field erected air cooled industrial steam condenser according to an embodiment of the invention in which the steam distribution manifolds are connected to a ground level turbine exhaust duct via end risers.

[0035] FIG. 21 is an elevation view of the embodiment of FIG. 20, along section A-A.

[0036] FIG. 22 is an elevation view of the embodiment of FIG. 20, along section B-B.

[0037] FIG. 23 shows a top perspective view of a single pre-assembled condenser module including the upper steam distribution manifold suspended therefrom.

[0038] FIG. 24 shows a bottom perspective view of a single pre-assembled condenser module including a steam distribution manifold suspended therefrom.

[0039] FIG. 25 shows a top perspective view of a fan deck and fan (plenum) subassembly for a single cell corresponding to the condenser module shown in FIGS. 23 and 24.

[0040] FIG. 26 shows a bottom perspective view of a fan deck and fan (plenum) subassembly for a single cell corresponding to the condenser module shown in FIGS. 23 and 24.

[0041] FIG. 27 shows a perspective view of a tower frame for a single cell corresponding to the condenser module shown in FIGS. 23 and 24.

[0042] FIG. 28 shows a fully assembled ACC cell with the fan deck and fan (plenum) sub-assembly of FIGS. 25 and 26 installed atop the condenser module of FIGS. 23 and 24 and the tower section of FIG. 27.

[0043] FIG. 29 is a representation of a fan deck plate according to an embodiment of the invention in which each plenum section module supports a plurality of fan deck plates, each fan deck plate supporting a plurality of fans.

[0044] FIG. 30 is a representation of an embodiment of the invention in which the fan deck includes a plurality of fan deck plates supported on the fan deck structure above the heat exchange module, where each fan deck plate includes a plurality of fans, and the fan deck plates are arranged so that their longitudinal axis is perpendicular to the longitudinal axis of the heat exchange panels.

[0045] Features in the attached drawings are numbered with the following reference numerals:

TABLE-US-00001    2 heat exchanger panel  3 primary tube outlet orifice  4 primary condenser section  5 primary tube outlet cap/plate  6 secondary condenser section  7 tubes  8 condenser bundles 10 top tube sheet 12 top bonnet 14 bottom tube sheet 15 lifting/support angle 16 bottom bonnet 18 stem inlet/condensate outlet 20 shield plate 21 perforations 22 scalloped edge 24 secondary bottom bonnet 26 nozzle (for secondary bottom bonnet) 27 ACC condenser module (cell) 29 Y-shaped nozzle 31 turbine exhaust duct (generic) 34 street/row of ACC cells 36 frame (of heat exchange section) 37 heat exchange module 40 deflector shield 42 condensate piping 50 hangers 62 understructure module 64 plenum section module 66 steam distribution manifold (SDM) 68 elevated turbine exhaust duct 72 fan deck plate 74 small fan 76 ground level turbine exhaust duct (GLTED) 78 end riser (GLTED to SDM)

DETAILED DESCRIPTION

[0046] As outlined in the Summary of the Invention, a central innovation of the present invention is a primary condenser tube for an ACC having primary tube outlet cap/plate 5 with an outlet orifice 3 as shown in FIG. 1B. The orifices can have any shape, including round, rectangular, oval and elliptical. Each tube may have an outlet cap/plate with only a single orifice, or each tube's outlet cap/plate may have more than one orifice. The total area of all outlet orifices 3 for one tube is preferably 50% or less of the cross-sectional area of the tube. According to preferred embodiments, the total area of the one or more outlet orifices for a single tube is 5% to 50% of the cross-sectional area of tube. According to more preferred embodiments, the total area of the one or more outlet orifices for a single tube is 10% to 40% of the cross-sectional area of tube. According to even more preferred embodiments, the total area of the one or more outlet orifices for a single tube is 20%-30% of the cross-sectional area of the tube. The proportion of primary condenser tubes to secondary condenser tubes in a cell/module, in a row or street of cells/modules, or across the entire ACC is preferably 90:10, but may range from 85:15 to 95:5. As noted above, the size of the primary tube outlet orifices 3 and the proportion of secondary tubes may be selected to reduce outlet manifold pressure to a desired target in order to regulate and balance the vapor flow across the primary condenser tubes, thereby reducing or eliminating the risk of backflow and the formation of dead zones at the top of the primary condenser tubes.

[0047] The features of the invention may be used in conjunction with ACCs of any configuration, but are most preferably in conjunction with an ACC according to the various configurations shown in FIGS. 3-30. Referring to FIGS. 3-8, the heat exchanger panel 2 includes two primary condenser sections 4 flanking an integrated and centrally located secondary condenser section 6. Each heat exchanger panel 2 consists of a plurality of separate condenser bundles 8, with a first subset of condenser bundles 8 making up the centrally located secondary section 6, and a second subset of different condenser bundles 8 making up each flanking primary section 4. The dimensions and constructions of the tubes 7 of the primary and secondary sections are preferably identical with the exception of the outlet orifices at the top of the tubes in the primary section. At their top, all of the tubes 7 of both the primary and secondary sections 4, 6 are joined to a top tube sheet 10, on which sits a hollow top bonnet 12 which runs the length of the top of the heat exchanger panel 2. The bottom of all of the tubes 7 of the primary and secondary sections 4, 6 are connected to a bottom tube sheet 14, which forms the top of a bottom bonnet 16. The bottom bonnet 16 likewise runs the length of the heat exchanger panel 2. The bottom bonnet 16 is in direct fluid communication with the tubes 7 of the primary section 4 but not with the tubes of the secondary section 6. The bottom bonnet 16 is fitted at the center point of its length with a single steam inlet/condensate outlet 18 which receives all the steam for the heat exchanger panel 2 and which serves as the outlet for condensate collected from the primary sections 4. The bottom of the bottom bonnet 16 is preferably angled downward at an angle of between 1° and 5°, preferably about 3° with respect to the horizontal from both ends of the bonnet 16 toward the steam inlet/condensate outlet 18 at the middle of the heat exchanger panel 2. According to a preferred embodiment and referring to FIGS. 9-12, the bottom bonnet 16 may include a shield plate 20 to partition condensate flow from the steam flow. The shield 20 may have perforations 21 and/or have a scalloped edge 22 or have other openings or configuration to allow condensate falling on top of the shield 20 to enter the space beneath the shield and to flow beneath the shield toward the inlet/outlet 18. When viewed from the end of the bottom bonnet 16, the shield plate 20 is secured at a near-horizontal angle (between horizontal and 12° from horizontal in the crosswise direction) so as to maximize the cross-section provided by the bottom bonnet 16 to the flow of steam. The shield plate 20 may be flat as shown in FIG. 11 or bended as shown in FIG. 12. The top tube sheet 10 and bottom tube sheet 14 may be fitted with lifting/support angles 15 for lifting and/or supporting the heat exchangers 2.

[0048] An internal secondary chamber, or secondary bottom bonnet 24, is fitted inside the bottom bonnet 16 in direct fluid connection with only the tubes 7 of the secondary section 6 and extends the length of the secondary section 6, but preferably not beyond. This secondary bottom bonnet 24 is fitted with a nozzle 26 to withdraw non-condensables and condensate.

[0049] The steam inlet/condensate outlet 18 for the heat exchanger panel 2 and the steam inlet/condensate outlets 18 for all of the heat exchanger panels in the same ACC cell/module 27 are connected to a steam distribution manifold 66 located beneath the heat exchanger panels 2 and which runs perpendicular to the longitudinal axis of the heat exchanger panels 2 at their midpoint See, e.g., FIGS. 23, 24 and 30. In this embodiment, the steam distribution manifold 66 extends across the width of the cell/module 27 and continues to adjacent cell/modules. Where the top surface of the steam distribution manifold (SDM) 66 passes below the center point of each heat exchanger panel 2, the steam distribution manifold 66 is fitted with a Y-shaped nozzle 29 which connects to the steam inlet/condensate outlets 18 at the bottom of each adjacent pair of heat exchanger panels 2 (See, e.g., FIG. 16).

[0050] According to this construction, each cell 27 of the ACC receives steam from a steam distribution manifold 66 located directly beneath the center point of each heat exchanger panel 2, and the steam distribution manifold 66 feeds steam to each of the heat exchanger panels 2 in a cell 27 via a single steam inlet/condensate outlet 18.

[0051] Therefore, the steam from an industrial process travels along the turbine exhaust duct 31 at or near ground level, or at any elevation(s) suited to the site layout. When the steam duct 31 approaches the ACC of the invention, it splits into a plurality of sub-ducts (steam distribution manifolds 66), one for each street (row of cells) 34 of the ACC (See, e.g., FIG. 13). Each steam distribution manifold 66 travels beneath its respective street of cells 34. The steam distribution manifold 66 may be suspended from the frame 36 of the condenser module 37, supported in the frame of understructure module 62 or supported from below by separate structure. The steam distribution manifold 66 delivers steam through a plurality of Y-shaped nozzles 29 to the pair of bonnet inlets/outlets 18 of each adjacent pair of heat exchanger panels 2, FIGS. 15 and 16. The steam travels along the bottom bonnet 16 and up through the tubes 7 of the primary sections 4, condensing as air passes across the finned tubes 7 of the primary condenser sections 4. The condensed water travels down the same tubes 7 of the primary section 4 counter-current to the steam, collects in the bottom bonnet 16 and eventually drains back through the steam distribution manifold 66 and turbine exhaust duct 31 to a condensate collection tank (see, e.g., FIG. 21). According to a preferred embodiment, the connection between the bottom bonnet 16 and the steam distribution manifold 66 may be fitted with a deflector shield 40 to separate the draining/falling condensate from the incoming steam.

[0052] The uncondensed steam and non-condensables are collected in the top bonnet 12 and are drawn to the center of the heat exchanger panel 2 where they travel down the tubes 7 of the secondary section 6 co-current with the condensate formed therein. Non-condensables are drawn into the secondary bottom bonnet 24 located inside the bottom bonnet 16 and out through an outlet nozzle 26. Additional condensed water formed in the secondary section 6 collects in the secondary bottom bonnet 24 and travels through the outlet nozzle 26 as well and then travels through condensate piping 42 to the steam distribution manifold 66 to join the water collected from the primary condenser sections 4.

[0053] According to another feature of the invention, the heat exchanger panels 2 are suspended from framework 36 of the condenser module 37 by a plurality of flexible hangers 50 which allow for expansion and contraction of the heat exchanger panels 2 based on heat load and weather. FIG. 16 shows how the hangers 50 are connected to the frame 36 of the condenser module 37

[0054] The heat exchange panels 2 may each be independently loaded into and supported in heat exchange module framework 36. The heat exchange panels 2 may be supported in the heat exchange module framework 36 according to any of a variety of configurations. FIGS. 14-16 show the heat exchange panels 2 independently supported in the heat exchange module framework 36 with adjacent heat exchange panels 2 inclined relative to vertical in opposite directions in V-shaped pairs.

[0055] According to one embodiment of the invention, shown in FIGS. 17-19, the steam distribution manifolds 66 may be connected directly to an elevated turbine steam duct 68 and each steam distribution manifold 66 runs the beneath the center points of the heat exchange panels of a plurality of heat exchange modules along the length of a street/row 34 of condenser cells 27. The steam distribution manifolds 66 may be suspended from the heat exchange module frame as discussed previously or may be supported by other portions of the ACC frame, or may be supported from below by a separate structure.

[0056] According to a further alternate embodiment of the invention, shown in FIGS. 20-27, the plurality of steam distribution manifolds (SDM) 66 may be connected to a ground level turbine exhaust duct (GLTED) 76 via end risers 78.

[0057] According to preferred embodiments of the invention, the ACCs of the invention are constructed in a modular fashion. According to various embodiments, understructure 62, condenser modules 37 and plenum sections 64 may be assembled separately and simultaneously on the ground. Once the condenser module 37 is assembled it may be lifted and placed on top of the corresponding completed understructure 62 (See, e.g., Figs. FIGS. 23-28).

[0058] The plenum section 64 for each ACC module 27, including the plenum section frame, fan deck supported on the plenum section frame, fan(s) and fan shroud(s), may be assembled at ground level with a single large fan, as shown, e.g., in FIGS. 13, 14, 17-22, 25 and 28, or it may be assembled (also at ground level) with a plurality of elongated fan deck plates 72, each supporting a plurality of smaller fans 74 in a row, as shown in FIGS. 29 and 30.

[0059] While the assembly described herein is described as being performed at grade, the assembly of the various modules may be performed at their final position if planning and construction schemes allow.

[0060] Every feature and alternative embodiment herein is intended and contemplated to work with and be used in combination of every other feature and embodiment described herein with the exception of embodiments with which it is incompatible. That is, each heat exchange module arrangement described herein, and each heat exchange panel arrangement described herein, and each tube type and each fin type described herein, each steam manifold arrangement described herein, and each fan arrangement, is intended to be used in various ACC assemblies with every combination of embodiments with which they are compatible, and the inventors do not consider their inventions to be limited to the exemplary combinations of embodiments that are reflected in the specification and figures for purpose of exposition.