MODULAR AIR COOLED CONDENSER APPARATUS AND METHOD

• US 20190339010A1
• Filed: 07/18/2019
• Published: 11/07/2019
• Est. Priority Date: 05/23/2012
• Status: Active Grant

• Current Assignee: SPG Dry Cooling USA LLC
• Original Assignee: SPG Dry Cooling USA LLC
• Inventors: VOUCHE, Michel, DELEPLANQUE, Christophe, FAUCONNIER, Fabien
• Granted Patent: US 10,527,354 B2
• Time in Patent Office: Days
• CPC Class Codes: B23P 15/26 heat exchangers or the like making heat exchangers by methods covered by other subclasses B21D53/02
• CPC Class Codes: F28B 1/06 using air or other gas as the cooling medium
• CPC Class Codes: F28B 7/00 Combinations of two or more condensers, e.g. provision of reserve condenser
• CPC Class Codes: F28B 9/02 for feeding steam or vapour to condensers
• CPC Class Codes: Y10T 29/4935 Heat exchanger or boiler making

Abstract

Modular air cooled condenser apparatus and related methods are disclosed. An example mechanical draft modular air cooled condenser includes a first condenser bundle having a set of tubes arranged parallel to each other in a first plane that is inclined by an angle α with respect to the horizontal; a second condenser bundle having a set of tubes arranged parallel to each other in a second plane that is inclined by an angle (180°-α) with respect to the horizontal; a third condenser bundle having a set of tubes arranged parallel to each other in a third plane that is inclined by an angle α with respect to the horizontal; a fourth condenser bundle having a set of tubes arranged parallel to each other in a fourth plane that is inclined by an angle (180°-α) with respect to the horizontal; and a fan to create a draft to flow over the condenser bundles.

Claims

1. A mechanical draft modular air cooled condenser for condensing steam comprising:

a condenser module including;

a first condenser bundle having a first set of tubes having first ends and second ends, the second ends arranged lower than the first ends, and a first condensate header connected to the second ends, the first condensate header arranged substantially horizontally, the tubes of the first set of tubes arranged parallel to each other in a first plane that is inclined by an angle α

with respect to the horizontal;

a second condenser bundle having a second set of tubes having third ends and fourth ends, the fourth ends arranged lower than the third ends, and a second condensate header connected to the fourth ends, the second condensate header parallel to the first condensate header, the tubes of the second set of tubes arranged parallel to each other in a second plane that is inclined by an angle (180°

-α

) with respect to the horizontal;

a third condenser bundle having a third set of tubes having fifth ends and sixth ends, the sixth ends arranged lower than the fifth ends, and a third condensate header connected to the sixth ends, the third condensate header parallel to the first condensate header and parallel to the second condensate header, the tubes of the third set of tubes arranged parallel to each other in a third plane that is inclined by an angle α

with respect to the horizontal;

a fourth condenser bundle having a fourth set of tubes having seventh ends and eighth ends, the eighth ends arranged lower than the seventh ends, and a fourth condensate header connected to the eighth ends, the fourth condensate header parallel to the third condensate header, the tubes of the fourth set of tubes arranged parallel to each other in a fourth plane that is inclined by an angle (180°

-α

) with respect to the horizontal;

the first, the second, the third, and the fourth condensate headers arranged in a single horizontal plane;

the first, the second, the third, and the fourth condensate headers being distinct from each other;

the second condensate header directly adjacent the third condensate header;

a shroud that houses a single fan, the single fan positioned to create a draft to flow over the first condenser bundle, over the second condenser bundle, over the third condenser bundle, and over the fourth condenser bundle; and

a support frame that supports the first, the second, the third, and the fourth condenser bundles.

2. The modular air cooled condenser according to claim 1, wherein a is equal to approximately sixty degrees to approximately seventy degrees.

3. The modular air cooled condenser according to claim 2, wherein a is equal to approximately sixty-four degrees.

4. The modular air cooled condenser according to claim 1, wherein the tubes of the first, the second, the third, and the fourth sets of tubes have fins attached thereto.

5. The modular air cooled condenser according to claim 1, wherein the tubes of the first, the second, the third, and the fourth sets of tubes each have a length equal to approximately two meters.

6. The modular air cooled condenser according to claim 1, wherein the first, the second, the third, and the fourth condenser bundles each have a length greater than ten meters.

7. The modular air cooled condenser according to claim 1, wherein the second condensate header and the third condensate header are disposed between the first condensate header and the fourth condensate header.

8. The modular air cooled condenser according to claim 1, wherein the first condensate header and the second condensate header are separated by a first distance, and the third condensate header and the fourth condensate header are separated by the first distance.

9. The modular air cooled condenser according to claim 8, wherein the second condensate header and the third condensate header are separated by a second distance, the second distance less than the first distance.

10. A mechanical draft modular air cooled condenser for condensing steam comprising:

a condenser module including;

a first condenser bundle having a first set of tubes having first ends and second ends, the second ends arranged lower than the first ends,

a second condenser bundle having a second set of tubes having third ends and fourth ends, the fourth ends arranged lower than the third ends,

a third condenser bundle having a third set of tubes having fifth ends and sixth ends, the sixth ends arranged lower than the fifth ends, and

a fourth condenser bundle having a fourth set of tubes having seventh ends and eighth ends, the eighth ends arranged lower than the seventh ends,

the first ends of the first set of tubes separated from the fifth ends of the third set of tubes by a first distance,

the third ends of the second set of tubes separated from the seventh ends of the fourth set of tubes by the first distance;

a shroud that houses a single fan, the single fan positioned to create a draft to flow over the first condenser bundle, over the second condenser bundle, over the third condenser bundle, and over the fourth condenser bundle, the shroud having a diameter greater than the first distance; and

a support frame that supports the first, the second, the third, and the fourth condenser bundles.

11. The mechanical draft modular air cooled condenser according to claim 10, further including:

a first condensate header coupled to the second ends of the tubes of the first set of tubes;

a second condensate header connected to the fourth ends of the tubes of the second set of tubes;

a third condensate header connected to the sixth ends of the tubes of the third set of tubes, the third condensate header parallel to the first condensate header and parallel to the second condensate header; and

a fourth condensate header connected to the eighth ends of the tubes of the fourth set of tubes, the fourth condensate header parallel to the third condensate header,

the fan to create the draft over the first condensate header, over the second condensate header, over the third condensate header, and over the fourth condensate header.

12. The mechanical draft modular air cooled condenser according to claim 11, wherein the first, the second, the third, and the fourth condensate headers are arranged in a single horizontal plane;

wherein the first, the second, the third, and the fourth condensate headers are distinct from each other; and

wherein the second condensate header is directly adjacent the third condensate header.

13. The mechanical draft modular air cooled condenser according to claim 12, wherein the first condensate header and the second condensate header are separated by the first distance, and the third condensate header and the fourth condensate header are separated by the first distance.

14. The modular air cooled condenser according to claim 13, wherein the second condensate header and the third condensate header are separated by a third distance, the third distance less than the first distance.

15. The modular air cooled condenser according to claim 10, wherein:

the tubes of the first set of tubes are arranged parallel to each other in a first plane that is inclined by an angle α

with respect to the horizontal;

the tubes of the second set of tubes are arranged parallel to each other in a second plane that is inclined by an angle (180°

-α

) with respect to the horizontal;

the tubes of the third set of tubes are arranged parallel to each other in a third plane that is inclined by an angle α

with respect to the horizontal; and

the tubes of the fourth set of tubes are arranged parallel to each other in a fourth plane that is inclined by an angle (180°

-α

) with respect to the horizontal.

16. An air cooled condenser comprising:

a heat exchange module including;

a plenum;

a first exchanger pair that includes;

a first condenser bundle positioned at a first angle relative to a first side of a first vertical axis, the first condenser bundle including;

a first set of tubes having first ends and second ends, and

a first condensate header connected to the second ends; and

a second condenser bundle positioned at a second angle relative to a second side of the first vertical axis, the first angle and the second angle having the same magnitude, the second condenser bundle including;

a second set of tubes having third ends and fourth ends, and

a second condensate header connected to the fourth ends,

the first condensate header and the second condensate header separated by a first distance;

a second exchanger pair that includes;

a third condenser bundle positioned at the first angle relative to a first side of a second vertical axis, the third condenser bundle including;

a third set of tubes having fifth ends and sixth ends, and

a third condensate header connected to the sixth ends, the second condensate header and the third condensate header separated by a second distance, the second distance less than the first distance; and

a fourth condenser bundle positioned at the second angle relative to a second side of the second vertical axis, the fourth condenser bundle including;

a fourth set of tubes having seventh ends and eighth ends, and

a fourth condensate header connected to the eighth ends, the third condensate header and the fourth condensate header separated by the first distance; and

a support frame that supports the plenum, the first exchanger pair, and the second exchanger pair; and

a fan to generate an air current over both the first exchanger pair and the second exchanger pair.

17. The air cooled condenser of claim 16, wherein the magnitude is between approximately twenty degrees and approximately thirty degrees.

18. The air cooled condenser of claim 17, wherein the magnitude is approximately twenty-six degrees.

19. The air cooled condenser of claim 17, further including a third exchanger pair that includes:

a fifth condenser bundle positioned at the first angle relative to a first side of a third vertical axis, the fifth condenser bundle including;

a fifth set of tubes having ninth ends and tenth end, and

a fifth condensate header connected to the tenth ends; and

a sixth condenser bundle positioned at the second angle relative to a second side of the third vertical axis, the sixth condenser bundle including;

a sixth set of tubes having eleventh ends and twelfth ends, and

a sixth condensate header connected to the twelfth ends, the fifth condensate header and the sixth condensate header separated by the first distance, wherein the fan is to generate the air current over the third exchanger pair.

20. The air cooled condenser of claim 19, wherein the fourth condensate header and the fifth condensate header are separated by the second distance.

21. A mechanical draft modular air cooled condenser for condensing steam comprising:

a condenser module including;

a first condenser bundle having a first set of tubes having first ends and second ends, the second ends arranged lower than the first ends, and a first condensate header connected to the second ends, the first condensate header arranged substantially horizontally, the tubes of the first set of tubes arranged parallel to each other in a first plane that is inclined by an angle (180°

-α

) with respect to the horizontal;

a second condenser bundle having a second set of tubes having third ends and fourth ends, the fourth ends arranged lower than the third ends, and a second condensate header connected to the fourth ends, the second condensate header parallel to the first condensate header, the tubes of the second set of tubes arranged parallel to each other in a second plane that is inclined by an angle α

with respect to the horizontal;

a third condenser bundle having a third set of tubes having fifth ends and sixth ends, the sixth ends arranged lower than the fifth ends, and a third condensate header connected to the sixth ends, the third condensate header parallel to the first condensate header and parallel to the second condensate header, the tubes of the third set of tubes arranged parallel to each other in a third plane that is inclined by an angle (180°

-α

) with respect to the horizontal;

a fourth condenser bundle having a fourth set of tubes having seventh ends and eighth ends, the eighth ends arranged lower than the seventh ends, and a fourth condensate header connected to the eighth ends, the fourth condensate header parallel to the third condensate header, the tubes of the fourth set of tubes arranged parallel to each other in a fourth plane that is inclined by an angle α

with respect to the horizontal;

the first, the second, the third, and the fourth condensate headers arranged in a single horizontal plane;

the first, the second, the third, and the fourth condensate headers being distinct from each other;

the first condensate header directly adjacent the second condensate header;

a shroud that houses a single fan, the single fan positioned to create a draft to flow over the first condenser bundle, over the second condenser bundle, over the third condenser bundle, and over the fourth condenser bundle; and

a support frame that supports the first, the second, the third, and the fourth condenser bundles.

22. The modular air cooled condenser according to claim 21, wherein a is equal to approximately sixty degrees to approximately seventy degrees.

23. The modular air cooled condenser according to claim 22, wherein a is equal to approximately sixty-four degrees.

24. The modular air cooled condenser according to claim 21, wherein the tubes of the first, the second, the third, and the fourth sets of tubes have fins attached thereto.

25. The modular air cooled condenser according to claim 21, wherein the tubes of the first, the second, the third, and the fourth sets of tubes each have a length equal to approximately two meters.

26. The modular air cooled condenser according to claim 21, wherein the first, the second, the third, and the fourth condenser bundles each have a length greater than ten meters.

27. The modular air cooled condenser according to claim 21, wherein the second condensate header and the third condensate header are disposed between the first condensate header and the fourth condensate header.

28. The modular air cooled condenser according to claim 21, wherein the first condensate header and the second condensate header are separated by a first distance, and the third condensate header and the fourth condensate header are separated by the first distance.

29. The modular air cooled condenser according to claim 28, wherein the second condensate header and the third condensate header are separated by a second distance, the second distance greater than the first distance.