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Steam Condenser

Introduction:
A steam condenser is a closed vessel into which steam is condensed by extracting
the latent heat of condensation from it and pressure is maintained below the
atmospheric pressure. It is the most essential component of the modern steam
power plants.

Types of steam Condensers:

There are two principal types of condensers the jet condenser or mixing type which
employs a jet of cold water to condense the steam and a surface condenser or Non-
mixing type which employs cold metal surfaces. The surface condenser is used for
the majority of steam engine & steam turbine applications which is not in the scope
of our company.

High level Jet condensers:

Our company manufactures highly Exhaust
efficient & durable mixing type high level Steam
jet condenser (also called Barometric Belt
Condenser) for syrup boiling pans in the Shell Spray
sugar plants as shown in Figure 1. Nozzles
This type of condenser is suitable where Spray
conditions permit condensation of Box
exhaust steam by direct contact with the W ater Spray
cooling water. It can maintain a Entry
pressure of less than 0.88 bars (650mm
of Hg vacuum Gauge) or 0.1333 bar Frustum Jet
(100mm of Hg Absolute). The vacuum Nozzles
is created inside the condenser by the
high velocity of water jets through jet Reducer
nozzles. The cooling water is sprayed
into the shell and the fine spray contacts
the steam thus steam get condensed. Tail
The condensate (condensed steam) and Pipe
sprayed water is withdrawn along with
the water jets through the tail pipe.
Some times a separate air ejector is
attached to the condenser for the
removal of non condensable gases which
are necessary to be withdrawn to
diminish the back pressure.
Figure 1
Operating Principle:
The shell is placed at a height greater
than the barometric height of water column (i.e. 10336mm).If a long pipe more than
10336mm length is held vertical with one end immersed in a water vessel open to
atmosphere and other end subjected to suction pressure, the atmospheric pressure
will hold the column of water in the pipe equal to the suction pressure.
This height of shell needs a separate pump for injection of cold water. There is no
need of water extraction pump. The condensate and water will move down due to

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gravity to the hot well. This height will always be maintained and excess will fall to
the hot well.

List of components of Condenser:

Assemblies of main components of SEDL’s mixing type high level jet condenser are
listed below.

1. MS Belt 9. Cone
2. Shell 10. Reducer
3. Water Entry 11. Tail Pipe
4. Counter Current Air Cooler (CCAC) 12. Tail Pipe Clamp
5. Strainer Cleaning Mechanism (SCM) 13. Bellow
6. Automation nipples 14. Diffuser
7. Spray Box 15. Flange
8. Man-hole 16. MS Stool

General introduction to Components:

We shall study in detail all above listed components in the upcoming
chapters of Production Manual here general introduction is stated below.

1. MS Belt:
It is a circular ring manufactured from 10mmX100mm Mild Steel Flat and
used to fasten the condenser with the application of welding process to the pan vapor
outlet pipe which makes the joint leak proof.

2. Shell:
It is a vertical cylinder manufactured from Austenitic Stainless Steel. It is
attached to the pan vapor outlet and condenser cone from the top and bottom
respectively. It surrounds the spray box and provides provisions of water entry, man-
hole, SCM, automation nipples and air line. Greater portion of the shell is utilized to
provide space for condensation of steam.

3. Water Entry:
It is a horizontal pipe through it cold water is sent into the spray box for
injection and jet. It is manufactured from Austenitic Stainless Steel to prevent corrosion

Spray Nozzles

Spray Box

SCM

Jet Nozzles Strainer Water Entry Water Inlet Hinge Assembly

Figure 2

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attack. Half portion of water entry is inserted in the shell while other half portion is out
of shell. It contains a strainer for filtration of cold water. Inner end of the water entry is
fitted on the spray box while on outer end it contains a hinge assembly through which
strainer can be removed for its periodical cleaning as shown in Figure 2. It also contains
the provisions for the CCAC and water inlet nipple.

4. Counter Current Air Cooler:

Continuous condensation of steam causes formation of Non Condensable
Gases (NCG) since steam contains some extent of air which can not be condensed at
normal temperature. In other words condensation temperature of air is too low therefore
it is necessary to be withdrawn from the condenser otherwise it will tend to create back
pressure to the syrup boiling pan. The Counter Current Air Cooler is used to catch NCG
from the condenser. It is also known as wash box. It is fitted on the water entry near
spray box inside the condenser. This equipment is attached to an Air Ejector. When ever
pressure inside the Condenser increases due to formation of NCG a Non Returning Valve
is opened thus NCGs are sucked by the Air Ejector through CCAC.

5. Strainer Cleaning Mechanism:

In the Sugar Plants there is always a problem of pure cold water for
injection. Impurities present in the water may block Spray and Jet Nozzles. To minimize
this problem a Strainer Basket is
provided in the Water Entry of
Condenser. But at the same time
another problem arises. After a short
SCM Handle
interval of operation, strainer gets
chocked with impurities like leaves,
pebbles, baggase which may cause a
greater head loss in to the Condenser.
To minimize the above stated problems SCM Nut Condenser
a Strainer Cleaning Mechanism is Shell
provided which cleans the strainer SCM Shaft
Strainer
without interrupting the operation. Cold Water Strainer Cleaning
It is fitted on the shell Mechanism
SS Cover
opposite to water entry as shown in
Plate
Figure 3. It comprises of a helical
Spray Box Spray Box
(screw nut) pair mechanism which gives Nipple
linear motion to its shaft. This Shaft is
provided with a handle at the outer end
which is revolved manually in order to Water
Entry
give linear motion to the shaft which
pulls back the attached SS Cover. This
action permits cold water to flow
through Spray Box Nipple and forces
impurities outside the strainer and are
Figure 3
ejected to hot water channel through
Tail Pipe.

6. Automation Nipples:
Automation Nipples are provided with automatic Condensers. These are
welded on the Condenser shell and Spray Box. High pressure (3kg/cm2) water from the
Accumulator is transferred through these Nipples in to the condenser to govern specific
spray & jet nozzles according to the vapor load on to the Condenser.

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7. Spray Box:
Spray Box is very essential component of Condenser. It is a hollow
cylindrical container of water; it is concentric to the shell and fitted on the inner side of
Water Entry in the Condenser. Jet nozzles are fitted on the bottom of Spray Box with the
help of jet plate while the spray nozzles are fitted normal to the Spray Box Shell above
the Water Entry. A Hand hole is provided (At 90°to the Water Entry) on it for the
maintenance of Jet Nozzles while top part of Spray Box is provided with flange blind for
maintenance of spray nozzles. Cold water through Water Entry enters in to it and
distributed to spray and jet nozzles. It is manufactured from highly corrosion resistant
austenitic Stainless Steel to prevent corrosion attack.

8. Man Hole:
It is provided for cleaning and maintaining the interior of
Condenser. It is fitted on shell at 90° to the Water Entry and
faces Hand Hole fitted at Spray Box. It is generally made up of
two types, Hinge type and Flange type. Hinge type Man Hole
takes comparatively lesser time to open or close
than Flange Type Man Hole

a Figure 4 b

Hinge Type Manhole Assembly

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