BUNDELKHAND INSTITUTE OF ENGINEERING AND TECHNOLOGY

JHANSI , UTTAR PRADESH(284128)

Topic : Steam Condensers

Submitted to : Submitted by :-
Dr. Ravindra Kumar Prakhar Mishra (2100430510007)

Department of Chemical Engineering BIET Jhansi

CONTENTS

 Introduction
 Functions of Steam Condensers
 Steam Condensers Parts
 Working Principle
 Types of Steam Condensers
 Advantages
 Limitations
 Applications
 Conclusion
 References
INTRODUCTION

• A steam condenser is a closed vessel-type heat exchanger applied to convert low-pressure exhaust steam from the
turbine to water.
• A steam condenser is a mechanical device employed to condense exhaust steam of the turbine into the water.
• It conducts this process with the help of cooling water that circulates inside it from the cooling tower.
• The pressure within a steam condenser is held below the atmospheric pressure to enhance efficiency.
• It is commonly used to lower the backpressure of the exhaust at the turbine end.

Reference : https://www.linquip.com/blog/steam-condenser/

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Functions of the Steam Condenser

• The steam condenser takes exhaust steam from one end and contacts cooling water circulating within
it from the cooling tower on the other. In power plants, the steam condenser is an essential product of
industrial tools.

The purpose of using a steam condenser is:

• Helping keep the pressure low (below atmospheric pressure) at the steam turbine end to get
maximum possible energy and reduce the specific steam consumption of a power plant.
• Supplying pure feed water to and from the hot well. The water is again pumped to the boiler using a
boiler feed pump.
• Raising the heat transfer rate by removing other non-condensable gases from the exiting steam

Reference : https://www.linquip.com/blog/steam-condenser/

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Steam Condenser Parts

The components required to operate a steam condenser are as follows.

Condenser
It is used to condense the steam. The steam with low pressure delivers its heat to the coolant (here water from the
cooling tower), and it converts into the water through the condensation process.

Condensate Extraction Pump

A Condensate Extraction Pump (CEP) is a pump installed between the condenser and the hot well to transfer the
condensate from the condenser to the hot well.

Hot Well
It is a pit between the condenser and the boiler. It takes the condensate by condensate pump from the condenser. The
feed water is carried from the hot well to the boiler.

Reference : https://www.linquip.com/blog/steam-condenser/

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Boiler Feed Pump
It is a pump located between the hot well and boiler to deliver the feed water from the hot well to the boiler. This is
accomplished by increasing the condensate pressure above boiler pressure.

Air Extraction Pump

It is a pump utilized to extract or remove the air from the steam condenser.

Cooling Tower
It is a tower containing cold water, and this water is provided to circulate inside the condenser to cool the steam.

Cooling Water Pump

It is a pump installed between the condenser and the cooling tower. It circulates the coolant within the condenser.

Reference : https://www.linquip.com/blog/steam-condenser/

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Components of the steam condenser (Reference: slideshare.net)

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Steam Condenser Working Principle

• A flow of cooling water is continuously circulating from the condenser inside a steam condenser to the
cooling tower and the cooling tower to the condenser.

• When low-pressure exhaust steam leaves the turbine and passes through the condenser, it loses the heat
and condenses into water.

• The circulating cooling water performs the extraction of the heat from the steam.

• Two types of devices are installed on the condenser: the condensate extraction pump and the air
extraction pump.

Reference : https://www.linquip.com/blog/steam-condenser/
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• Therefore, when the steam condenses into water, it re-circulates again to the steam generator with the help of a
condensate extraction pump. Using the air extraction pump, a vacuum (the pressure below the atmospheric
pressure) is created inside the condenser so that cooling water can circulate easily and also the condensate flow
can be stabilized.

• Due to the low pressure inside the condenser, the air enters the system so that the condenser is filled with a
mixture of water, air, and steam.

Reference : https://www.linquip.com/blog/steam-condenser/

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Types of Steam Condenser

1. Direct Contact-type Steam Condenser

In this type, the steam (condensate) and the cooling water are mixed
and become a single stream.
In general, it is available in the market at a low cost.
Moreover, the design of the direct contact type of
condenser is very simple.
However, in some cases, the mixture of cooling water and
condensate is not allowed, and this type of condenser
cannot be used.

A simplified schematic of mixing (direct

contact) condensers
Reference : https://www.linquip.com/blog/steam-condenser/ (Reference: koerting.de)

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2. Jet Condenser

• Since it is a direct contact type condenser, the cooling water, and the condensate are mixed together and come out.

• As the steam is mixed with the cooling water, it is not possible to recirculate the cooling water to the boiler until
it crosses through a water treatment plant.

• Because the condensate contains salt, it cannot be utilized as feed water to the boiler. The application of this type
of condenser is where enough amount of good quality water exists.

• Jet condenser sometimes loses some of the condensate and needs much power to pump during the condensation
process. The condensing capability of the jet condenser is much higher than other types.

Reference : https://www.linquip.com/blog/steam-condenser/

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The jet condenser can be classified into four types:

A. Parallel Flow Condenser

The direction of the steam flow and the cooling water flow direction is the same in a parallel flow jet
condenser.
Both flows come from the top of the condenser and, after mixing, come out from the bottom of the
condenser.
As the steam and cooling water mix, the steam condenses.

B. Counter Flow Condenser

This is exactly the opposite of a parallel flow jet condenser, where cooling water comes from the top side of
the condenser, and exhaust steam enters the condenser from the bottom of the condenser. Therefore, the
cooling water direction is downwards, and contrarily, the direction of exhaust steam is upwards.

Reference : https://www.linquip.com/blog/steam-condenser/

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.

Schematic diagram of parallel and counter flow steam condensers

(Reference: mechanicalbooster.com)

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C. Barometric Jet Condenser

In the barometric condenser (or high-level jet condensers),

the shell is installed on top of the hot well at the height of
10.36 meters. To achieve this, the discharge segment of the
condenser is fitted with a long vertical tube which is called
a tailpipe. No condensate extraction pump exists in this type
of condenser. The current is entirely flowing with the help
of gravity. However, there is a cooling water injection pump
to deliver the cooling water from above the condenser. The
barometric condenser is used with a vertical discharge pipe
at a high level.

Reference : https://www.linquip.com/blog/steam-condenser/

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D. Ejector Condenser

• In the Ejector condenser, the cooling water is injected

from above.

• This condenser is equipped with a no-return valve

through which exhaust steam enters the condenser.

• This condenser also has multiple convergent nozzles that

help reduce the pressure inside the condenser.

• So, due to low pressure, the exhaust steam is drawn into

the condenser through the no-return valve and mixed with
the condensate and the cooling water.

Reference : https://www.linquip.com/blog/steam-condenser/

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Surface Condenser

In general, surface condensers are used in the power plant. This condenser is also known as the shell and tube type
condenser. No contact exists between the cooling water and exhaust steam. Therefore, the extracted condensate can
be reused without any water treatment in the boiler. It is also called a non-mixing type condenser.
The surface condensers are classified based on the condensate flow direction, the arrangement of the tubes, and
installation of the extraction pump, as follows:

A. Down Flow Surface Condensers

In this type of surface condensers, the steam enters at the top portion of the condenser. It moves downwards over
the tubes because of the gravity and air extraction pumps. The condensate is gathered at the bottom and then
pumped by a condensate extraction pump.The tube of the dry air extraction pump exists near the bottom and is
covered by baffle plates to prevent the condensate from entering.

Reference : https://www.linquip.com/blog/steam-condenser/

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B. Central Flow Surface Condensers

In the central flow surface condenser, the steam enters from

the top of the condenser and flows downwards. In this
condenser, the suction pipe of the air extraction pump is
located in the center of the tube nest. Due to this placement,
the exhaust steam moves radially inward across the tubes to
the suction pipe. The radial motion of the steam ensures
better heat transfer as the contact area with the tubes
increases. The condensate is collected at the condenser
bottom and pumped to the hot well.

Schematic comparison between down flow and

central flow surface condensers
(Reference: mechanicalbooster.com)
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C. Regenerative Surface Condensers

In this condenser, the condensate is heated using the regenerative procedure. In this method, the condensate passes
through the exhaust steam coming into the condenser from the turbine or engine. So, its temperature increases, and it
can be used as the feed water to the boiler. It enhances the efficiency of the steam generation plant remarkably.

Reference : https://www.linquip.com/blog/steam-condenser/

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D. Evaporative Surface Condensers

In evaporative surface condensers, the steam enters the

condenser from the top part in a series of tubes on which
a cold water film falls. At the top of the condenser, a
couple of nozzles are installed to spray cooling water. At
the same time, the air flow is created to circulate over the
water film. As the air circulates over the film of water,
some of the cooling water evaporates.

Evaporative steam condenser

(Reference: slideshare.net)
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Advantages

Increased efficiency
Steam condensers increase the efficiency of power plants by capturing latent heat and reducing back
pressure.

More work output

Steam condensers reduce the temperature of exhaust steam, which results in more work output.

Condensed steam reuse

Condensed steam can be reused as feed water for boilers, which reduces the cost of power generation.

Avoid boiler tube failures

Steam condensers can help avoid boiler tube failures, which are a major cause of forced outages.

References : https://brausupply.com/blogs/learn-to-brew/steam-condensing-unit

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Phase change
Steam condensers use the principle of phase change, where steam is cooled to become liquid

Heat transfer
Steam condensers exchange heat as steam loses heat and transitions into liquid form.

References : https://brausupply.com/blogs/learn-to-brew/steam-condensing-unit

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Limitations

Air leakage
Air leakage can decrease the thermal efficiency of the steam power plant, increase the need for cooling
water, and reduce heat transfer. Air can leak through joints and packing, or it can be dissolved in the feed
water.

Mixing of cooling water and condensate

In jet condensers, the cooling water and condensed steam mix together, so the condensate can't be reused
as feed water for the boilers.

Temperature limit
Air-cooled condensers have a temperature limit of 20–55°C, and are not recommended for areas with an
ambient temperature above 42°C.

Reference : https://www.researchgate.net/publication/324168245_Steam_Condenser
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Applications

Maintaining turbine efficiency: Steam condensers create a vacuum that optimizes the steam cycle,
which helps maintain the turbine's efficiency.

Reducing operational costs: Condensation and heat recovery can reduce a plant's operational costs.

Reusing exhaust steam: The condensed steam can be reused in liquid form.

Power plants: Steam condensers work with steam turbines to condense exhaust steam into water.

HVAC systems: Condensers are used in HVAC systems.

Reference : https://www.researchgate.net/publication/324168245_Steam_Condenser
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CONCLUSION

Steam condensers are critical in optimizing the performance of power plants and conserving resources. By
efficiently condensing steam into water, they reduce energy losses and support sustainable operation. With
advancements in technology, condensers are becoming more efficient and eco-friendly.

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References

 Thermodynamics textbooks (e.g., Engineering Thermodynamics by P.K. Nag).

 Power plant operation manuals and industrial design guides.
 Research papers and case studies from journals like Energy Conversion and Management.
 Online resources from engineering platforms like NPTEL or ScienceDirect.

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THANK YOU