U.S. patent application number 15/629205 was filed with the patent office on 2017-12-21 for all-secondary air cooled industrial steam condenser.
The applicant listed for this patent is Evapco, Inc.. Invention is credited to Thomas W. Bugler, III, Mark Huber, Jean-Pierre Libert.
Application Number | 20170363358 15/629205 |
Document ID | / |
Family ID | 60660107 |
Filed Date | 2017-12-21 |
United States Patent
Application |
20170363358 |
Kind Code |
A1 |
Bugler, III; Thomas W. ; et
al. |
December 21, 2017 |
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.
Inventors: |
Bugler, III; Thomas W.;
(Frederick, MD) ; Libert; Jean-Pierre; (Frederick,
MD) ; Huber; Mark; (Sykesville, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Evapco, Inc. |
Taneytown |
MD |
US |
|
|
Family ID: |
60660107 |
Appl. No.: |
15/629205 |
Filed: |
June 21, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62353030 |
Jun 21, 2016 |
|
|
|
62430345 |
Dec 5, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25B 2339/04 20130101;
F28B 1/06 20130101; F28F 2009/0287 20130101; F28F 9/02 20130101;
F28B 2001/065 20130101; F25B 39/04 20130101; F28D 1/0426
20130101 |
International
Class: |
F28B 1/06 20060101
F28B001/06 |
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.degree.-65.degree. 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.degree. 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
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to large scale field erected
air cooled industrial steam condensers.
Description of the Background
[0002] The current finned tube used in most large scale field
erected air cooled industrial steam condensers ("ACC") uses a
flattened tube that is approximately 11 meters long by 200 mm wide
(also referred to as "air travel length") with semi-circular
leading and trailing edges, and 18.8 mm internal height
(perpendicular to the air travel length). Tube wall thickness is
1.35 mm. Fins are brazed to both flat sides of each tube. The fins
are usually 18.5 mm tall, spaced at 11 fins per inch. The fin
surface has a wavy pattern to enhance heat transfer and help fin
stiffness. The standard spacing between tubes, center to center, is
57.2 mm. The tubes themselves make up approximately one third of
the cross sectional face area (perpendicular to the air flow
direction); whereas the fins make up nearly two thirds of the cross
section face area. There is a small space between adjacent fin tips
of 1.5 mm. For summer ambient conditions, maximum steam velocity
through the tubes can typically be as high as 28 mps, and more
typically 23 to 25 mps. The combined single A-frame design along
with these tubes and fins has been optimized based on the length of
the tube, the fin spacing, fin height and shape, and the air travel
length. The finned tubes are assembled into heat exchanger bundles,
typically 39 tubes per heat exchanger bundle, and 10 to 14 bundles
are arranged into two heat exchangers arranged together in a single
A-frame per fan. The fan is typically below the A-frame forcing air
up through the bundles. The overall tube and fin design, and the
air pressure drop of the tube and fin combination, has also been
optimized to match the air moving capacity of the large (36 ft
diameter) fans operating at 200 to 250 hp. This optimized
arrangement has remained relatively unchanged across many different
manufacturers since the introduction of the single row elliptical
tube concept over 20 years ago.
[0003] The typical A-Frame ACC described above includes both
1.sup.st stage or "primary" condenser bundles and 2.sup.nd stage or
"secondary" bundles. About 80% to 90% of the heat exchanger bundles
are 1.sup.st stage or primary condenser bundles. The steam enters
the top of the primary condenser bundles and the condensate and
some steam leaves the bottom. The first stage configuration is
thermally efficient; however, it does not provide a means for
removing non-condensable gases. To sweep the non-condensable gases
through the 1.sup.st stage bundles, 10% to 20% of the heat
exchanger bundles are configured as 2.sup.nd stage or secondary
bundles, typically interspersed among the primary bundles, which
draw vapor from the lower condensate manifold. In this arrangement,
steam and non-condensable gases travel through the 1.sup.st stage
bundles as they are drawn into the bottom of the secondary bundle.
As the mixture of gases travels up through the secondary bundle,
the remainder of the steam condenses, concentrating the
non-condensable gases. The tops of the secondary bundles are
attached to a vacuum manifold which removes the non-condensable
gases from the system.
[0004] Variations to the standard prior art ACC arrangement have
been disclosed, for example in US 2015/0204611 and US 2015/0330709.
These applications show the same finned tubes, but drastically
shortened and then arranged in a series of small A-frames,
typically five A-frames per fan. Part of the logic is to reduce the
steam pressure drop, which has a small effect on overall capacity
at summer condition, but greater effect at a winter condition.
Another part of the logic is to weld the top steam manifold duct to
each of the bundles at the factory and ship them together, thus
saving expensive field welding labor. The net effect of this
arrangement, with the steam manifold attached at the factory and
shipped with the tube bundles, is a reduction of the tube length to
accommodate the manifold in a standard high cube shipping
container. Because the tubes are shorter, and therefore the overall
amount of surface area is reduced, comparative capacity to the
standard single A-frame design of similar overall dimension, summer
condition, is reduced by about 3%.
SUMMARY OF THE INVENTION
[0005] The inventions presented herein are 1) a new tube design for
use in heat exchanger systems, including but not limited to large
scale field erected industrial steam condensers; and 2) a new
design for large scale field erected industrial steam condensers
for power plants and the like, both of which significantly increase
the thermal capacity of the ACC while, in some configurations,
reduce the material. Various aspects and/or embodiments of the
inventions are set forth below:
[0006] According to various embodiments of the tube design
invention, the tubes are 2.044 m in length, the cross-sectional
dimensions of the tubes are 100-200 mm wide, preferably 125 mm wide
(air travel length) with a cross-section height (perpendicular to
the air travel length) of 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 in height (also "outside tube width"), with fins
that are arranged at 9 to 12, preferably 9.8, fins per inch.
According to a further preferred embodiment, actual fins may be
17-20 mm in height, preferably 18.5 mm in height and span the space
between two adjacent tubes, effectively making 9.25 mm of fin
available to each tube on each side.
[0007] The making of smaller cross-section tubes (same air travel
length but significantly smaller height) is directly counter to the
current prevailing view in the art that the tubes should be made
with as large a cross-section as possible in order to accommodate
the massive volumes of steam that is output by a large scale power
plant, and because larger tubes drive down costs. While the cost of
this arrangement is significantly more than the prior art tube
arrangement, the inventors unexpectedly discovered that the
increases in efficiency with the lower height tubes (in the most
preferred embodiment exceeding 30% greater efficiency as compared
to the prior art tubes) more than make up for the increase in cost.
This new tube design may be used in large scale field erected
industrial steam condensers of the prior art (for example as
described in the background section), or it may be used in
conjunction with the new ACC design described herein below.
[0008] Turning to the new design for large scale field erected
industrial steam condensers, the primary feature of this invention
is that all of the tube bundles of the ACCs according to this
invention are constructed as secondary tube bundles, in that steam
is fed to upwardly oriented tubes (aligned parallel with the
transverse axis of the bundle, each tube generally oriented
25.degree.-35.degree., and preferably 30.degree. from the vertical)
from the bottom and condensate is collected from the tube bundles
from the bottom, preferably using a combination/hybrid manifold
that both delivers steam to the tubes and collects condensate from
the tubes. According to one embodiment, the combination/hybrid
manifold may be constructed so that the condensate is prevented
from returning down the steam delivery riser(s) and instead is
delivered to a condensate recovery tube connected to the
combination/hybrid manifold. According to an alternative
embodiment, the combination/hybrid manifold may be constructed so
that the condensate is allowed to travel down the steam delivery
risers and is removed from the steam delivery ducting closer to the
ground. The tops of the tubes are connected to a separate manifold
for collecting the non-condensable gases. This new "all secondary"
ACC arrangement may be configured in an A-Frame, with two secondary
bundles joined at the top with a single manifold collecting the
non-condensable gases from the tubes, or with two non-condensable
manifolds, one at the top of each bundle.
[0009] As used herein, the terms "all secondary" and "no primaries"
shall refer to a large scale field erected air cooled industrial
steam condensers in which all of the tube bundles receive steam
from the bottom and collect condensate at the bottom, and deliver
non-condensable gases out through the top. By comparison, primary
tube bundles in a large scale field erected air-cooled industrial
steam condenser receive steam at the top, deliver condensate at the
bottom, and deliver non-condensable gases at the bottom to a
separate, secondary condenser.
[0010] Preferably, however, the ACC of the invention may be
arranged in a V-configuration in which two secondary-only condenser
bundles are joined at the bottom with a single combination steam
distribution manifold/condensate collection manifold, with a
separate non-condensable collection manifold at the top of each
bundle.
[0011] According to the preferred V-configuration embodiment, since
the steam manifold is at the bottom of the bundles, entering the
manifold at more than one location reduces the size of the manifold
and allows the finned tubes to be a bit longer. When combined with
smaller cross-sectional tubes described herein (200 mm by 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 in height), the
system shows improved performance of at least 25% to 30%, relative
to the standard ACC arrangement and configuration described
hereinabove, and the unit may be made smaller by a similar amount
in plan area.
[0012] According to a further alternative embodiment, the new ACC
design of the present invention may be used with tubes having
dimensions of 100 mm by preferably 4-10 mm, more preferably 5.0-9
mm, even more preferably 5.2-7 mm, and most preferably 6.0 mm in
height, having offset fins.
[0013] According to a further embodiment, the new ACC design of the
present invention may be used with 120 mm or up to 200 mm by 5 mm
to 7 mm tubes having "Arrowhead"-type fins arranged at 9.8 fins per
inch.
[0014] According to yet another embodiment, the new ACC design of
the present invention may be used with tubes having "louvered"
fins, which perform approximately as well as offset fins, and are
more readily available and easier to manufacture.
[0015] According to preferred and a most preferred embodiments of
the invention, combining the most preferred ACC configuration and
the most preferred tube dimensions, an ACC of the present invention
has the following features and dimensions: [0016] 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; [0017] Four, five (most
preferred) or six V-shaped bundle pairs per cell/fan; [0018] 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; [0019]
Tube spacing c-c 20-29 mm (most preferred: 24.5 mm); [0020] Tube
wall thickness 0.7-0.9 mm (most preferred: 0.8 mm); [0021] Tubes
per bundle=40-60 (most preferred 50); [0022] Tube length
1,700-2,400 mm (most preferred 2,044 mm); [0023] Arrowhead fins
(preferred, not required) spanning between adjacent tubes and
thermally connected to both tubes; [0024] Fin height 17-19 (most
preferred 18.5 mm (effective height 9.25 mm per tube side); [0025]
Air travel length fins 95 mm-195 mm, most preferred: 120 mm.
[0026] According to this most preferred embodiment, the total
bundle face area versus the prior art ACC having the same total fan
power, steam volume, and thermal conditions is 79%; likewise, the
total plan area for this most preferred embodiment is 79% the area
of the prior art ACC having the same total fan power, steam volume,
and thermal conditions.
[0027] Additionally, the ACC design of the present invention can be
sited more easily, requiring less overall space within the power
plant.
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.degree.-35.degree., and preferably
30.degree., 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.degree.-35.degree., and preferably
30.degree., 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.degree.-65, preferably 60.degree..
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.times.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.
* * * * *