Doctoral Degrees (Mechanical and Mechatronic Engineering)

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Browsing Doctoral Degrees (Mechanical and Mechatronic Engineering) by Subject "Air-cooled steam condenser"

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    Air-cooled condenser steam flow distribution and related dephlegmator design considerations
    (Stellenbosch : Stellenbosch University, 2013-12) Owen, Michael Trevor Foxwell; Kroger, D. G.; Stellenbosch University. Faculty of Engineering. Dept. of Mechanical and Mechatronic Engineering.
    ENGLISH ABSTRACT: The steam-side side operation of a practical air-cooled steam condenser is investigated using a combination of CFD, numerical, analytical and experimental methods. Particular attention is directed towards the vapor flow distribution in the primary condensers and dephlegmator performance. Analysis of the vapor flow in the distributing manifold, connecting the steam turbine exhaust to the air-cooled heat exchangers, highlights the importance of careful design of the guide vanes in the manifold bends and junctions. Improved guide vane design and configuration can reduce the steam-side pressure drop over the manifold and improve the vapor flow distribution, which may be beneficial to condenser operation. The vapor flow in the primary condensers is shown to exhibit a non-uniform distribution amongst the heat exchanger tubes. The vapor flow distribution is strongly linked to the distribution of tube inlet loss coefficients through the heat exchanger bundles. The non-uniform flow distribution places an additional demand on dephlegmator performance, over and above the demands of row effects in the case of multi-row primary condenser bundles. Row effects are shown to account for as much as 70 % of available dephlegmator capacity in this case. Simultaneously, inlet loss coefficient distributions can account for up to 30 % of dephlegmator capacity. In some situations then, the dephlegmator is fully utilized under ideal operating conditions and there is no margin of safety to cope with non-ideal operation of the primary condensers. The upstream regions of the primary condensers are therefore exposed to a high risk of undesirable noncondensable gas accumulation. Reduced dephlegmator capacity due to insufficient ejector performance may further compound this problem. Single-row primary condenser bundles eliminate row effects and thereby significantly reduce the demands on dephlegmator performance. The use of such bundles in the dephlegmator would also measurably reduce ejector loading. In light of the findings of this study, it is recommended that single-row bundles be considered as the primary option for future air-cooled condenser applications. A hybrid (dry/wet) dephlegmator concept is analysed and shown to be able to provide measurably enhanced dephlegmator performance when operating in wet mode, while consuming only a small amount of water. The enhanced dephlegmator cooling translates to an increase in total air-cooled condenser capacity of up to 30 % at high ambient temperatures in this case. The benefit of this enhanced cooling capacity to steam turbine output may be significant. The hybrid dephlegmator concept therefore offers a simple, cost-effective and sustainable solution to the issue of reduced air-cooled condenser performance during hot periods. Careful design of the first and second stage bundle configurations in the hybrid dephlegmator is necessary to avoid flooding in the first stage during wet operation of the second. Furthermore, the slightly poorer dry-operation performance of the hybrid dephlegmator results in increased risk of non-condensable gas accumulation in multi-row primary condensers. Again, single-row primary condenser bundles would lay rest to such concerns.