| Home > Products & Services > Air Cooled Vacuum Steam Condensers |
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| Experience and Track Record of GEI |
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Air Cooled Vacuum Steam Condenser were first introduced by GEI in the year 2002 when the awareness of water conservation for the power plants started in India. Today GEI is the market leader an Air Cooled Vacuum Steam Condenser having reference of 115 units totaling to combine plant capacity of about 3500 MW. The largest of these are 4 units of 150 MW capacities which will be the largest capacity ACC operating in India.
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| Innospin AG – Technological Partner for GEI |
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GEI has tied up with Innospin AG of Switzerland to offer Air Cooled Vacuum Steam Condensers from 200 MW upto 660 MW and beyond using single row tube. GEI and Innospin has signed an agreement for mutual co-operation on 11th May, 2011 at Mumbai.
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Switzerland-headquartered Innospin, global specialist in power generation equipments, is one of the leading providers of comprehensive engineering and consulting services. Its services include complete design and engineering of power plant systems including Air cooled steam condensers, together with technology and know-how transfer.
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Innospin is the technological partner to GEI for Air Cooled Steam Condensers for large power plants and will be giving technical support in the form of sizing, detailed design and engineering, assistance for erection and commissioning and performance guarantee.
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With the tie-up, GEI is set to be the only Indian company that will be equipped to locally manufacture and supply air-cooled steam condensers to new and upcoming super critical thermal power stations. The products will be manufactured at its manufacturing facility in Bhopal.
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Innospin has references of Air Cooled Steam Condenser for a total plant capacity of 18572 MW with 46 units ranging from 300 to 660 MW and 25 units ranging from 52 to 200 MW for projects in China, Middle East & Europe.
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| Wet Cooling System Vs. Dry Cooling System |
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Air Cooled Condenser have become the need of the hour due to its striking advantages over the conventional water cooled system which uses surface condenser along with cooling tower.
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Water is in shortage and plant locations where water is available today will be facing the tomorrow leading to power plant shut down in summer. Sea water is no longer a viable option as once through cooling systems are not environmental friendly and have social problems with fisherman.
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It is now a very well known and accepted fact that water is becoming a scarce natural resource. Using water for thermal power plants has negative impact on environment and ecology. Besides this the cost of storage, pump and treatment of water for cooling power application is a major concern.
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| Advantage of Dry Cooling System |
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| Systems |
Wet Cooling System |
Dry Cooling System |
| Major Equipments |
Cooling tower and surface condenser |
Air Cooled Condenser |
| Availability of coolant |
Water at a cost or is it available ? |
Air is free |
| Plant location |
Should be near water and fuel source |
Water source is not criteria |
| Maintenance cost |
High |
25% of that for wet cooling system |
| Effluent treatment |
Necessary |
Not required |
| Fouling and scaling |
Major concern |
Not a concern |
| Cleaning |
Frequent tube side cleaning is necessary |
Occasional fin cleaning is required |
| Total plant set up |
Involves intake water, pumping system and storage facility |
No such infrastructure required |
| Space for complete system |
Same |
| Annual Energy Consumption |
High |
Low |
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| Application |
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Coal and Biomass based Thermal Power Plants. |
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Solar Power Plants |
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Gas Based Combined Cycle Power Plants. |
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| Finned Tubes |
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Single row aluminium clad flat tubes with brazed Aluminium Fins which provide good resistance to corrosion and offers low power consumption. |
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Extruded bi-metallic fins for severe dusty environment like cement plants where heavy dust can be removed using can be removed with high pressure water jet. |
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LL type overlapped fins for dusty environment which can be cleaned with water pressure jet. |
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L type single foot fins for clean environment. |
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| Construction |
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A frame type construction with tube bundle having separate condensing (primary) and air evacuation (dephlagmetor) sections. |
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Large diameter low speed fans driven through gear box by AC motors are used in forced draft mode pushing atmospheric air from below to the tube bundles mounted on the A-Frame. |
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All round wind wall and module partition walls prevents hot air recirculation. |
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The condensed steam (condensate) is collected in condensate storage tank and pumped to the deaerator as feed water to the boiler. |
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Tube bundles |
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Fans either in FRP or Aluminium construction driven by gear box. |
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A-frame mounting structure. |
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Wind wall to arrest cross winds & avoid recirculation. |
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Steam duct from turbine exhaust frame to condenser with expansion bellows. |
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2 x 100% holding ejectors and 1 x 100% hogging ejector. |
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Condensate and hotwell drain tanks. |
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Condensate extraction pumps. |
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Hotwell pumps. |
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Control instrumentation. |
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Piping from the condenser upto ejector. |
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| Major components of ACC: |
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Condensing & venting modules. |
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Air movement equipments. |
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Windwall and module partition walls. |
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Air Evacuation equipment with piping. |
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Condensate collection headers. |
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Condensate storage tank and pumping system. |
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Exhaust steam ducting with expansion joints. |
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Fin cleaning system. |
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Instrumentation & controls. |
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Pressure relief device ( rupture disc) for protection of ducting. |
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Steam duct condensate draining system. |
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Electricals – VFD, MCC and Cables etc. |
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| Completely covers the base tube and is suitable for dusty environment. Then fins are found to be an economical alternative to the much expensive extruded bi-metallic fins. |
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| References |
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Major end users for Captive Power Plants are Birla White, Heera Group, Jaypee Group, J.K. Laxmi, Shree Cements and Ultratech Cements. |
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Independent Power Plants producers to whom GEI has supplied ACC include Ind Barath Power India Ltd., KSK, Sarda Energy. |
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EPC companies include Cethar Vessels, Shriram EPC, Tata Projects, Thermax, Thyssen Krupp, Toyo and Walchandnagar Industries. |
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