Surface Condenser
What is a surface condenser?
A surface condenser that is utilized to condense the exhaust steam of the turbine back to water is a crucial component of power plants and industrial processes. It is necessary for sustainable operations because it is effective in cooling steam, which makes the operations energy efficient and allows reuse of water.How does a condenser work on a surface?
- Heat Exchange: The condenser is a big heat exchanger that transfers the heat of the steam to cooling water without mixing.
- Condensation of Steam: Low-pressure steam is passed through tubes of cold water, through which it condenses (to liquid) in the turbine.
- Forming a vacuum: The condensing of steam forms a vacuum that maintains the turbine at optimal pressure levels hence it works more efficiently.
- Water Recycling: The condensed water is clean and can be recycled in boilers, which reduces wastage and running costs of the business.
How Steam Conversion Works
1. The process of exchanging heat
- The steam that is exhausted enters the condenser shell at a low pressure of 0.1 to 0.2 bar.
- Coolant tube flows that are typically water-filled at (“20–30°C”).
- The heat travels within the tube walls without mixing with the fluid.
2. Change of phase and making a vacuum
- Steam turns into liquid when it cools below its saturation temperature.
- The volume reduces by 1000:1 to give a vacuum of 27-29" Hg.
- The non-condensable gases are removed with the help of the vacuum pump.
3. System for Recovering Energy
- Water expenses are reduced by 90% when pure condensate is returned to the boiler.
- The most efficient vacuum can enhance the heat rate by 2-5 percent.
Critical Performance Factors
| Parameter | Ideal Range | Impact on Efficiency |
|---|---|---|
| Vacuum Level | 28-29" Hg | +1" Hg = 1% output gain |
| Cooling Water ΔT | 8-12°C | Higher ΔT = better heat transfer |
| Condensate O₂ | <10 ppb | Prevents corrosion |
| Tube Cleanliness | <20% fouling | 10% fouling = 1% efficiency loss |
Industry-Specific Surface Condenser Applications
1. Power Plants That Use Heat
Function: Convert the steam emerging out of the turbine into condensate in order to be reused by the boiler.Nuclear Plants
- Material: stainless steel 304/316L
- Special Features: Seismic-rated supports and nuclear-grade welding.
- The steam capacity is 500-2000 tons per hour.
Plants that burn coal
- Material: Sacrificial anodes, Admiralty brass
- Fouling Solutions: Tube brushing systems
- Design: High-ash flue gas combined cycle (CCGT) large footprint (up to 30 m long)
- Material: Titanium in coastal areas
- Space-saving: Vertical condensers occupy 40 percent less space.
- Fast Startup: Supports 50° C / min ramping Fast Startup: Supports 50° C / min ramping
2. Marine & Shipbuilding
Function: Maintain steam cycle efficiency in propulsion systemsKey Configurations:
Seawater-Cooled
- Tube Material: 90/10 Cu-Ni or 70/30
- Anti-Biofouling: Chlorination injection ports
- Pressure: 15-25 bar on high speed vessels
Environments with a lot of chloride
- Tube Material: Titanium grade 2
- Special Features: System of cathodic protection
- Maintenance: Tube bundles which can be removed to receive drydock repair services
3. Heating, Ventilation, and Air Conditioning (HVAC)
Function: Get rid of heat from big chillersDesign Variants:
Districts Making things cooler
- Material: epoxy coated carbon steel
- Powers: 5-50 MW of thermal rejection
- Noise Control: the in-built soundproofing
Refrigeration in factories
- Ammonia Service: It is steel composed of all its parts.
- Type of Tube: Tubes are rifled and have improved surfaces.
- Approach Temp: Approximately 2° C
4. Industrial Processing
Petrochemical and ChemicalMaterials:
- Hastelloy C-276 grade HCL service
- In case of HF alkylation graphite
- In case of sour gas a duplex stainless steel is used.
- Explosion-proof (ATEX certified) designs
- In the case of dangerous fluids, we have in the double tubular sheets
- Online pH monitoring ports
Mills of Paper
- Fiber Resistance: Large 2" tubes diameters
- Automatic backflush systems
- Wear-resistant tube entry areas
Refineries for Oil
- ASME Sec VIII DIV 2 fabrication of high-pressure design
- Working pressure de-super heaters (50-100 bar)
Industry-Specific Surface Condenser Requirements
| Industry | Key Material | Unique Feature | Maintenance Need |
|---|---|---|---|
| Nuclear | SS316L | Seismic bracing | Eddy current testing |
| Marine | Cu-Ni | Sea chest filters | Annual tube brushing |
| Chemical | Titanium | PTFE gaskets | Quarterly UT thickness checks |
| Paper | Carbon Steel | Fiber traps | Monthly strainer cleaning |
Why Industry-Specific Design Matters:
- Steam carryover of 0.1 percent is needed by the power plant to protect turbine
- Marine installations require 20 years of service in the salt spray areas
- Chemical plants require less than 1 ppm pollution in condensate.
Types of Surface Condensers We Offer
At United Heat Exchangers, we offer various configurations to suit unique plant needs:1. Horizontal Shell and Tube Surface Condensers
- The majority of the design of power plants and heavy industries.
- Because it is horizontal, the layout is small and maintenance is simple.
- High vacuum and wide steam flows design.
2. Vertical Surface Condensers
- Suitable in space-limited areas or modular spaces.
- They are often found on offshore platforms and industrial facilities.
3. Single-Pass and Multi-Pass Condensers
- Better heat transfer is provided by multi-passes.
- It can be used in different temperature gradients and different rates of flow.
4. Water-Cooled and Air-Cooled Options
- Cooling towers or raw water is utilized by water-cooled units.
- Water-scarce environments can be catered to with the provision of air-cooled condensers.
Standards for Design and Construction
We adhere to international performance codes, safety, and reliability. Unit heat exchangers make all surface condensers in TEMA (Tubular Exchanger Manufacturers Association) standard.- ASME Section VIII and ASME Section I (pressure vessel as well as boiler)
- The oil and gas and chemical industries have API 660 and API 617.
Advantages of Our Surface Condensers
- Condensation Efficiency 100%
- Decreased Turbine Back-pressure
- Reusable High-Purity Condensate
- Support to vacuum systems
- More Operating and Maintenance Costs
- Environmental Compliance
- Modular and scalable designs
- Less thermal pollution
Quality Assurance & Testing
Every unit passes through a robust quality process, including:- Thermal Performance Checking
- Pressure Testing Hydraulic
- Pneumatic Leak Testing
- Optional Helium Leak Test (Helium Leak Test)
- Dye Penetrant Testing (DPT)
- Radiography and ultrasonic testing.
- Witness Inspection (TPI agencies requested)
Why Choose United Heat Exchangers?
United Heat Exchangers distinguishes itself by:- Custom Engineering: Our engineers adapted designs per specifications of processes, pressure, and layout constraints.
- Quality Material: We apply high-quality materials such as carbon steel, stainless steel, copper alloy, titanium, and duplex materials to suit the environments of corrosion.
- Thermal Expertise: Our experience with calculations and optimization of heat transfer based on LMTD and NTU methods is decades old.
- Accuracy: ASME, TEMA, and API codes on safe, compliant, and lasting equipment.
- Global Supply Chain: The retail leading industries in India, North America, Middle East, Europe, and Southeast Asia are on our trust.
After-Sales Support & Services
We are believers in long-term relationships. Our after-sales services are:- Install and commission on site
- Tube bundle replacements and spare parts
- Annual maintenance contracts (AMCs)
- Performance audits and retrofitting
- Emergency repair services
- Re-tubing and cleaning of heat exchangers