A surface condenser is primarily the most significant equipment in a thermal power plant. These condensers are a game changer, maximising efficiency in areas with minimal water access. If you handle heavy industrial processes, you should have an in-depth understanding of surface condensers.
Many people are conflicted between surface and jet condensers because they are slightly similar. However, surface condenser manufacturers can confirm that surface condensers function differently and have various benefits compared to jet condensers. These complex machines can be challenging for unseasoned professionals. Understanding the different types of surface condensers and their applications can help make things run more smoothly. Here’s everything you need to know and the reason why surface condensers dominate heavy industrial processes.
What Is A Surface Condenser?
A surface condenser is a type of heat exchanger used primarily in power plants to convert steam from the turbine into pure water. Pure water, also known as condensate, is then reused as cooling water in the boiler, minimising the need for a large amount of water. The regular surface condenser features an outer shell, vacuum system, tubes, tube sheets, and water boxes.
However, surface condenser manufacturers produce various software condensers for different applications. Apart from thermal power plants, surface condensers work for vacuum refrigeration, geothermal energy recovery, and desalination systems.
Types of Surface Condensers
There are four types of surface condensers, including central flow, down flow, regenerative, and evaporative surface condensers. Manufacturers design these condensers to favour the arrangement of tubing systems and the direction of flow. Below is an overview of each surface condenser.
Down Flow Condenser
In the down flow surface condenser, the exhaust steam will enter from the top and travel downwards due to gravity. In addition, cooling water will simultaneously flow through the tubes perpendicularly to the flow of steam in a two-pass setup. The two-pass setup facilitates the flow of water through the tubes in one direction, the lower half, and exiting in the upper half of the opposite direction.
Central Flow Condenser
The central flow surface condenser is an evolved version of the down flow condenser, with a few directional differences. The central flow features an air pump at the centre of the system, and its role is to pump air away from the centre. Steam comes in from the top due to gravitational force and flows over the water tubes for refinement. Eventually, the condensate gathers at the bottom of the condenser, and the extraction pump collects it.
Regenerative Condenser
The regenerative surface condenser works well for high-temperature power plants. Once the condensate leaves the tube, it will pass through the exhaust steam to increase its temperature. The condensate then acts as feed water for the bottom, enhancing the condenser’s efficiency.
Evaporative Condenser
In this condenser, manufacturers place gilled pipes inside the condenser. The exhaust steam will enter through the top and flow over these pipes while cooling water continuously sprays over the pipes. As a result, the flow of steam increases the evaporation of cooling water and condensate steam.
Advantages of a Surface Condenser
- Surface condensers facilitate pure condensation. Typically, the surface condenser will transfer heat from the high-temperature body (steam) to a lower temperature (cooling water) while avoiding contact between the two.
- It’s possible to reuse the cooling water continuously because it is pure, meaning they are reliable in areas with low water supply.
- The large size and high efficiency make surface condensers perfect for industrial processes.
- The high vacuum from the air pump helps eliminate uncondensed air. It also lowers pressure inside the condenser to increase thermal efficiency.
Disadvantages of A Surface Condenser
- It can be challenging to understand the complex design of surface condensers. Luckily, expert manufacturers like Godrej, a heavy equipment manufacturer, prioritise customer education.
- Surface condensers are quite large and require a lot of space to function efficiently.
- Although they are cost-effective for the company, purchasing a surface condenser is expensive.
- You will need a large amount of water for the processes.
There you have it, surface condensers may be complex in design, but they are very efficient in the long run. Once you understand the moving parts and how each type functions, select the right surface condenser for your power plant. Contact seasoned surface condenser manufacturers for guidance.
