ALL-SECONDARY AIR COOLED INDUSTRIAL STEAM CONDENSER

Abstract

A new design for large scale field erected industrial steam condensers in which all of the bundles are constructed as secondary bundles, in A-frame or V-Shape configuration, with tubes oriented 25-35 degrees from the vertical, steam fed from the bottom and condensate is collected from the bundles from the bottom using a combination/hybrid manifold that both delivers steam to the tubes and collects condensate from the tubes and which is constructed so that the condensate is prevented from returning down the steam delivery riser(s) and in which the cross-sectional dimensions of the tubes are 125 mm wide with a cross-section height of less than 10 mm with fins that are 9.25 mm in height, arranged at 9 to 12 fins per inch.

Claims

1. An all secondary bundle large scale field erected air cooled industrial steam condenser connected to an industrial steam producing facility, comprising: two bundles each comprising a plurality of finned flattened tubes fitted adjacent to one-another, each of said bundles oriented so that the longitudinal axis of said finned flattened tubes is positioned at an angle of 55°-65° from horizontal; a combined steam distribution-condensate collection manifold attached to a bottom of each of said bundles and running along a length of said bundles configured both to deliver steam to a bottom of said tubes and to collect condensate that forms in said tube from said steam as it cools; a non-condensable collection manifold attached to a top of each of said bundles and running along a length of said bundles parallel to said steam distribution manifold and configured to collect non-condensable gases from said steam.

2. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein all of the condensate collected from said tubes is collected in said combined steam distribution-condensate collection manifold.

3. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein all of the steam delivered to said tubes is delivered from said combined steam distribution-condensate collection manifold.

4. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein the longitudinal axis of said finned flattened tubes is positioned at an angle of 60° from horizontal.

5. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, comprising no primary condenser tubes.

6. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said two bundles are arranged in an A-frame configuration with a single non-condensable collection manifold attached to the tops of both said bundles and with separate combined steam distribution-condensate collection manifold connected to bottoms of both said two bundles.

7. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said two bundles are arranged in an A-frame configuration, with two non-condensable collection manifolds, each attached at the top of one of said two bundles, and with two combined steam distribution-condensate collection manifolds, each attached at the bottom of one of said two bundles.

8. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said two bundles are arranged in a V-shape with a single combined steam distribution-condensate collection manifold connected to bottoms of both said two bundles and with two separate non-condensable collection manifold, one attached to a top of each of said two bundles.

9. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have a cross-sectional width of 100 mm-200 mm and a cross-sectional height of 4-10 mm.

10. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have a cross-sectional width of 125 mm and a cross-sectional height of 5.2-7 mm.

11. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have a cross-sectional width of 125 mm and a cross-sectional height of 6.0 mm.

12. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have fins attached to flat sides of said tubes, said fins having a height of 10 mm, and spaced at 9 to 12 fins per inch.

13. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have a cross-sectional width of 200 mm and a cross-sectional height of 17-20 mm.

14. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have a cross-sectional width of 200 mm and a cross-sectional height of 18.8 mm.

15. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have a cross-sectional width of 125 mm and a cross-sectional height of 4-10 mm.

16. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, wherein said tubes have length of about 1,700 mm to about 2,400 mm.

17. An all secondary bundle large scale field erected air cooled industrial steam condenser according to claim 1, comprising about 40 to about 60 of said tubes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1A is a perspective view representation of the heat exchange portion of a prior art large scale field erected air cooled industrial steam condenser.

[0029] FIG. 1B is a partially exploded close up view of the heat exchange portion of a prior art large scale field erected air cooled industrial steam condenser, showing the orientation of the tubes relative to the steam distribution manifold.

[0030] FIG. 2 is a perspective view representation of the heat exchange portion of a large scale field erected air cooled industrial steam condenser (“ACC”) according to a first embodiment of the invention.

[0031] FIG. 3 is a perspective view representation of the heat exchange portion of a large scale field erected air cooled industrial steam condenser (“ACC”) according to a second embodiment of the invention.

[0032] FIG. 4A is a perspective view representation of the heat exchange portion of a large scale field erected air cooled industrial steam condenser (“ACC”) according to a third embodiment of the invention.

[0033] FIG. 4B is a perspective view representation of the heat exchange portion of a large scale field erected air cooled industrial steam condenser (“ACC”) according to a fourth embodiment of the invention.

[0034] FIG. 5 is a perspective view of cross-section of a prior art ACC tube and fins.

[0035] FIG. 6 is a perspective view of a mini-tube and fins according to one embodiment of the invention.

[0036] FIG. 7 is a perspective view of mini-tubes and fins according to another embodiment of the invention.

[0037] FIG. 8 is a side view of one street of a large scale field erected air cooled industrial steam condenser according to an embodiment of the invention with V-shaped secondary only heat exchange bundle pairs arrangement shown in FIG. 4A.

[0038] FIG. 9 is an end view of the large scale field erected air cooled industrial steam condenser shown in FIG. 8.

[0039] FIG. 10 is a top view the large scale field erected air cooled industrial steam condenser shown in FIG. 8, showing one turbine exhaust duct splitting into 6 longitudinal steam headers (6 streets) of 6 cells each.

[0040] FIG. 11 is a perspective view drawing of a secondary condenser finned tube bundle according to an embodiment of the invention.

[0041] FIG. 12 is a perspective view photograph of the secondary condenser finned tube bundle rendered in the drawing of FIG. 11.

DETAILED DESCRIPTION OF THE INVENTION

[0042] A-Frame ACC with All Secondary Bundles

[0043] Referring to FIG. 2, tubes 2 are arranged in secondary bundles 4. The longitudinal axes of the tubes 2 are aligned parallel with the transverse axis of the tube bundle, each tube generally oriented 25°-35°, and preferably 30°, from the vertical). Combination steam distribution/condensation collection manifolds 6 are attached at the bottom of each of two secondary bundles 4 that are joined at their top in an A-frame configuration. Steam is distributed to the tubes 2 via the combined steam distribution/condensate collection manifolds 6, and condensate forms in the tubes 2 as the steam condenses and travels down the tubes 2 into the combined steam distribution/condensate collection manifold 6. A single non-condensable collection manifold 8 is attached to the top of both bundles 6 to collect the non-condensable gases that travel to the top of the tubes 2. Steam is supplied to the combined steam distribution/condensate collection manifold 6 from steam duct 10 via risers 12. Condensed water that collects in the combined steam distribution/condensate collection manifold 6 is carried away from the ACC in condensate recovery tube 14.

[0044] FIG. 3 shows an embodiment very similar to the embodiment of FIG. 2, except that each bundle 4 is attached at its top to a dedicated non-condensable collection manifold.

[0045] V-Shaped ACC with All Secondary Bundles

[0046] Referring to FIGS. 4A and 4B, tubes 2 are arranged in secondary bundles 4. The longitudinal axes of the tubes 2 are aligned parallel with the transverse axis of the tube bundle, each tube generally oriented 25°-35°, and preferably 30°, from the vertical). A combination steam distribution/condensation collection manifold 6 is attached at the bottom of two secondary bundles 4 that are joined in a V configuration at an angle of 55°-65, preferably 60°. Steam is distributed to the tubes 2 via the combined steam distribution/condensate collection manifold 6, and condensate forms in the tubes 2 as the steam condenses and travels down the tubes 2 into the combined steam distribution/condensate collection manifold 6. A non-condensable collection manifold 8 is attached to the top of both bundles 6 to collect the non-condensable gases that travel to the top of the tubes 2. Steam is supplied to the combined steam distribution/condensate collection manifold 6 from steam duct 10 via risers 12. Condensed water that collects in the combined steam distribution/condensate collection manifold 6 is carried away from the ACC in condensate recovery tube 14.

[0047] The new ACC design described above may be used with any prior art tubes, including the tubes shown in FIG. 5 having a length of approximately 11 meters long and a width (or “air travel length”) of 200 mm with semi-circular leading and trailing edges, and having an internal height (perpendicular to the air travel length) 18.8 mm and a tube wall thickness of 1.35 mm, with fins brazed to both flat sides of each tube, usually 18.5 mm tall, spaced at 11 fins per inch. According to a more preferred embodiment, however, the new ACC design of the present invention has the following features and dimensions: [0048] All secondary bundles (all tubes receive steam from the bottom, distribute condensate through the bottom and distribute non-condensable gases out the top); no primary bundles; [0049] Four, five (most preferred) or six V-shaped bundle pairs per cell/fan; [0050] Tube outside dimension 4-10 mm (preferred 5-7 mm and most preferred: 6.0 mm) by 100-200 mm (most preferred 125 mm) cross section; [0051] Tube spacing c-c 20-29 mm (most preferred: 24.5 mm); [0052] Tube wall thickness 0.7-0.9 mm (most preferred: 0.8 mm); [0053] Tubes per bundle=40-60 (most preferred 50); [0054] Tube length 1,700-2,400 mm (most preferred 2,044 mm); [0055] Arrowhead fins (preferred, not required) spanning between adjacent tubes and thermally connected to both tubes; [0056] Fin height 18.5 mm (effective height 9.25 mm per tube side); [0057] Air travel length fins 95 mm-195 mm, most preferred: 120 mm. [0058] According to this preferred embodiment, an increase in capacity of 25-30% is provided over the prior art A-frame design with standard tubes, for a single cell at constant fan power.

[0059] FIGS. 8-10 show a representative large scale field erected air cooled industrial steam condenser according to an embodiment of the invention with V-shaped secondary only heat exchange bundle pairs shown in FIG. 4A. The device shown in FIGS. 8-10 is a 36 cell (6 streets×6 cell) ACC, with the most preferred embodiment of five bundle pairs per cell, but the invention may be used with any size ACC, and with any number of bundle pairs per cell.