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Solution to fouling
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-: PRESENTED BY :-
SANKET CHAUDHARI (096380319510)
ARGHYA GOSWAMI (096380319523)
PARUL INSTITUTE OF ENGINEERING & TECHNOLOGY (DS) 2ND SHIFTLIMDA, DIST. VADODARA.
YEAR: 2011-12
INTERNAL EPOXY COATING
IN SURFACE CONDENSER
INTRODUCTION
DEFINITION :-
Steam condenser is an appliance in which the steam exhausted
from a steam engine is condensed. Condenser is installed such
that the exhaust steam from a Steam Engine is delivered into it.
In the condenser, the heat is removed from the exhausted
steam in form of latent heat by means of cooling water which
absorbs this latent heat. The exhaust steam after losing its
latent heat changes its state into water, which is termed as
Condensate and this process, is called as condensation.
INTRODUCTION
INTRODUCTION
Elements of Condensing Plants :- Condenser where steam is condensed,
Hot well in which the condensate is collected.
Pump for circulating Cooling Water, supply of Circulating Cooling
Water,
Air pump (or ejector) to remove air and non-condensing gases from the
condenser
Condensate Pump (extraction pump) to remove Condensate from the
condenser,
Feed Pump for supplying feed water from De aerator to the boiler.
INTRODUCTION
INTRODUCTION
FUNCTIONS :- Reduce the back pressure of steam primemovers.
Increases the expansion ratio of steam hence thermal
efficiency .
Decreases the temperature of the exhaust steam & increases
power output.
Supply of clean & soft water to the boiler.
It stores water, hence additional storage space is not required.
Because of higher temperature of feed water thermal stresses
are reduced.
PROBLEM IDENTIFICATION
1. Corrosion
2. High Condenser Back Pressure
3. Tube fouling
4. Low Cleanliness Factor
5. Low Heat Transfer
6. Air In-Leakage
7. Dissolved Gases (Oxygen, Carbon Dioxide, Ammonia, etc.)
8. Low Pump/Exhaust Capacity
9. Other Efficiency/Maintenance/Design/Operations Concerns
EXPECTED OUTCOME
Condenser fouling is a major economic problem, and
maintenance costs are estimated to account for 0.25% of
the world GDP (Gross domestic product). To remain
competitive and reduce energy costs power plant operators
must pay attention to the small details involved in the
proper maintenance of tubular systems in condensers, heat
exchangers and other heat transfer equipment to realize
significant savings. By utilizing the best available
technology reliability, and energy efficiency gains can be
realized.
EXPECTED OUTCOME
Another method to cut plant and equipment downtime,
recover energy efficiency, and achieve fewer stoppages for
routine maintenance is by using thin film polymer coatings
applied to full length tube IDs. This process is low cost
procedure to solve condenser tube fouling and corrosion
problems.
When a thin layer of epoxy is applied in the inner wall of shell
and tubes, tube sheet and water box, the effect of corrosion
and erosion is almost eliminated. Hence the service life
increases and efficiency is also maintained.
EXPECTED OUTCOME
Polymer tube linings have always suffered from an initial
perception of heat transfer penalties due to their lower
thermal conductivities but quantitative data and strong long
term case history has demonstrated just the opposite.
Decades of service history have shown that tube coatings can
enhance heat transfer and overall performance to a
significant degree. While the thermal conductivity of the
coating is much less than the parent tube, this factor is
mitigated by inherent properties of the coating. The impact to
overall thermal conductivity is nil or minor.
EXPECTED OUTCOME
21 mm brass tube x 2.3
mm wall - conditions
Thermal conductivity
W/ m K
1. Average scaled - < 0.150 mm14.9
2. 100% solids – applied at 75
microns average2.737
3. Epoxy phenolic – applied at 75
microns average8.82
4. Epoxy phenolic – proprietary
pigment loading14.764
EXPECTED OUTCOME
ADVANTAGES By this method service life of condenser increases &
efficiency is maintained.
It reduces downtime & maintenance cost upto 50% compared
to retubing.
Feed water process cost also reduces.
DISADVANTAGE Efficiency may be reduced by 0.5 % to 0.7 % which can be
considered as negligible.
CONCLUSION
As this method reduces the maintenance cost it direct affects
the energy production cost, gives strong support to the power
plant operators to remain in this competitive market & helps
to get out from the energy crisis.
Thus by application of epoxy coating in some parts of
condenser the major problems can be minimized like,
Corrosion,
Tube fouling,
Low cleanliness,
Chocking of tubes etc.