Condenser and its types

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Steam Condenser
and it’s types
By:
Ankit Saxena
Asst. Professor
Mangalmay institute of engineering and technology

Definition:
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Condenser is a device in which steam is condensed to
water at a pressure less than atmosphere.
Condensation can be done by removing heat from
exhaust steam using circulating cooling water.
During condensation, the working substance changes its
phase from vapour to liquid and rejects latent heat.
The exhaust pressure in the condenser is maintaned
nearly 7 to 8 kpa which corresponds to condensate
temperature of nearly 313 kelvin.

Functions of Condenser:
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To reduce the turbine exhaust pressure so as to
increase the specific output and hence increase the
plant efficiency and decrease the specific steam
consumption.
To condense the exhaust steam from the turbine and
reuse it as pure feed water in the boiler. Thus only
make up water is required to compensate loss of water
Enables removal of air and other non condensable
gases from steam. Hence improved heat transfer.

Elements of Condensing Plant:
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Condenser
 Air Extraction Pump
 Condensate Extraction Pump
 Cooling Water Circulating Pump
 Hot Well
 Cooling Tower
 Make up Water Pump
 Boiler Feed Pump

Advantage of a Condenser
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It increases the work output per kg of steam supplied
to the power plant. It also reduces the specific steam
consumption, therefore reduces the size of power
plant of given capacity.
It improves the thermal efficiency of the power plant.
It affects the saving in cost of water to be supplied to
the boiler since the condensate is returned to the
boiler.
Cost of water softening plant is also reduced since
pure feed water is available for the boiler.

Classification of Condensers:
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According to the type of flow:
 Parallel flow , Counter flow & Cross flow
According to the Cooling Action:
 Jet Condensers or mixing type
 Low Level Parallel Flow Jet Condenser
 Low Level Counter Flow Jet Condenser
 High Level Jet Condenser
 Ejector Jet Condenser
 Surface Condensers or Non-mixing type
1. Down Flow 2. Central Flow 3. Inverted Flow 4.
Evaporative type 5. Regenerative type

Jet Condensers
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 In jet condensers exhaust steam and cooling water come
in direct contact and mix up together. Thus, the final
temperature of condensate and cooling water leaving the
condenser is same.
 Such condensers are normally used for small power units.
 It can be used when cooling water is cheaply and easily
available.
 These condensers are not usually employed since the
Condensate collected can not be reused in boiler, because
it contains impurities like dust, oil, metal particles etc in
the condensate.

Low Level Parallel Flow Jet Condenser
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Exhaust steam and
cooling water both flow in
the same direction.
Wet air pump is used to
extract the mixture of
condensate, air & coolant.
This limits the vacuum
created in the condenser
up to 600 mm of Hg.

Low Level Counter Flow Jet Condenser:
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The cooling water is supplied from
the top of the condenser and steam
from side of the condenser.
The water flows in downward
direction through a series of
perforated trays. Steam gets
condensed while it comes in contact
with the falling water.
The air pump always maintains the
required vacuum in the condenser
and induces the cooling water to be
lifted into the condenser up to a
height of 5.5m.
The excess amounts of condensate
from hot well flows into the cooling
pond by an overflow pipe.

High Level Jet Condenser or Barometric jet
condenser
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Condenser shell is installed at height
greater than that of atmospheric
pressure in water column i.e. 10.33 m.
A tall pipe more than 10.33m length is
attached to the bottom of the
condenser. This allows the condensate
and coolant to be discharged from
condenser under the gravity action;
hence a condensate extraction pump is
not required.
The water from the hot well will not
be able to rise into the condenser and
flood the turbine due to vacuum pr.
Maintained in condenser.

Ejector Condenser:
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 In this cooling water enters from
the top of the condenser at least
under a head of 6m of water
pressure with the help of a
centrifugal pump and then it passes
over a series of convergent nozzles
and finally it leaves through a
convergent divergent nozzle.
 The non return valve helps in
preventing the rush of water from
hot well to the engine in case the
cooling water supply fails.
 Momentum of flowing water is
used to remove the mixture of
condensate & coolant from
condenser without the use of any
extraction pump.

Advantages & Disadvantages of Jet
Condensers:
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Advantages:
 Simple in design & cheaper.
 Less floor area is required.
Disadvantages:
 Condensate is not pure hence can not be reused.
 Low vacuum efficiency.

Surface Condensers
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 In surface condenser, the exhaust steam and cooling water
do not come in physical contact, rather they are separated
by heat transfer wall. Hence condensate remains pure &
can be reused.

Down Flow Surface Condenser:
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 Exhaust steam enters the
top of condenser shell &
flows downward over
water tubes.
 Water tubes are double
passed. The cold water
flows in lower side first
& then in upper side in
the reverse direction,
which enables the
maximum heat transfer.

Central Flow Surface Condenser
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 The steam flows radially inward
 The condensate is collected
at the bottom of the shell from
where it is taken out by the
condensate extraction pump.
 The steam gets access to the
entire periphery of tubes, and
thus a large surface area for the
hear transfer is available as
compared to the down flow.

Inverted Flow Condenser:
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 The steam enters the bottom of the shell and air
extraction pump connected at the top.
 Steam flows upward first and subsequently,
returns to the bottom of the condenser.
 The condensate extraction pump is connected
at the bottom of the shell to extract the
condensate.

Evaporative Condenser:
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 The evaporation of some
cooling water provides the
cooling effect, thereby
steam condenses.
 Steam to be condensed is
passed through grilled tubes
& cooling water is sprayed
over outer surface of tubes.
 The evaporative condensers
are most suitable for small
plants, where supply of cold
water is limited.

Advantages & Disadvantages of Surface
Condensers:
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Advantages:
 High vacuum efficiency.
 Pure condensate.
 Low quality cooling water can be used.
 It allows the expansion of steam through a higher pressure ratio.
Disadvantages:
 Large amount of water is required.
 Construction is complicated.
 Costly maintenance and skilled workers.
 Large floor area.

Jet Condensers Surface Condensers
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1) Cooling water and steam are mixed up
2) Requires small floor space
3) The condensate cannot be used as feed water
to boiler unless it is free from impurities
4) More power is required for air pump
5) Less power is required for water pump
6) Requires less quantity of cooling water
7) The condensing plant is simple
8) Less suitable for high capacity plants due to
low vacuum efficiency
1) Cooling water & steam aren’t mixed up
2) Requires large floor space
3) The condensate can be used as feed water to
boiler as it is not mixed with cooling water
4) Less power is required for air pump
5) More power is required for water pump
6) Requires large quantity of cooling water
7) The condensing plant is complicated
8) More suitable for high capacity plants as
vacuum efficiency is high
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Comparison of Jet & Surface Condensers:

Sources of Air in the Condenser:
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 The ambient air leaks to the condenser chamber at the joints &
glands which are internally under pressure lower than that of
ambient.
 Another source of air is the dissolved air with feed water. The
dissolved air in feed water enters into boiler and it travels with
steam into condenser.
Effects of Air Leakage:
 The presence of air lowers vacuum in the condenser. Thus back
pressure of the plant increases, and consequently, the work
output decreases.
 Air has very poor thermal conductivity. Hence, the rate of heat
transfer from vapour to cooling medium is reduced.
 The presence of air in the condenser corrodes to the metal
surfaces. Therefore, the life of condenser is reduced.

Vacuum Creation in Condenser:
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• When the steam condenses in a closed vessel, the vapour phase of
working substance changes to liquid phase, and thus its specific
volume reduces to more than one thousand times.
• Due to change in specific volume, the absolute pressure in the
condenser falls below atmospheric pressure and a high vacuum is
created.
• This minimum pressure that can be attained depends on the
temperature of condensate and air present in the condenser.
The absolute pressure = Atmospheric pressure – Vacuum Gauge
in the condenser Pressure

Effect of Condenser Pressure on Rankine Efficiency:
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 Lowering the condenser pressure
will increase the area enclosed by
the cycle on a T-s diagram which
indicates that the net work will
increase. Thus, the thermal
efficiency of the cycle will be
increased
 Lowering the back pressure causes
an increase in moisture content of
steam leaving the turbine.
 Increase in moisture content of
steam in low pressure stages, there
is decrease in efficiency & erosion
of blade may be a very serious
problem and also the pump work
required will be high.

Condenser and its types

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