maximization of the efficiency of the steam cycle
Shell & Tube Steam
Optimization of the global efficiency of a power plant based on the Rankine Cycle, requires the incorporation of highly specialized equipment that supports the maximization of the efficiency of the steam cycle, reducing the primary energy consumption, minimizing the environmental impact and helping to optimize the OPEX and consequently the return on the investment.
The highly increasing competitiveness among the different centralized electricity generation technologies and the increasing concern on environmental issues, force all the available generation technologies to improve their efficiencies, reducing the primary energy consumption.
Most of the existing fossil power plants are based both in the Rankine Cycle technology or in the Combined Cycle technology. Both of them share the target of optimizing the total electrical output by increasing the efficiency of the steam turbine. Such efficiency basically is determined by the degree of vacuum you are able to reach in the condensing section. A properly designed vacuum surface condenser is of vital importance to obtain a high efficiency.
In a similiar way and in order to increase the thermal efficiency of the cycle, it is recommended to preheat the boiler feed water through efficient feed water heaters.
Recent trends point to the de-centralized energy generation as one of the key solutions to improve the overall energy efficiency of a country or region. Technologies such as Combined Heat and Power, CHP or co-generation, are widely used by many industries to satisfy their needs of electricity and heat in a very efficient way. District Heating is more and more used to provide heating and cool to municipalities and at the same time to produce electricity to be used by the community or to be sold to the network. The key element to determine the efficiency of these plants is the ability to recover the exhaust heat coming from the main driving equipment: gas turbines or combustion engines. The availability of efficient recovery systems are of vital importance to reach a high overall efficiency.
- Long lifetime
- Proven design
The performance of a steam turbine vacuum condenser has a major impact on the overall operational efficiency of a power plant working under a Rankine cycle.
We are a specialist in the design (thermal and mechanical), basic and detail engineering, procurement, manufacturing, testing, delivery and commissioning of turbine exhaust steam water cooled condensing units.
Condensers can be manufactured in diverse materials. Depending on the quality and nature of the cooling water (brine water, sea water, cooling tower water, river water, etc.) the material selection of tubes and tube sheets are carefully selected. Tube materials can be: carbon steel, stainless steel, copper alloys, nickel alloys or titanium. Tube sheets are selected accordingly and they can be of the solid type or cladded.
Our standard supply normally consists of:
• Transition duct between steam turbine outlet and condenser with necessary expansion bellows
• Main condenser: circular or rectangular cross-section with axial or vertical steam entry
• Dump tube and pressure reduction desuperheated system
• Gland condenser
• Vacuum system, either steam-jet ejectors or liquid ring vacuum pump type
• Flash tank, drain header and/or vacuum drains lifting system
• Condensate pumps system either electric motor or steam turbine driven
• Ball type tube cleaning system
• Safety devices
• Control system including: level control valves and level, pressure and temperature indicators and transmitters,
• Interconnecting piping
All components mentioned above are mounted and/or prefabricated up to a maximum extent in our workshop in common base steel frames.
Combined Heat and Power (CHP) is one of the most efficient ways to generate electricity and heat simultaneously (hot water, steam or hot gases for drying applications).
Such technology is normally based in a gas turbine or a combustion engine where burning natural gas or light fuel oil produces electricity. The combustion gases leaving such equipment have enough mass and enthalpy to be recovered and produce steam to be used in an industrial process or to be sent to a steam turbine (Combined Cycle).
A heat recovery steam generator (HRSG) is a boiler that is specifically designed to recover the enthalpy from the gases coming from one/several gas turbine(s) or one/several combustion engine(s) to produce steam and, if wished, hot water.
We are highly specialized in the basic and detail engineering, material purchasing, manufacturing, testing, delivery and commissioning of HRSG after gas turbines up to 30 Mw(e). Our flexible and modular design together with a very reliable pre-assembled design makes our HRSG the industry preferred choice for small and medium size CHP or Combined Cycle applications.
Our design is a water tube, natural circulation boiler, with extended surface heat exchange sections.
Our scope includes:
• By-pass system
• Insulated ducts
• Additional firing / Burner including natural gas measuring and regulating rack and burner management system
• Evaporator and drums
• Additional hot water recovery system
• Final stack
• Fresh air system
• Chemical dosing system
• Flash tank
• Feed water pumps
• Valves and trims
• Local and remote instrumentation
• Control system
Combustion engines are equipment where, by burning natural gas or light fuel oil, it produces electricity. The combustion gases leaving the engine have enough enthalpy to be recovered and to produce hot water to be used in any industrial process or for heating or cooling (absorption chiller) applications.
We are specialized in the basic design and detail engineering, purchasing, manufacturing, testing, delivery and commissioning of recuperators installed after any size of combustion engines.
Recuperators can produce hot water at one or two temperature levels, thermal oil or any kind of heated fluid to be used in the customer processes.
Our supply normally includes:
• By-pass system
• Final stack with silencer
In a power plant based in the Rankine cycle, the overall efficiency is highly influenced by the boiler thermal efficiency. As a first estimation, the boiler efficiency increases a 1% per each 10 F rise in the temperature of the feed water.
FWH are a kind of heat exchangers where, by using the enthalpy of certain steam turbine bleedings, it can be preheated the condensate coming from the hotwell of the vacuum surface condenser before entering into the deaerator (low pressure FWH) but also the feed water coming from the deaerator storage tank, after the boiler feed water pumps and before entering into the boiler economizer (high pressure FWH).
We are specialized in the basic and detail engineering, material purchasing, manufacturing, testing, delivery and commissioning of FWH of any size and any operating temperature and pressure.
We can offer you horizontal or vertical (channel up and channel down) FWH. On top of the regular condensing zone, they might have a de-superheating as well as a sub-cooling area.
Material selection is done carefully considering the operating conditions from the most simple ones, carbon steel, to the most complex ones. Tube sheets can be solid type or cladded, depending the material selection and can be as thick as 500 mm in case of supercritical boilers operating at very high pressure.