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Condensers are pivotal in various industrial and HVAC applications, playing a critical role in converting vapour streams into liquid. They function through heat transfer and compression techniques. They find applications in cooling gases and process fluids and are integral components of systems designed to cool external environments, including air conditioners.
The condenser in power plant: Every condenser is built to specific standards, considering flow rates, operating pressures and temperatures and condensing capacity. They are versatile, finding use in automotive air conditioning, central air systems for buildings, process cooling, refrigeration and steam power turbines in power plants.
These can transform gas into liquid via heat transfer. There are two primary types:
Direct Contact Condensers: These facilitate heat transfer through the direct interaction of gas and liquid, typically of the same material.
Indirect Contact Condensers: They use a conductive boundary, like a shell or tube, for heat transfer, avoiding fluid mixing.Large surface condensers with &#;U&#; bent tubes are used in coal-fired power stations and nuclear power stations.
A surface condenser is a type of heat exchanger integrated into the steam boiler exhaust which drives the turbines in power stations. The process of gaseous-liquid conversion condenses superheated steam into pure water. In addition, the condenser recovers heat and generates energy. The pure water and the recovered energies are recirculated into the steam generators and boilers, making the condenser performance a significant factor in the overall efficiency of power plants.
Corrosion in condensers is a serious issue which can cause expensive equipment damage and threaten operational efficiency and safety. Therefore, alloys used in the construction of the &#;U&#; bent tubing condensers must be strong and practically immune to all corrosion processes in challenging operational conditions, e.g. hot, cold and cyclical changes in temperatures.
Titanium is the best technical choice for condenser tubes as it exhibits corrosion resistance to all types of water and significant resistance to general pitting corrosion, crevice corrosion and stress corrosion. The corrosion resistance of this low-density, high-strength material in a boiling water environment is significantly higher than that of copper-nickel alloys. Due to increasing environmental concerns the copper-bearing alloys are now rarely used.
Several million metres of titanium welded tubes, especially Ti Grade 2, (ASTM B 338, ASTM B 861, ASME II Part B SB) are in service worldwide. The power industry has proved titanium to be the most reliable choice for condenser tubing. While Titanium tubes constitute the main part of a condenser, a lot of titanium sheet and plate products are used in the construction of baffle plates and vessels as well as cladding for the condensers&#; shells. This avoids the need for cathodic protection and issues with galvanic corrosion.
Experience gathered from these condenser units in various conditions has guaranteed a long-life expectation of titanium components which virtually eliminates condenser corrosion problems from power plant economics. However, due to the high price and installation cost of titanium tubes, they are generally only used in coastal and nuclear power stations.
Stainless Steel Tube (ASTM A 249 / ASME SA 249) is also used extensively, when possible, and has good mechanical properties, corrosion resistance and economy. Alloy 800H/AT (ASTM B 407, ASME SB 407) is another austenitic heat-resistant alloy. Designed for high-temperature structural applications, the strength of 800H/AT is achieved by controlled levels of carbon, aluminium and titanium along with an °C minimum anneal to achieve a grain size of ASTM 5 or coarser.
While titanium leads in performance, stainless steel tubes (ASTM A 249 / ASME SA 249) are also widely utilised. They offer a balance of good mechanical properties, corrosion resistance, and cost-effectiveness. Another notable material is Alloy 800H/AT (ASTM B 407, ASME SB 407), an austenitic heat-resistant alloy designed for high-temperature structural applications. It gains its strength from controlled carbon, aluminium, and titanium levels, and a specific annealing process.
Duplex stainless steels, , (ASTM A789, ASME SA789) have excellent corrosion resistance, good mechanical, and welding properties with high thermal conductivity, but processing can be difficult with high costs.
We&#;ve looked in-depth at a surface condenser, the importance of the correct condenser in power plant and understanding the various aspects of condensers. From types and material properties to technical specifications and standards, is vital to select the right component for your plant. For further help and support, get in touch today.
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What does a condenser do in a plant?
Condensers are essential in power plants for their pivotal role in the steam power cycle. They recover heat energy from steam, significantly enhancing the efficiency of the power generation process.
Why does a plant need a condenser?
Surface condensers in thermal power plants serve a dual function. They are designed to condense the steam exiting a steam turbine, maximising the plant&#;s efficiency. Additionally, they transform the turbine exhaust steam back into pure water, known as steam condensate. This recycled water can then be reused in the steam generator or boiler as feed water, promoting efficient resource utilisation.
What is air cooled condenser in power plant?
An Air Cooled Condenser (ACC) operates as a direct dry cooling system where steam condenses within air-cooled finned tubes. The key to its functionality lies in the cool ambient air that flows outside these finned tubes, effectively removing heat and enabling the ACC&#;s operation.
by AMC
Posted on September 05, at 12:40 PM
In this blog, we&#;ll explore copper-nickel alloys&#;an essential material that often flies under the radar. Known for their exceptional resistance to rust and wear, copper-nickel alloys are ideal for demanding environments such as ships, cooling systems, and chemical plants. Discover why these alloys are a top choice for reliable and long-lasting performance in challenging conditions.
Copper-nickel alloy, also known as cupronickel, is a metal blend primarily composed of copper and nickel, with small amounts of iron and manganese. This alloy is valued for its excellent corrosion resistance, especially in marine environments, and its durability. The nickel content typically ranges from 10% to 40%, which enhances the alloy&#;s strength and resistance to wear. Copper-nickel alloys are commonly used in applications such as marine hardware, heat exchangers, and various industrial piping systems due to their robustness and resistance to biofouling and oxidation.
The most commonly used copper-nickel alloys contain either 10% or 30% nickel, known as 90-10 and 70-30 alloys. These alloys include small amounts of iron and manganese to improve their rust resistance. They are very flexible and can be strengthened through cold working, with the 70-30 alloy being stronger and able to handle higher flow rates. They also conduct heat well, which is useful for heat exchangers and condensers. These alloys are easy to shape and weld, and they can be welded to steel as well.
There are other types of copper-nickel alloys, like one with 2% manganese and 2% iron (66-30-2-2), which are used in tubing for higher flow rates and abrasive conditions. A newer alloy with chromium (Cu-30Ni-Cr) is also available for even higher flow rates.
Cast copper-nickel alloys are used too, though nickel aluminum bronzes are often preferred for pumps and valves. A cast Cu-30Ni-Cr alloy is used by the UK Royal Navy as an alternative to nickel aluminum bronze.
High-strength copper-nickel alloys come in two types: those strengthened by aging (Cu-Ni-Al alloys) and those strengthened by a special heat treatment (Cu-Ni-Sn and Cu-30Ni-Cr). Some of these alloys are as strong as high-strength steel and have useful properties like being anti-galling and non-sparking.
Explore our wide range of Copper Nickel Products, including pipes, tubes, flanges, and fittings, known for their excellent corrosion resistance.
Contact us to discuss your requirements of Nickel Alloy Condenser Tube. Our experienced sales team can help you identify the options that best suit your needs.
Copper-nickel alloys, such as the 90-10 and 70-30 types, use a protective surface film to resist corrosion. Unlike some alloys that form a protective oxide layer in air, these alloys develop a complex, multi-layered film in seawater, made up of oxides, chlorides, and hydroxy-chlorides. This film forms quickly and improves over time, leading to low corrosion rates. Because of this, short-term corrosion tests may not reflect their long-term performance. Ensuring that the alloys are exposed to the right seawater conditions during initial use is crucial for forming an effective protective film.
Copper-nickel alloys are not prone to problems like chloride-induced pitting, crevice corrosion, or stress corrosion cracking, which are issues with some stainless steels. However, they can be affected by sulfides and ammonia. While sulfide stress corrosion and hydrogen embrittlement are not concerns, sulfides can change the protective film, potentially causing pitting and higher corrosion rates. Therefore, these alloys should avoid long-term exposure to polluted seawater with sulfides or areas with sulfate-reducing bacteria (SRBs). Unlike brass, copper-nickel alloys resist ammonia stress cracking, though ammonia can increase corrosion rates.
In high-velocity or turbulent conditions, the protective film can wear away, leading to erosion-corrosion. This is less of a problem for copper-nickel alloys compared to other copper alloys, but it&#;s important to follow design and operational guidelines to minimize issues, such as avoiding partially throttled valves and tight bends in piping systems.
Copper-nickel alloys are generally compatible with other copper alloys and are more resistant to corrosion than steel and aluminum. However, they may corrode more quickly when connected to passive stainless steels, high-nickel alloys, and titanium.
Nickel plays a key role in shaping the properties of copper-nickel (Cu-Ni) alloys. As the amount of nickel increases, the alloy's tensile strength, corrosion resistance, and heat resistance improve. However, its ability to conduct heat and electricity decreases. For example, while tensile strength goes up with more nickel, the material's ability to stretch (elongation) stays mostly the same after a small initial decrease with up to 5% nickel.
Cu-Ni alloys are mainly heat-treated for soft annealing and stress relief. Recrystallization annealing occurs at 620°C to 900°C, with higher temperatures requiring shorter times. Stress-relief annealing is done at 280°C to 500°C.
Anneal in an air-free or slightly reduced atmosphere to avoid contamination and pickling. Some alloys can be age-hardened, like CuNi30Cr and CuNi5Al4Mn2, with specific heat treatments for each.
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Copper-nickel alloys, such as the 90-10 and 70-30 grades, provide excellent durability and corrosion resistance, making them ideal for harsh environments like marine applications and industrial systems. These alloys, enhanced with elements like manganese and chromium, offer great performance and flexibility. Proper heat treatment and care in design help maintain their effectiveness. Overall, copper-nickel alloys are a reliable choice for demanding conditions, offering long-lasting performance and resistance to rust and wear.
Copper-nickel alloys are used in marine hardware, heat exchangers, hydraulic tubing, cooling systems, and antimicrobial surfaces for their strength and corrosion resistance.
Copper-nickel alloys, like 70/30 cupronickel, are silver and contain 70% copper and 30% nickel, improving strength and corrosion resistance. Pure copper is reddish-brown and mainly used for its conductivity.
Copper-nickel alloys excel in marine environments due to their superior resistance to seawater corrosion, while stainless steel is better for handling harsh chemicals and acids.
The price of copper-nickel alloy varies depending on factors like the alloy grade and market conditions. As of recent estimates, For the most accurate and current pricing, please free to contact us.
Copper-nickel alloys are used in applications with maximum operating temperatures up to 600°C (1,110°F). They maintain consistent performance due to their low-temperature coefficient of electrical resistance.
In this article, we'll take a closer look at copper-nickel pipes&#;an important yet often overlooked material.
ASTM A29 is a specification standard published by ASTM International, defining the requirements
Steel has a density of approximately 7.85 g/cm³ or kg/m³, which is about 490 pounds per cubic foot.
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