KR20220100094A - All-secondary air cooled industrial steam condenser - Google Patents

Abstract

The new design for large field upright industrial steam condensers is that every bundle is configured as secondary bundles, in an A-frame or V-shaped configuration, the tubes are oriented 25-35 degrees from vertical, steam and condensate fed from the bottom This vapor is collected from the bundles from the bottom using a combination/hybrid manifold configured to deliver this vapor to the tubes, collect the condensate from the tubes and prevent the condensate from returning down the vapor delivery inlet(s). Their cross-sectional dimensions are 125 mm in width, less than 10 mm in cross-sectional height, and 9.25 mm in height of the pins, with 9 to 12 pins placed per inch.

Description

ALL-SECONDARY AIR COOLED INDUSTRIAL STEAM CONDENSER

BACKGROUND OF THE INVENTION Field of the Invention [0002] The present invention relates to large-scale up-to-the-ground air-cooled industrial vapor condensers.

The current finned tube, most used in large-scale field upright air cooled industrial steam condensers ("air cooled industrial steam condenser"), is approximately 11 meters long x 200 mm wide ("air movement") with semi-circular tips and tails. (also referred to as "air travel length"), and a flat tube of 18.88 mm inner height (perpendicular to air travel distance). The tube wall thickness is 1.35 mm. The pins are soldered to the flat sides of each tube. The pins are typically 18.5 mm long and are spaced 11 pins per inch. The fin surface has a moire pattern to improve heat transfer and contribute to fin stiffness. The standard deep-to-center spacing between tubes is 57.2 mm. While the tubes themselves constitute approximately one third of the cross-sectional area (perpendicular to the direction of air flow); The fins make up nearly two-thirds of the cross-sectional area. There is a small space of 1.5 mm between adjacent pin tips. In a summer ambient environment, the rate of maximum vapor velocity through the tubes may typically be 28 mps, more typically between 23 mps and 25 mps. The single A-frame design combined with these tubes and fins was optimized based on tube length, fin spacing, fin height and shape and air travel. Finned tubes are assembled into heat exchanger bundles (typically 39 tubes per heat exchanger bundle), and bundles of 10 to 14 are arranged into two heat exchangers arranged together in a single A-frame per fan. A fan is typically below the A-frame to raise air through the bundles. The overall tube and fin design and the air pressure drop of the tube and fin combination is also optimized for the moving capacity of large (36 foot diameter) fans operating from 200 hp to 250 hp. This optimized arrangement has remained relatively unchanged by several manufacturers since the introduction of the single row elliptical tube concept 20 years ago.

The conventional A-frame ACC described above includes both first stage or “primary” condenser bundles and second stage or “secondary” bundles. About 80% to 90% of the heat exchanger bundles are first stage or primary condenser bundles. Steam enters the top of the primary condenser bundles and condensate and some steam pass through the bottom. The first stage configuration has excellent thermal efficiency; No means is provided for removing the uncondensed gas. In order to remove uncondensed gas through the first stage bundles, 10% to 20% of the heat exchanger bundles are typically interspersed between the primary bundles to be configured as a second stage or secondary bundles, resulting in lower condensate The steam is drawn from the manifold. In this arrangement, vapor and non-condensable gas travel through the first stage bundles as they are drawn to the bottom of the secondary bundle. As the gas mixture moves upwards through the secondary bundle, the remaining vapors condense and condense the uncondensed gases. Attached to the top of the secondary bundles is a vacuum manifold that removes uncondensed gases from the system.

Variations on the standard prior art ACC arrangement are disclosed, for example, in US 2015/0204611 and US 2015/0330709. These applications show the same, but dramatically shortened fin tubes and then a series of small A-frames (typically five A-frames per fan) arranged, part of the logic is to reduce the vapor pressure drop, This has a small effect on the total capacity in summer, but has a greater effect in winter. Another part of the logic is to cut the cost of field welding labor as the factory welds the top vapor manifold duct to each of the bundles and transports them together. The net effect of this arrangement in which the vapor manifold is attached at the factory and transported with tube bundles is to reduce the tube length that will accommodate the manifold in a standard height cube carrying container. Because the tubes are shorter and thus the amount of total surface area is reduced, in summer, the comparative capacity for a standard single A-frame design of similar overall dimensions is reduced by about 3%.

The inventions presented in this application are: 1) a novel tube design for use in heat exchanger systems, including but not limited to large scale on-site industrial vapor condensers; and 2) a new design for large-scale on-site industrial steam condensers for power plants and the like, both of which significantly increase the heat capacity of the ACC, while, in some configurations, reduce material. Various aspects and/or embodiments of the inventions are set forth below:

According to various embodiments of the present tube design invention, the tubes are 2.044 m long, the cross-sectional dimensions of the tubes are 100-200 mm wide, preferably 125 mm wide (air travel distance) and cross-sectional height (air travel distance) perpendicular to the distance) less than 10 mm, preferably 4-10 mm, more preferably 5.0-9 mm, even more preferably 5.2-7 mm, and most preferably 6.0 mm high (also referred to as “outer tube width”). "), and the pins are arranged at 9 to 12 per inch, preferably 9.8. According to a more preferred embodiment, the actual fins are 17-20 mm high, preferably 18.5 mm high, spanning the space between two adjacent tubes, effectively fins of 9.25 mm each tube on each side. make it available

The manufacture of smaller cross-section tubes (same air travel distance but significantly smaller height) requires that the larger tubes lower costs, and that the tubes must be made of as large a cross-section as possible to accommodate the large volume of steam output by large power plants. It goes directly against the currently known aspects of the art. Although the cost of this arrangement is significantly higher than that of the prior art tube arrangement, the inventors have unexpectedly increased the efficiency of the lower height tubes (30 compared to the prior art tubes in the most preferred embodiment) rather than compensating for the increase in cost. % higher efficiency). This new tube design can be used in prior art large-scale field-standing industrial steam condensers (eg as described in the Background section), or it can be used in conjunction with the new ACC design described below in this application. .

Referring to the new design for large-scale field-standing industrial steam condensers, a key feature of the present invention is that the steam is oriented from bottom to top of tubes (aligned parallel to the transverse axis of the bundle, each tube approximately 25° from vertical). oriented at -35°, preferably 30°) and the condensate preferably using a combination/hybrid manifold that delivers vapor to and collects condensate from the tubes, It is that all tube bundles of ACCs according to the invention are constructed as secondary tube bundles in that they are collected from tube bundles from According to one embodiment, the combination/hybrid manifold may be configured such that the condenser does not return down the vapor delivery inlet tube(s) but instead passes to a condensate return tube that is connected to the combination/hybrid manifold. According to an alternative embodiment, the combination/hybrid manifold may be configured to allow condensate to travel down the vapor delivery inlets and to be removed in a vapor delivery duct closer to the ground. The tops of the tubes are connected to a separate manifold to collect uncondensed gas. This new "all secondary" ACC arrangement joins either a single manifold where the top of two secondary bundles collects uncondensed gas from the tubes, or two non-condensate manifolds, one at the top of each bundle. It can be configured as an A-frame.

As used in this application, the terms "all secondary" and "no primary" refer to a large site where all tube bundles receive vapor from the bottom, collect condensate at the bottom, and pass uncondensed gas out through the top. will refer to upright air-cooled industrial vapor condensers. By comparison, primary tube bundles in large-scale up-to-the-ground air-cooled industrial steam condensers receive steam at the top, pass condensate at the bottom, and pass uncondensed gas at the bottom to a separate secondary condenser.

Preferably, however, the ACC of the present invention comprises a single vapor distribution manifold/condensate collection manifold combination in which the bottom of two secondary unique condenser bundles is joined, and the top of each bundle is joined with a separate non-condensate collection manifold. It can be arranged in a V configuration.

According to a preferred V configuration embodiment, the vapor manifold is at the bottom of the bundles, so that entering the manifold in more than one position reduces the size of the manifold and allows the fin tubes to be slightly longer. The smaller cross-section tubes described in this application (200 mm x 10 mm, preferably 4-10 mm, more preferably 5.0-9 mm, even more preferably 5.2-7 mm, and most preferably 6.0 mm height), the present system exhibits at least a 25% to 30% performance improvement over the standard ACC arrangement and configuration described above, and the unit can be made smaller by a similar amount in planar area.

According to a further alternative embodiment, the novel ACC design of the present invention is 100 mm x preferably 4-10 mm, more preferably 5.0-9 mm, even more preferably 5.2-7 mm, and most preferably It has dimensions of 6.0 mm high and can be used with tubes with fins offset.

According to a further embodiment, the novel ACC design of the present invention can be used with 120 mm or less than 200 mm x 5 mm to 7 mm tubes with “arrowhead” fins placed at 9.8 fins per inch.

According to another embodiment, the novel ACC design of the present invention can be used with tubes with "louvered" fins, which perform like roughly offset fins, are more readily available and manufactured. easier to do

According to preferred and most preferred embodiments of the present invention, combining the most preferred ACC configuration and most preferred tube dimensions, the ACC of the present invention has the following features and dimensions:

● Bundles are all secondary (all tubes receive vapor from the bottom, distribute condensate through the bottom and distribute uncondensed gas out of the top); no primary bundles;

● 4, 5 (most preferred) or 6 V-pack pairs per cell/fan;

• Tube outer dimensions of 4-10 mm (preferably 5-7 mm, most preferably 6.0 mm) x 100-200 mm (most preferably 125 mm) cross section;

● tube spacing c-c 20-29 mm (most preferably: 24.5 mm);

• tube wall thickness of 0.7-0.9 mm (most preferably: 0.8 mm);

● Tubes per bundle = 40-60 (most preferably 50);

• Tube lengths of 1,700-2,400 mm (most preferably 2,044 mm);

• arrowhead pins (not required, but preferably) span between adjacent tubes and are thermally associated with both bundles;

• Fin height 17-19 (most preferably 18.5 mm (effective height 9.25 mm per tube side);

● Air travel pins 95 mm-195 mm, most preferably: 120 mm.

According to this most preferred embodiment, the total bundle area is 79% compared to the prior art ACC with the same total fan power, vapor volume and thermal conditions; Likewise, the total plan area for this most preferred embodiment is 79% compared to the area of a prior art ACC with the same total fan power, vapor volume and thermal conditions.

In addition, the ACC design of the present invention can be seated more easily, requiring less overall space in the power plant.

1A is a perspective view of a heat exchanging portion of a prior art large-scale in-situ air-cooled industrial steam condenser.
1B is an exploded assembly detail of a heat exchanging portion of a prior art large-scale in-situ air-cooled industrial steam condenser showing the orientation of the tubes with respect to the vapor distribution manifold.
2 is a perspective view of a heat exchange portion of a large-scale upright air-cooled industrial vapor condenser (“ACC”) according to a first embodiment of the present invention;
3 is a perspective view of a heat exchange portion of a large-scale upright air-cooled industrial vapor condenser (“ACC”) according to a second embodiment of the present invention;
4A is a perspective view of a heat exchange portion of a large-scale upright air-cooled industrial vapor condenser (“ACC”) according to a third embodiment of the present invention;
4B is a perspective view of a heat exchange portion of a large-scale upright air-cooled industrial vapor condenser (“ACC”) according to a fourth embodiment of the present invention;
5 is a cross-sectional perspective view of a prior art ACC tube and fins;
6 is a perspective view of a mini tube and fins according to an embodiment of the present invention.
7 is a perspective view of mini tubes and fins according to another embodiment of the present invention.
8 is a one-street side view of a large-scale upright air-cooled industrial vapor condenser in accordance with an embodiment of the present invention having the V-shaped secondary unique heat exchange bundle pair arrangement shown in FIG. 4A.
9 is a cross-sectional view of the large-scale upright air-cooled industrial vapor condenser shown in FIG. 8 ;
FIG. 10 is a top view of the large-scale upright air-cooled industrial vapor condenser shown in FIG. 8, showing one exhaust duct splitting into six longitudinal vapor headers (six streets) of six cells each.
11 is a perspective view of a secondary condenser fin tube bundle according to an embodiment of the present invention.
12 is a perspective view of the secondary condenser fin tube bundle rendered in the drawing of FIG. 11 .

A-frame ACC where all bundles are secondary

Referring to FIG. 2 , the tubes 2 are arranged in sub-bundles 4 . The longitudinal axes of the tubes 2 are aligned parallel to the transverse axis of the tube bundle, each tube oriented generally at 25°-35°, preferably 30° from vertical. A vapor distribution/condensate collection manifold combination (6) is attached to the lower end of each of the two secondary bundles (4) that are joined at the top in the A-frame configuration. The vapor is distributed to the tubes (2) via a vapor distribution/condensate collection manifold combination (6) and as the vapor condenses, condensate forms in the tubes (2) to distribute the vapor below the tubes (2). /Go to the condensate collection manifold combination (6). A single non-condensate collection manifold 8 is attached to the top of both bundles 6 to collect uncondensed gas traveling to the top of the tubes 2 . Vapor is supplied from the vapor duct 10 via inlets 12 to the vapor distribution/condensate collection manifold combination 6 . The condensate that collects in the vapor distribution/condensate collection manifold combination (6) is conveyed away from the ACC in a condensate return line (14).

Figure 3 shows an embodiment very similar to the embodiment of Figure 2, except that the top of each bundle 4 is attached to a dedicated non-condensate collection manifold.

V-shaped ACCs in which all bundles are secondary

Referring to FIGS. 4A and 4B , the tubes 2 are arranged in sub-bundles 4 . The longitudinal axes of the tubes 2 are aligned parallel to the transverse axis of the tube bundle, each tube oriented generally at 25°-35°, preferably 30° from vertical. In the V configuration, a vapor distribution/condensate collection manifold combination (6) is attached to the bottom of the two secondary bundles (4) at an angle of 55°-65°, preferably 60°. The vapor is distributed to the tubes (2) via a silver vapor distribution/condensate collection manifold combination (6) and as the vapor condenses, condensate forms in the tubes (2) to distribute the vapor below the tubes (2). /Go to the condensate collection manifold combination (6). A non-condensate collection manifold 8 is attached to the top of both bundles 6 to collect uncondensed gas traveling to the top of the tubes 2 . Vapor is supplied from the vapor duct 10 via inlets 12 to the vapor distribution/condensate collection manifold combination 6 . The condensate that collects in the vapor distribution/condensate collection manifold combination (6) is carried away from the ACC in a condensate return line (14).

The new ACC design described above is approximately 11 meters long and 200 mm wide (or "air travel"), has an internal height (perpendicular to air travel) of 18.8 mm, and has a tube wall thickness of 1.35 mm, with each tube Can be used with any prior art tubes, including the tubes shown in FIG. 5 that have fins (typically 18.5 mm long, 11 fins per inch spaced apart) brazed to flat sides of the . However, according to a more preferred embodiment, the novel ACC design of the present invention has the following features and dimensions:

● Bundles are all secondary (all tubes receive vapor from the bottom, distribute condensate through the bottom and distribute uncondensed gas out of the top); no primary bundles;

● 4, 5 (most preferred) or 6 V-pack pairs per cell/fan;

• Tube outer dimensions of 4-10 mm (preferably 5-7 mm, most preferably 6.0 mm) x 100-200 mm (most preferably 125 mm) cross section;

● tube spacing c-c 20-29 mm (most preferably: 24.5 mm);

• tube wall thickness of 0.7-0.9 mm (most preferably: 0.8 mm);

● Tubes per bundle = 40-60 (most preferably 50);

• Tube lengths of 1,700-2,400 mm (most preferably 2,044 mm);

• arrowhead pins (not required, but preferably) span between adjacent tubes and are thermally associated with both bundles;

● 18.5 mm fin height (effective 9.25 mm per side of tube);

● Air travel pins 95 mm-195 mm, most preferably: 120 mm.

According to this preferred embodiment, for a single cell with constant fan power, the capacity is increased by 25-30% compared to a prior art A-frame design with standard tubes.

8-10 show an exemplary large-scale upright air-cooled industrial vapor condenser in accordance with an embodiment of the present invention having the V-shaped secondary unique heat exchange bundle pair arrangement shown in FIG. 4A. The device shown in Figures 8-10 is a 36 cell (6 street x 6 cell) ACC, with the most preferred embodiment being 5 stacked pairs per cell, but the present invention provides an ACC of any size and any number of ACCs per cell. It can be used as a bundled pair.

Claims (11)

A large on-site upright air-cooled industrial steam condenser connected to an industrial steam production facility, comprising:
a rectangular array of air-cooled condensation cells arranged in a plurality of rows, each of said plurality of rows comprising a plurality of said air-cooled condensation cells;
each air cooled condensing cell comprising a single fan and a plurality of pairs of condenser bundles arranged in either an A or V configuration, each condenser bundle comprising a single row of finned flat channel tubes mounted adjacent to each other, each the bundle is oriented such that the longitudinal axis of the finned flat tube is positioned at an angle of 55°-65° from horizontal; the finned flat single channel tube having a cross-sectional width perpendicular to the transverse and longitudinal axes of the bundle of 100 mm - 200 mm and a constant cross-sectional height parallel to the longitudinal axis of the bundle of 4-10 mm;
Each condenser bundle has a combined vapor distribution-condensate collection manifold attached at the bottom end that runs along the length of the condenser bundle configured to deliver steam to the bottom of a flat, finned single channel tube and collect condensate that forms at the fins. flat single channel tube from the vapor when cooled;
each condenser bundle having a non-condensable collection manifold configured to collect non-condensable gas from the vapor and extending along a length of the condenser bundle parallel to each of a vapor distribution-condensate collection manifold coupled to an upper end;
Each row of air-cooled condensing cells includes steam ducts running below the midpoint of the condenser bundles in the row, each steam duct having a longitudinal axis perpendicular to the longitudinal axis of the condenser bundles in the row and on the lower surface of each row. connected. a combined vapor distribution-condensate collection manifold of said condenser bundles in a row by riser ducts, each said vapor duct connected at one end to a turbine exhaust duct having a longitudinal axis perpendicular to each vapor duct;
and all vapor delivered to said condenser bundle is delivered from said combined vapor distribution-condensate collection manifold. The large-scale upright air-cooled industrial vapor condenser of Claim 1 wherein all condensate collected from said finned flat single channel tube is collected in said combined vapor distribution-condensate collection manifold. The large-scale in-situ upright air-cooled industrial vapor condenser of claim 1, wherein the longitudinal axis of the finned flat single channel tube is positioned at an angle of 60° from horizontal. The large scale on-site upright air-cooled industrial vapor condenser of claim 1, wherein the finned flat single channel tube has a cross-sectional width of 125 mm and a cross-sectional height of 5.2-7 mm. The large scale on-site upright air-cooled industrial vapor condenser of claim 1, wherein the finned flat single channel tube has a cross-sectional width of 125 mm and a cross-sectional height of 6.0 mm. The large scale on-site upright air-cooled industrial vapor condenser of claim 1, wherein said finned flat single channel tube has a height of 10 mm and has fins attached to the flat face of said tube spaced apart from each other by 9 to 12 fins. The large scale in-situ upright air-cooled industrial vapor condenser of claim 1, wherein the finned flat single channel tube has a cross-sectional width of 200 mm and a fin height of 17-20 mm. The large scale in-situ upright air-cooled industrial vapor condenser of claim 1, wherein the finned flat single channel tube has a cross-sectional width of 200 mm and a fin height of 18.8 mm. The large scale on-site upright air-cooled industrial vapor condenser of claim 1, wherein the finned flat single channel tube has a cross-sectional width of 125 mm and a cross-sectional height of 4-10 mm. 2. The large scale upright air cooled industrial vapor condenser of claim 1, wherein said finned flat single channel tube has a length of about 1,700 mm to about 2,400 mm. The large scale on-site upright air cooled industrial vapor condenser of claim 1 comprising about 40 to about 60 finned flat single channel tubes.

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