Metal Finned Tubes for Air Cooled Condensers | ZHM,China Manufacturer Factory Supplier-Zhejiang Huawu Steel Structure Engineering Co Ltd

Metal Finned Tubes for Air Cooled Condensers | ZHM,China Manufacturer Factory Supplier

2024-8-20 12:43:59

Metal Finned Tubes for

Introduction

Metal Finned Tubes for Heat Exchangers and Air Cooled Condensers

thermal biomass power plants Air Cooled Condenser Exhaust Steam Duct

DIRECT AIR COOLED CONDENSER SYSTEM

In regions which are remote from water resources, air cooled condenser (ACC) is an important role of a condensing equipment.

Air Cooled Condenser utilizes ambient air through finned tubes for heat exchanging to remove heat out of exhaust steam for thermal or biomass power plants.

Description

Generally, applying another type in an insufficient-water area needs to make a water reservoir to collect the water for serving cooling tower. Thus, Air cooled condenser (ACC) will help reduce capital cost of such a water reservoir, save water consumption cost during operation. Also, it solves the problem of diverting water from the community.

In the thermal power plants, exhaust steam from the steam turbine flow into the air cooled condenser (ACC) where the condensation occurs. Then the condensate-water returns to the boiler in a closed loop. Meanwhile the exhaust steam coming from the turbine is at a low pressure, the Air Cooled Condenser works at pressure as vacuum to avoid the pressure drop increase and impact to the efficiency of power generation, and then the non-condensable gases will be removed continuously by the air evacuation system.

Configuration and Scope of ZHM Huawu Steel Air Cooled Condenser

Scope normally covers equipment and ducts from turbine exhaust to inlet of condensate pump, mainly including:

Tube bundle
Air supply system
Air evacuation system
Condensate system
Cleaning system
Exhaust steam ducting system
Supporting structure
Draining system
Electric system
Instrument & control system

Configuration ZHM Air Cooled Condenser finned tube bundles air evacuation condensate exhaust steam ducting supporting structures

Configuration ZHM Huawu Steel Air Cooled Condenser

Principle of Air cooled condenser

The working principle of Air Cooled Condenser is to distribute the exhaust steam from the steam turbine straightly to the stream condensers in several rows through ducting. At the same time, the large axial-flow fans intake air and sweep over the finned tube bundles externally to carry away heat. In finned tube bundles, the exhaust steam gradually changes to condensates and is accumulated in the condensate tank through the bottom headers. Moreover, the vacuum of the whole Air cooled condenser (ACC) covers by the air evacuation system. For this reason, the steam turbine can activate smoothly and confirm power generation efficiency.

air cooled condenser config steam turbine finned tube bundles fan condensate air evacuation

air cooled condenser config steam turbine finned tube bundles fan condensate air evacuation

Air cooled condenser process

The steam condensers are consisted of two types of tube bundles: parallel- flow and counter-flow types.

In the parallel-flow tube bundles, most of the steam is condensed, meanwhile the non-condensing gas is extracted in counter-flow tube bundles which they are connected through the bottom headers.

Additionally, the advantages of the direct air cooled condenser system (ACC) is occupying less floor area, various anti-freezing methods and flexible arrangement.

Technical and Advantage of ZHM Huawu Steel Air cooled condenser

Single-Row Finned Tube Bundles

ZHM Huawu Steel Single-Row Tube bundles is one of the best selective innovations which is applied in Air Cooled Condenser (ACC), characteristics designed by welded large flat tube and aluminum snake-like fins, are rolled from single-sided aluminum cladded carbon steel strip. The flat tubes and fins are connected by brazing.

single roll tube in air cooled condenser

ACC config single Row finned tube flat type aluminum steel strip brazing

ZHM Huawu Steel Single-Row Tube design

1. High heat transfer efficiency

The heat exchange at both sides of tube bundle is fully activating, mean to the exhaust steam has large size of flow area and very low-pressure loss, so the heat transfer efficiency is extremely high.

2. Strong resistance to corrosion

To have strong corrosion resistance, the external surface of base tube for the tube bundle is clad with aluminum alloy, the heat exchange fins of tube bundle also aluminum alloy spray coating, even after those materials are processed, aluminum oxide protective layer will still be formed thereon to achieve good corrosion resistance.

3. High strength and good cleaning ability

Welding several single-row fin tubes and tube-sheet was also applied in order to strengthen all the structures. Moreover, this process would apply for facilitate installation and transportation. Another distinctive characteristic, using straight-line type in single-row tube fins are easy to wash with high-pressure water without any deformation.

single row finned tube bundle cleaning washing high pressure water

tube bundle cleaning

4. Good anti-freezing performance

In order that the condensate flows more smoothly, we create a large length-width ratio of the base tube. Furthermore, this specific characteristic is able to reduce the extent of sub-cooling and the risk of tube freezing in winter.

5. Weld seam position

The weld seam is on the arc of the base tube of the single-row tubes, The arc spray aluminum coating has the better welding strength.

ZHM Huawu Steel does not need to be worried about the leak occurring during the operation since it can be repaired immediately without removing the entire tube bundle or replacement. Above all, we do believe in Easy maintenance and low maintenance costs.

ACC config finned tube bundle weld seam position exhaust steam condensate

ACC config finned tube bundle weld seam position exhaust steam condensate

Weld treatment-The weld seam is on the arc of the base tube

6. Single-Row Tube Bundle Fatigue test

Evacuated by vacuum pumping, the finned tube bundle will be reached to vacuum condition and then returned to normal pressure. After that, cycle tests will evaluate the number of cycles (fatigue life) in which the change occurs abruptly in the single-row finned tube bundles.

To ensure reliance of ZHM Huawu Steel Air cooled condenser (ACC), the qualified value of the product (including the finned tube bundles) fatigue life should be more than 1,000 times and more than ten times the actual fatigue times. Due to qualified value, our customers can assure that our product’s safety lasts the 30-year design life.

single row finned tube bundle fatigue testing vacuum condition

fatigue test 2 of finned tube bundles

fatigue-test-ACC fin tube bundles vacuum pumping cycle test

fatigue test 1 of heat exchanging fin tube bundles

THREE MAJOR TEST DEVICES

1. Performance testing device on tube bundles of Air cooled condenser (ACC)

The Performance testing device on tube bundle as applies for experimenting heat exchange performance of various types of fined tube bundle structure and online random test of finished products.

After pressure and temperature of the steam are gradually reducing, the testing device will simulate several operating backpressures of the steam turbine, measure the heat exchange performance and resistance loss of the tube bundle. It also obtains the heat exchange coefficient and air resistance of tube bundle at different air speed and internal flow resistance of tube bundle at different steam flow speed.

Furthermore, to evaluate actual performance of tube bundle, the testing device is also utilized for examining thermal performance of tube bundle.

ACC finned tube bundle structure random Perfomance Test device backpressure

ACC finned tube bundle structure random Perfomance Test device backpressure

Performance testing device of finned tube bundles

2. The unique environmental test laboratory : 1×4 Air cooled condenser (ACC) environmental test device

ZHM Huawu Steel Air cooled condenser is available for worldwide. It can simulate the summer operating conditions and winter operating conditions of Air cooled condenser (ACC), the unique environmental test laboratory will imitate ambient temperature of 50°C~-25°C. Therefore, there are two operating conditions to test in different situations.

One is the summer operating condition. It’s for testing the heat transfer performance of the tube bundles of the Air cooled condenser (ACC) which provides the basis for the design of the actual Air cooled condenser (ACC).

The other is the winter operating condition. It is for evaluating whether the control program of Air cooled condenser (ACC) is valid for antifreeze protection measures during operating conditions such as the machine functional of start, stop and low load operating conditions. Finally, it could test the minimum antifreeze steam flow under different temperature conditions.

ACC finned tube bundle Environment Performance Test simulate summer winter

ACC finned tube bundle Environment Performance Test simulate summer winter

Environmental test device

3. The unique large full-performance test bed: Hot-state test device for one unit of 1000MW Air-cooled condenser (ACC)

Full performance test bed

The unique large full-performance test device can simulate the main operating conditions of power station for the performance test, heat exchange performance, system reliability, stability, and economy of ZHM Huawu Steel Air Cooled Condenser (ACC). Particularly ensure the ACC can operate capacity at summer full load and winter anti-freezing running reliability.

ZHM Huawu Steel Air cooled Research and Development

Achieving the great leap of Air cooled condenser (ACC) for power plants from theoretical R&D to engineering application isn’t an easy thing. To solve several errors in our industry, we conduct nine fundamental research to provide design support for Air cooled condenser (ACC) for power station. Therefore, It’s more suitable for Global market.

Experimental Research on heat exchange performance of heat exchange component
Experimental Research on resistance characteristic on air side of heat exchange component
Investigation on resistance characteristic on steam side inside the finned tube of heat exchange component
Experimental Research on atmospheric corrosion resistance of fins
Fouling performance test of finned tube bundle
Cleaning test of fins of finned tube bundle
Experimental Research on freezing protection of finned tube bundle
Experimental Research on computer numerical simulation of Air cooled condenser (ACC)
Experimental research on fatiguing test of tube bundle

ZHM Huawu Steel Air Cooled Condenser Reference in Power Plant

Singapore Tuas IWMF Garbage Power Plant ACC ZHM

TUAS IWMF garbage power plant project

ZHM Huawu Steel has received the letter of award (LOA) from Singapore ST Marine. It’s about the award of bidding for air-cooled condenser in TUAS IWMF garbage power plant project. It is planned for two phases, each phase to generate 2 X 65 MW power with waste treatment capacity to be 2,900 tons/day. In conclusion, when the project is completed, it will be the largest garbage incineration power plant in Singapore and even in whole Southeast Asia.

References in biomass power plant and solid waste power plant

Biomass References

No	Pro.Name	Type	Capacity (MW)	Customer	Year of Installation	Country
1	Iseriohn	Waste	36	AMK	Ongoing	Germany
2		Waste	25	Imtech	2015	UK
3		Waste	22	Hitachi Zosen Inova	2016	UK
4		Waste	21.4	Dollbergen Boienergie GmbH	Ongoing	Germany
5		Waste	20	Aalborg Energie Tecknik a/s	2018	France
6		Waste	17	Hagener Umweltservice-und investitionsgesellschaft mbH	2014	Germany
7		Waste	14	Siemens Czech	2017	Portugal
8		Waste	12	Aalborg Energie Technik a/s	2017	UK
9		Waste	11.3	Zweckverban Muellheizkraftwerk	2014	Germany
10		Waste	9.5	Wallstein	2016	Germany
11		Waste	7	TWL	2018	Germany
12		Waste	3	Enprotech Co.,Ltd.	2016	South Korea
13		Waste	3	Enprotech Co.,Ltd.	2019	South Korea

ACC Project for Siemens 4×1200MW New Capital CCPP in Egypt

Reference in Thermal Power Plant

Air cooled condenser Project for Siemens
Air -cooled condenser Project for Siemens 4×1200MW New Capital CCPP in Egypt ( ACC for the largest CCPP in the world)
Botswana project (4×150MW)
Guohua Dingzhou Power Plant in Hebei Province (2×660MW)
Hulunbeier Power Plant (2×600MW)
Wison Cathay Power plant for 1 × 60,000 ASU of Wison Cathay
Air -cooled condenser unit for 4×60,000 ASU of Zhongmei Yulin Energy Chemical Co., Ltd.
Air- cooled condenser for 4×60000 ASU for coal-to-alkene project of Shenhua Baotou Energy Co., Ltd.
China Coal Tuke Energy Chemical Project for 2×40,000 ASU of China Coal Tuke Energy Chemical Co., Ltd.
Air- cooled condenser for 4 × 48,000 ASU of Datang Keqi Coal-to-Gas Co., Ltd.
Air cooled condenser unit for 1 × 35,000 ASU of Shenhua Yulin Energy Co., Ltd.

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