Air Cooled Condenser For Steam Engine Plant

For a steam engine plant with a capacity of 6 tons/hour (6,000 kg/h) and operating at 1-1.5 bar, you need a condenser that can handle the condensation of steam and reject the heat to the surrounding air. The heat load to be removed is approximately 4500 kW (based on the latent heat of vaporization of water at 1-1.5 bar).

Here’s a proposed solution for an air-cooled condenser (ACC):

Key Requirements:

Heat Load: ~4500 kW (based on condensing 6 t/h of steam).

Steam Pressure: 1-1.5 bar (saturation temperature ~100-110°C).

Cooling Medium: Ambient air.

Condenser Type: Air-cooled condenser (ACC).

Proposed Air-Cooled Condenser (ACC):

An air-cooled condenser is a suitable choice for your application, as it uses ambient air to cool and condense the steam. Below are the specifications and considerations for the ACC:

1. Design Parameters:

Heat Exchange Capacity: ~4500 kW.

Steam Flow Rate: 6,000 kg/h.

Steam Inlet Temperature: ~100-110°C (saturation temperature at 1-1.5 bar).

Condensate Outlet Temperature: ~90-100°C (slightly below saturation temperature).

Air Inlet Temperature: Assume ambient air temperature (e.g., 30-40°C).

Air Outlet Temperature: ~50-60°C (after absorbing heat).

Air Flow Rate: ~150,000-200,000 m³/h (depending on fan design and temperature rise).

2. Heat Exchanger Type:

Finned Tube Heat Exchanger:

Tubes with external fins to increase the heat transfer surface area.

Typically made of stainless steel or copper for corrosion resistance.

Fins made of aluminum for lightweight and efficient heat transfer.

3. Fan System:

Axial Fans:

Multiple fans to provide sufficient air flow.

Variable speed drives (VSD) to optimize energy consumption based on load and ambient conditions.

Air Flow Direction:

Forced draft (fans blow air through the condenser) or induced draft (fans pull air through the condenser).

4. Condenser Layout:

A-Frame Design:

Commonly used for air-cooled condensers.

Provides a large surface area for heat exchange in a compact footprint.

Modular Design:

Allows for easy installation and scalability.

5. Materials:

Tubes: Stainless steel or copper for corrosion resistance.

Fins: Aluminum for high thermal conductivity.

Frame: Galvanized steel for durability.

6. Control System:

Temperature Sensors: Monitor steam and air temperatures.

Fan Speed Control: Adjust fan speed based on load and ambient conditions.

Pressure Control: Ensure proper condensation of steam.