DESIGN OF CONDENSER

Steam after rotating steam turbine comes to condenser. Condenser refers here to
the shell and tube heat exchanger (or surface condenser) installed at the outlet of every
steam turbine in Thermal Power Stations of utility companies generally. These condensers
are heat exchangers which convert steam from its gaseous to its liquid state, also known
as phase transition. In doing so, the latent heat of steam is given out inside the condenser.

The purpose is to condense the outlet (or exhaust) steam from steam turbine to
obtain maximum efficiency and also to get the condensed steam in the form of pure water,
otherwise known as condensate, back to steam generator or (boiler) as boiler feed water.

Figure 5.21: Condenser

ILLUSTRATION:

Figure 5.22: Schematic Diagram of Condenser

Given and Assumptions:
Ws = 75.77883146 kg/s
Pc = 0.02MPa
θ₁ = 3 ºC
θ₂ = 5.6 ºC
h8 ' = 2144.941454 kJ/kg
Dv = D₀ 25.4 mm
Dw = Dı = 22.92 mm
kCal
Kt = 39.7
m−hr−⁰C

Heat from Steam:

hx = hf at P8
hf at P8 = 251.4 kJ/kg
Qs = (Ws) × (h8' – h9)
Qs = (75.77883146) (2144.941454 – 251.4)
; Qs = 143490.3587 kJ/s
In MKS:
kJ 3600 s 1kCal
; Qs = 143490.3587 × ×
s 1hour 4.187 kJ
; Qs = 123373606.7 kCal/hr
Logarithmic Mean Temperature Difference:
ts' = tsat at Pc
tsat at Pc = 60.06 ºC
twb' = ts' - θ₁
twb' = 60.06 - 3
twb' = 57.06ºC

twa' = twb' - θ₂
twa' = 57.06 - 5.6
twa' = 51.46 ºC
 θmax = ts - twa'= 60.06 – 51.46
θmax = 8.6 ⁰C
θmin = ts - twb'= 60.06 – 57.06
θmin = 3 ⁰C

θmax −θmin
LMTD =
ln(θmax /θmin)
8.6−3
LMTD = 8.6 = 5.317382 ⁰C
ln
3

Coefficients of Heat Transfer (Total Surface Area of Tubes)

*Water Side Scale Coefficient, Us
Us = 19350 kCal/ m² - hr - ⁰C
*Water Film Coefficient,Uw
twb '+twa ' 57.06+51.46
tm = =
2 2
tm = 54.26 ⁰C
by Interpolation:
Viscosity at 54.26 ⁰C = 0.50255 CP
1 1
Fluidity, J = =
CP 0.50255

J= 1.98969754
J ⁰ ·² ⁴
b= 1379.7
Dw ⁰ · ²⁷

1.99 ⁰ · ² ⁴
b= 1379.7
0.023 ⁰· ²⁷

b= 4510.717178
Uw = bV⁰·⁷³ Velocity: 2.4 m/s
Uw = (4510.717178) 2.4⁰·⁷³
 Uw = 8546.707506 kCal/ m² - hr - ⁰C

*Tube Conductance, Ut

Dv−Dw 25.4−22.92
t= =
2 2
t= 1.24 mm
t= 0.00124 m
kt 39.7
Ut = =
t 0.00124

Ut = 32016.12903 kCal/ m² - hr - ⁰C

*Vapor Film Coefficient, Uv

111910
Uv = = 3370.69 Av⁰·¹⁸⁸
(Qs/ Av) ⁰ · ¹⁸⁸

Heat: Q = 1.23E+08 kCal/hr

LMTD: θ = 5.317382 ⁰C

U factors: 2nd Term in the Quantity:

2 Dv 2(25.4)
=
Ut ( Dw+ Dv) 32016.12903(22.92+ 25.4)
= 0.00003283733965002410 m² - hr - ⁰C / kCal
3rd Term in the Quantity:
Dv 25.4
=
Us Dw (19350)(22.92)
= 0.00005674359668617390 m² - hr - ⁰C / kCal
4th Term in the Quantity:
Dv 25.4
=
Uw Dw (8546.71)(22.92)
= 0.00012966425287450600
Total: = 0.00021924518921070400 m² - hr - ⁰C / kCal
; Simplification

1.23E+08 1
5.317381621 = [ ¿ + 0.0002192
Av 3370.692 Av ⁰ · ¹ ⁸⁸ ¿
36601.86 27049.07
5.317381621 = +
Av ¹ · ¹ ⁸⁸ Av
Av = 3587.44

Water Mass Flow Rate:

Qs = Qw = Ww × Cw × (twb' - twa')
Ww = 143490.3587 /(4.187 (1.444426395 -- 11.55557361))
Ww = 6119.72257 kg/s

Number of Tubes of the Condenser per pass:

Ww = Aw × Vw × Nt
π Dw ²
Ww = × Vw × Nt ×ρw
4

π (0.02292m) ²
6119.72257 = × 2.4m/s × Nt ×1000 kg/m³
4
Nt = 6180.183693
Nt = 6181

Length of the Tubes of Condenser:

Av = π × Do × Nt × Lt
3587.44 = π (0.0254) × 6181 × Lt
Lt = 7.273481077 m
Condenser Shell Dimensions:

At = 0.25 (As)

Total Area of Tubes and Area of Shell:

; As = 4 (At)
πD ₀ ²( Nta)
; At =
4
π (0.0254) ²(6181)
; At =
4
; At = 3.131958928 m²
; As = 3.131958928 (4)
; As = 12.52783571 m²
Shell Diameter:
πDs ²
; As =
4
((4 As)) ⁰ · ⁵
; Ds =
π
¿
; Ds =(4 (12.52783571)¿ ⁰ · ⁵ π ¿

; Ds = 3.993862271 m

Shell Thickness:
Pc ( Ds) (0.02)(3.99386)
; ts = =
2(Sd ) (2)(5 MPa)
 ; ts = 0.007987725 m
; ts = 0.314477344 inches

DESIGN OF COOLING TOWER

A cooling tower is heat removal device that uses water to transfer process waste
heat into the atmosphere. All cooling towers operate on the principle of removing heat
from water be evaporating a small portion of water that is recirculated through the unit.
The mixing of warm water and cooler air releases latent heat of vaporization, causing a
cooling effect to the water. They are a key component of many refrigeration systems and
can be found in industries such as power plants, chemical processing, steel mills, and
many manufacturing companies where process cooling is necessary. Also, cooling towers
can be used to provide comfort cooling for large commercial buildings like airports,
schools, hospitals, or hotels.
Cooling towers might be one of the most vital part of any industrial process. These
tall, open- topped, cylindrical structures are responsible for cooling water generated from
industrial or HVAC comfort cooling process. They are classified by the type of draft
(natural or mechanical) and by the direction of air flow (counter or cross).

Advancements in the manufacture and design of today’s engineered-plastic towers

have initiated a change in the idea of the cooling tower from a valuable support tool to one
of productivity and increases cost saving. Factory-assembled cooling towers formed with
engineered molded plastics continue to gain popularity over galvanized sheet metal
models that once dominated the cooling tower industry.
With the increasing concerns about meeting green standards and improving ROI
on capital equipment expenditures, there are some standards to consider. A systematic
approach to cooling tower greenness will improve sustainability, increase energy
efficiency, add water conservation and create a smaller carbon footprint; all while
improving some cost ramifications involved in achieving such green goals. While
conventional cooling towers, often constructed with sheet metal cladding, are
environmentally challenging and maintenance intensive, the alternative of using cooling
towers with molded seamless plastic is immediately beneficial to both the environment
and bottom line. Traditional metal towers, which last only a few years in many
applications, encounter environmental and economic issues including increased chemical
use, higher maintenance costs, replacement costs and disposal requirements.
 Figure 5.23: Cooling Towers
ILLUSTRATION:

Figure 5.26: Schematic Diagram of Cooling Tower

Given and Assumptions:

Qs = 143490.36 kJ/s
ts = 60.06 ⁰C
td₁ = 30 ⁰C
t w₁ = 20 ⁰C
RH₂ = 80 %
Twc = 20 ⁰C

Temperatures of Water:

Condenser - HE Loop:
twb' = ts - θ₁ = 60.06 - 3 = 57.06 ⁰C
twa' = twb' - θ₂ = 57.06 - 5.6 -= 51.46 ⁰C
HE - Cooling Tower Loop:
twb = twa' - θ₁ = -= 51.46 - 3.3 -= 48.16 ⁰C
 twa = twb - θ₂ = -= 48.16 - 5.9 -= 42.26 ⁰C
Make - up Water Temperature:
twc = 20 ⁰C

Cooling Tower Efficiency:

twb−twa 48.16−42.26
ƞct = = x 100%
twb−tw ₁ 48.16−20

ƞct = 20.951705 %

Height of Cooling Tower:

For Small Approach ;

tapp, ⁰F H, feet
10 - 25
11 - 26
12 - 27
13 - 28
14 - 29
15 - 30

tapp = -= 12.53 ⁰F
H = 27.528
Air Properties:
 Air Entry:( Given td₁,tw₁)
Ps at td₁ = 0.004246 MPa (from Table 1)
Pw at tw₁ = 0.002339 MPa

Determining Partial Pressure of Water Vapor by Carrier's Equation:

(P−Pw )(td ₁−tw ₁)( 1.8)

Pv₁ = Pw -
2800−1.3(1.8(td₁)+32)
(0.098986)(10)(1.8)
Pv₁ = 0.002339 -
2800−1.3(32)

Pv₁ = 0.001693065 MPa

Determining Specific Humidity of Air:

Pv
ω₁ = (0.622)
P−Pv
P - Pv
0.001693065
ω₁ = (0.622) - = 0.010569766
0.101325−0.001693065−¿ ¿

kgv
kgda
Determining Specific Enthalpy of Air:

h₁ ≈ cpa(td₁) + ω₁(2500+1.88(td₁))

h₁ ≈ 1.005 (30) + 0.010569766 ( 2500 + 1.88 (30) )

kJ
h₁ ≈ 57.17054943
kgda

Determining Specific Volume of Air:

 RT ₁ (0.287)(303) m³
v₁ = = = 0.872822551
P₁ 99.63193532 kg

Air Exit: (Given RH₂)

Determining Temperature of Air:
td₂ = twb - θ₁ = 48.16 - 3.3 =44.86 ⁰C
Ps = 0.0095311 MPa

Determining Partial Pressure of Water Vapor:

Pv₂ = RH₂ × Ps
Pv₂ = (0.8) (0.0095311)
Pv₂ = 0.0076249 MPa

Determining Specific Humidity of Air:

Pv
ω₂ = (0.622)
P−Pv

0.007624918 kgv
ω₂ = (0.622) = 0.0506157
0.101325−0.007624918 kgda

Determining Specific Enthalpy of Air:

td₂ = 44.86 ⁰C

h₂ ≈ cpa(td₂) + ω₂(2500+1.88(td₂))

h₂ ≈ 1.005 -(44.86) + 0.05061574 ( 2500 + 1.88 (44.86) )

kJ
h₂ ≈ 175.89243
kgda
 Determining Specific Volume of Air:

R T ₂ (0.287)(317.86) m³
v₂ = = = 0.973594
P₂ 93.7000816 kg

Water Mass Flow Rate:

Qc = Qct = 143490.36 kJ/s

Qct = Ww × Cw × (twb - twa)
97078.89266 = (Ww) (4.187) -( 48.16 -- 42.26 )
Ww = 5808.5502 kgw/s

Cooling Tower Sizing

From Kent's Mechanical Engineering Handbook,
Using the sizing chart for Atmospheric Cooling Tower from section 9-
25
Water Concentration, wc = 3 GPM/ft² = 0.189318 kg/s-ft²
Ww 5808.5502
Cooling Tower Area , Act = =
wc 0.18931818
Act = 30681.41775 ft²
Act = LW ; 2W
Act = 2W2 ; W = 30681.42/2
W = 123.85762 ft ; L = 247.71523 ft

Material and Heat Balance

1kg air + W₁ + Wm' + Ww" = 1kg air + W₂ + Ww"

Wm ' = W₂ - W₁
Wm' = 0.0175 - 0.01054
Wm' = 0.00696 kgw/kgda
Wc = .0.00696 kgw/kgda
At twc = 20 ⁰C
hc = hf at twc
hc = 83.96 kJ/kg

1kg air(h₁) + Ww"(hwa) +Wc(hc) = 1kg air(h₂) + Ww"(hb)

Ww" = H₂-H₁ - Wc(hc)

hwb - hwa
From the Steam Tables:
at twb = 48.16 ⁰C hwb = 201.64616 kJ/kg
at twa = 42.26 ⁰C hwa = 177.00776 kJ/kg
70.9−57.1706−0.00696(8 3.96)
Ww" =
201.64616( 177.00776)
Ww" = 0.536383791 kgw/kgda
Ww 5808.550223
Wair = = = 10829.0936 kgw/s
Ww ' ' 0.536383791
Wair = 33202001 kg/hr
Vair = Wair(v₁)
Vair = 10829.093 (0.873)
Vair = 9453.7986 m³/s
Vair = 28985347 m³/hr