International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
"Review Paper on improvement in the efficiency of evaporative condensers & cooling towers “
Aniket Satayanarayan Kadekar
M.Tech. Heat Power Engineering Registration No: 23AHPE2101004
Guide: Dr. Dipak S. Patil. Asst. Prof., G H Raisoni College of Engineering and Management, Wagholi,Pune
Abstract: Evaporativecondensersarecommonlyutilizedin industrialrefrigerationandairconditioningsystems.These systems use the evaporative cooling method, in which refrigerant loses heat as it passes through water-sprayed condensercoils.However,thesecondensersloseheat,water, energy,andhydraulicfluid.Thisprojectintendstoimprove waterqualityincondensersandcoolingtowersbyusingETP water, constructing DM plants, and optimizing the heat exchangeprocessinordertoincreaseoverallefficiencyand savecosts.
Keywords includeevaporativecondenser,coolingtower, waterquality,energyefficiency,DMplant,PHEinstallation, andevaporativelosses.
Key terms include evaporative condenser, cooling tower, waterquality,energyefficiency,DMplant,PHEinstallation, andevaporativelosses.
1. INTRODUCTION
Evaporative condensers are commonly used in industrial refrigerationandairconditioningsystemstorejectheatto the atmosphere by utilizing the principle of evaporative cooling.Insuchsystems,therefrigerantreleasesheatwhile passingthroughthecondensercoils,whicharesprayedwith watertoassistinheatdissipation.Theprocessreliesonthe evaporationofwater,wherepartofthewaterevaporatesas it absorbs heat from the refrigerant, thus enhancing the cooling efficiency. However, despite their efficiency, evaporativecondensersaresubjecttoseveraltypesoflosses thatcanaffectoverallsystemperformance.
• HeatLosses
• WaterLosses
• WaterQualityLosses
• EnergyLosses
• HydraulicLosses
1. Enhancing Efficiency of Vapor Compression Cooling Systems Using Evaporative Condensers
1.1 Study Overview
Thisstudyexploresevaporativecondensertechnologyasa solution to enhance the efficiency of vapor compression
cooling systems. It discusses the fundamentals, operating principles, and theoretical models of evaporative condensers, emphasizing how they improve heat transfer efficiency and reduce power consumption in refrigeration andairconditioningsystems.
1.2 Source
Title: "An Overview of Enhancing the Efficiency of Vapor Compression Cooling Systems by the Implementation of EvaporativeCondensers"
Publishedin:BasrahJournalforEngineeringSciences,Vol. 24,No.1,(2024),69-80
Authors:HaiderMumtazHussain,SalmanHashimHammdi
Institution: Department of Mechanical Engineering, UniversityofBasrah,Iraq
1.3 Objective
Analyze the benefits of evaporative condensers over traditionalair-cooledsystems.
Evaluate energy-saving potential by improving the coefficientofperformance(COP).
Investigate how air and water flow rates, wet bulb temperatures, and heat transfer coefficients influence performance.
Present experimental studies and theoretical models for evaporativecondensertechnology.
1.4 Key Findings
Evaporative condensers significantly improve cooling efficiencybyutilizinglatentheatofevaporationtodissipate heatmoreeffectively.
Energysavings: Powerconsumptionisreducedby15-58%.
COP increases by 14.3-113.4%, depending on the cooling load(0.7to3000kW).
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
Lower environmental impact: Evaporative condensers requirelesselectricity,reducingoverallCO₂emissions.
Challengesinmodelingevaporativecondensers:Theoretical models do not always align with real-world performance, highlightingtheneedforfurtherR&D.
1.5 Conclusion
Evaporative condenser technology enhances cooling efficiency, reduces energy consumption, and lowers environmental impact. However, challenges such as humidity effects, scaling, and accurate performance predictionmodelsmustbeaddressedtomaximizebenefits.
1.6 Final Summary and Recommendations
Evaporativecondensersshouldbewidelyimplemented in high-temperatureregionstoreducecoolingenergycosts.
Moreexperimentalvalidationisneededtorefinetheoretical models.
Further research on anti-scaling treatments and maintenancemethodsisrecommended.
1.7 Key Takeaways from the Study
Evaporativecondensersreducepowerconsumptionbyupto 58%.
COP improvements of over 100% are achievable with optimizeddesigns.
Challenges remain in accurate performance modeling and maintenance.
1.8 Recommendations for Future Research
Developbettermathematicalmodelstopredictevaporative condenserbehaviormoreaccurately.
Study long-term operational effects of evaporative condensersindifferentclimates.
Explore Nano coatings or water treatment solutions to reducescalingandfoulingissues.
2. Performance Optimization of Cooling Towers in Power Plants
2.1 Study Overview
This study examines the performance of a cross-flow induced draft cooling tower used in a 900 TR airconditioning plant. It focuses on water loss, cooling efficiency,andenvironmentalfactorsaffectingcoolingtower performance.
2.2 Source
Title:"PerformanceInvestigationsofaCross-FlowInduced DraftCoolingTowerEmployedinaWater CooledCondenser of900TRA/CPlant"
Published in: International Journal of Scientific & EngineeringResearch,Volume4,Issue12,December-2013
Authors:B.KiranNaikandP.MuthuKumar
Institution:IITGuwahati
2.3 Objective
Investigate water loss and efficiency variation in cooling towers.
Measuretheimpactofenvironmentalconditionsoncooling toweroperation.
Studytherange,approach,andoverallefficiencyofcooling towers.
2.4 Key Findings
Water loss varies between 3.3 to 3.71 liters/hr per TR dependingontemperature.
Coolingtowerefficiencyfluctuatesbetween25%and45% basedonambientconditions.
Peak water loss occurs between 1-2 PM, correlating with higherdrybulbtemperatures.
2.5 Conclusion
The study finds that cooling towers play a crucial role in thermal management, but their efficiency is highly dependent on ambient temperature and humidity. Proper monitoring and maintenance are essential for reducing waterlossandimprovingefficiency.
2.6 Final Summary and Recommendations
Coolingtowerdrifteliminatorsshouldberegularlyinspected tominimizewaterloss.
Advanced water treatment techniques can help reduce scalingandfouling.
Real-timemonitoringofwetbulbtemperatureandhumidity canimproveperformance.
2.7 Key Takeaways from the Study
Evaporative cooling efficiency is highly dependent on climaticconditions.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
Waterlossmanagementisessentialforsustainablecooling toweroperation.
2.8 Recommendations for Future Research
Study automated control systems for cooling tower efficiency.
ExploretheimpactofNanofluidsonevaporativecooling.
Investigatedrifteliminatortechnologyadvancements.
FinalThoughts
This report compiles detailed analyses of five research papersoncoolingtowerefficiency,evaporativecondensers, and thermal power plant cooling systems. The findings highlight key optimization techniques, performance challenges,andrecommendationsforfutureresearch.
3. Water Losses in the CondenserCooling System of a 905 MW Power Unit
3.1 Study Overview
Thisstudyfocusesonwaterlossesincoolingtowersatthe Opole Power Plant in Poland. It examines the evaporative anddriftlossesandevaluateshowreducingcoolingwater flowimpactscondenserefficiencyandoverallpowerplant performance.
Powerplantsrelyoncoolingtowerstodissipateheatfrom turbinecondensers.However,significantwaterlossesoccur due to evaporation and drift, leading to increased water demandandoperationalcosts.Thisstudyinvestigateshow atmosphericconditions,coolingwaterflux,andoperational settingsaffectwaterlossandplantefficiency.
3.2 Source
Title:"WaterLossesintheCondenserCoolingSystematthe 905MWePowerUnit"
Publishedin:EnergiesJournal,2022
Authors:JanuszPospolita,AnnaKuczuk,KatarzynaWidera, Zbigniew Buryn, Robert Cholewa, Andrzej Drajczyk, MirosławPietrucha,RafałSmejda
Institution:OpoleUniversityofTechnology,Poland
ThisresearchwasconductedatOpolePowerPlant,oneof Poland’slargestcoal-firedpowerplants.
3.3 Objective
Themaingoalsofthestudyare: Determinewaterlossesincoolingtowercircuits,focusingon evaporationanddriftlosses.
Assesstheimpactofreducingcoolingwaterflowonturbine efficiencyandcondenserpressure.
Investigate the effect of ambient temperature and wind speedonwaterlosses.
Evaluate how optimized cooling tower operation can improvepowerplantefficiency.
3.4 Key Findings
Evaporativelossistheprimarycauseofcoolingwaterloss, accountingfor80.9%oftotalwaterlosses.
Driftloss(smallwaterdropletscarriedawaybyairflow)was measuredat0.125–0.375%ofcoolingwaterflux,increasing withhigherunitpoweroutputandambienttemperature.
Windeffects:
Wind increases total water loss by up to 23% at 15°C ambienttemperature.
Waterlossvariationsdependoncoolingtowerdesignand operationaladjustments.
Reducingcoolingwaterflowfrom80,000to60,000tonsper hour:
Raisescondenseroutlettemperatureby0.75–1.5°C.
Increasescondenserpressure,reducingturbineefficiency.
3.5 Conclusion
Waterlossesincooling towerssignificantlyimpactpower plant efficiency. Wind conditions, cooling water flow rate, andevaporativeeffectsmustbecarefullymanagedtoreduce water consumption and maintain optimal condenser performance.
3.6 Final Summary and Recommendations
Drifteliminatorsshouldbeoptimizedtoreducewaterloss.
Cooling water flow adjustments should be carefully controlledtopreventexcessivecondenserpressure.
Wind effects on cooling tower losses should be studied furthertooptimizeplantoperations.
3.7 Key Takeaways from the Study
Evaporativelossesarethemainsourceofcoolingwaterloss.
Reducingcoolingwaterflowcanimproveplantefficiencybut mustbecarefullymanaged.
Windconditionssignificantlyinfluencewaterlossrates.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
3.8 Recommendations for Future Research
Studyadvanceddrifteliminatordesignstominimizewater loss.
Develop AI-based cooling tower control systems for optimizingwaterusage.
Investigatehybridcoolingmethodsthatreduceevaporation whilemaintainingefficiency.
4. Performance Analysis of Cooling Towers
4.1 Study Overview
This study examines the performance of mechanical draft cooling towers in thermal power plants. It analyzes how operational parameters, water flow rate,andatmospheric conditions impact cooling tower efficiency, evaporation losses,anddriftlosses.
4.2 Source
Title:"PerformanceAnalysisofCoolingTowers"
Publishedin:InternationalResearchJournalofEngineering andTechnology(IRJET),2022
Institution:Notspecified
Thisstudyprovidesatechnicalevaluationofcoolingtower performance,makingitvaluableforpowerplantoperators andengineers.
4.3 Objective
Evaluate cooling tower efficiency based on cooling range, approach,andL/Gratio.
Analyzetheimpactofevaporationanddriftlossesonwater consumption.
Determine how operational changes can improve cooling efficiency.
4.4 Key Findings
Coolingtowerefficiencywasmeasuredat68.57%,slightly belowitsdesignedefficiencyof70.97%.
Evaporation loss accounted for 369.67 m³/hr, requiring significantmakeupwater.
Driftlosscontributed41.588m³/hrofwaterloss.
Water-to-air mass flow ratio (L/G): Higher ratios led to bettercoolingperformance.
4.5 Conclusion
Coolingtowerperformancedependsonproperwaterflow rates, air distribution, and maintenance. Improving water treatment and optimizing drift eliminators can enhance efficiency.
4.6 Final Summary and Recommendations
Regular maintenance is essential to maintain cooling efficiency.
Watertreatmenttechniquesshouldbeoptimizedtoreduce scalingandfouling.
Drift eliminators should be upgraded to minimize water losses.
4.7 Key Takeaways from the Study
Coolingtowerefficiencyisdirectlylinkedtowaterandair flowcontrol.
Optimizingoperationalparameterscanreducewaterlosses.
Proper maintenance and chemical treatment can extend coolingtowerlifespan.
5. Cooling Tower Performance with Nano fluids
5.1 Study Overview
ThisstudyexplorestheuseofAl₂O₃,ZnO,andTi₂O₃-based Nano fluids in cooling towers to improve heat transfer efficiency.ItevaluateshowNanofluidconcentrationimpacts cooling performance, energy efficiency, and water consumption.
5.2 Source
Title: "Experimental Investigation on Cooling Tower PerformancewithAl₂O₃,ZnO,andTi₂O₃BasedNanofluids"
Publishedin:AIMSMaterialsScience,2024
Institution: Military Institute of Science and Technology, Bangladesh
5.3 Objective
Determine how Nano fluids impact cooling tower performance.
Comparedifferentnanomaterials(Al₂O₃,ZnO,Ti₂O₃).
AnalyzetheeffectsofNanofluidconcentration.
5.4 Key Findings
Nanofluidsincreasedcoolingefficiencybyupto50%.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
Highernanoparticleconcentrationsimprovedheattransfer butalsoincreasedviscosity.
ZnONanofluidsperformedbestathighflowrates.
6.
6.1Source: International Research Journal of Engineering andTechnology(IRJET)
6.2Objective:Toidentifyenergyconservationopportunities in cooling tower operations at Mettur Thermal Power Station(MTPS-I),TamilNadu,India.
6.3Key Findings:
CoolingTowerWorkingPrinciple
Hotwaterfromthecondenserentersacoolingtower,where itissprayedthroughnozzlesandcooledbyaircirculation.
Cooling efficiency depends on wet bulb temperature, dry bulbtemperature,andairflowrate.
EfficiencyImprovementStrategies
Modificationsincoolingtowercasing,fanblades,andblade anglesimprovedairflowandcoolingefficiency.
Replacing motors with energy-efficient models reduced powerconsumption.
Blowdown rate optimization ensured minimal water wastage.
PerformanceCalculation
CoolingWaterRange=Hotwatertemperature-Coldwater temperature Performance Analysis of Cooling Towers at Mettur Thermal Power Station (MTPS-I)
CoolingWaterApproach=ColdwateroutlettemperatureWetbulbtemperature
Efficiency=(Coolingrange)/(Coolingrange+Approach)× 100
6.4Results:
Thecoolingtowerefficiencywasfoundtobe64.1%,lower thanthedesignvalueof70.97%.
ImplementingGIroofsheetsonthehotwaterbasinhelped reducealgaegrowthandincreasedcoolingefficiencyby4%.
6.5Conclusion:
Cooling tower efficiency can be increased with periodic maintenance, optimized airflow, and better insulation techniques.
Energysavingscanbeachievedby reducingdriftloss and optimizingfanspeed.
7. Water Loss in Cooling Towers and Its Impact on Power Plants
Source: EnergiesJournal,2022
7.1Objective: To analyze water losses (evaporation and drift)ina905MWpowerunitinOpolePowerPlant,Poland.
7.2Key Findings:
TypesofWaterLosses
EvaporationLoss:ThePrimarycoolingmechanismincooling towers.
DriftLoss:Lossofwaterdropletscarriedawaybyair.
Blowdown Loss: Water is removed to maintain chemical balance.
FactorsAffectingWaterLoss
Higherambienttemperatureincreasesevaporationloss.
Windincreasesdrift loss by 10-23%dependingon power output.
OptimizationStrategies
Reducingcoolingwaterflowby20%loweredevaporation losswithoutaffectingpoweroutput.
Installing drift eliminators reduced drift loss to 0.1250.375%oftotalwaterflux.
7. Evaporative Condensers in Refrigeration and Air Conditioning Systems
7.1Source: BasrahJournalforEngineeringSciences,2024
7.2Objective: Investigate how evaporative condensers improve energy efficiency in refrigeration and HVAC systems.
KeyFindings
EvaporativeCondenserWorkingPrinciple
Uses water spray and forced airflow to improve heat transfer.
Reducescompressorpowerconsumptionby58%.
CoefficientofPerformance(COP)Improvement
Evaporative cooling increases COP by 113.4% in systems withcoolingcapacitiesfrom0.7kWto3000kW.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
EnergySavingsinHVACSystems
Air-cooledcondensersconsumemorepowercompared to evaporativecondensers.
In high-temperature regions, evaporative condensers improvesystemefficiencyby25-45%.
7.3Conclusion:
Evaporative condensers are highly effective in reducing energy consumption in refrigeration and air-conditioning systems.
They are most beneficial in regions with high ambient temperatures.
8. Performance Investigations
of a Cross-Flow Induced Draft Cooling Tower
8.1Source: InternationalJournalofScientific&Engineering Research
Objective:Evaluatewaterlossandefficiencyofacross-flow induceddraftcoolingtowerusedinanA/Cplantwitha900 TRrefrigerationcapacity.
8.2Key Findings:
WaterLossDuetoEvaporationandDrift
3,564 liters/hour of water evaporated from three cooling towersoverastudyperiodof4months.
Peakwaterlossreached3.71liters/hr-TRat32°CDBTand 30°CWBT.
CoolingTowerEfficiency
Efficiencyvariedbetween25%and45%.
Efficiency improved by reducing inlet water temperature andincreasingaircirculation.
OptimizationStrategies
Usinghigh-efficiencydrifteliminatorsreduceddriftloss.
Increasingfanspeedimprovedcoolingefficiency.
8.3Conclusion:
Cross-flow induced draft cooling towers experience significant water losses but can be optimized for better performance.
Watermanagementstrategies,suchasreducinginletwater temperature,canimproveoverallefficiency.
FinalSummaryandRecommendations
Key
TakeawaysfromtheStudies
Coolingtowerefficiencydependsonfactorssuchaswetbulb temperature,aircirculation,anddriftloss.
Evaporative condensers significantly improve energy efficiencyincoolingsystems.
Driftandevaporationlossesmustbecontrolledtooptimize waterusageinpowerplants.
Proper fan speed adjustments and material modifications improvecoolingtowerperformance.
RecommendationsforFutureResearch
Advancedmaterialsforcoolingtowerfanbladesandcasings toenhancedurability.
Real-time monitoring systems to track water losses and optimizecoolingperformance.
Hybrid cooling systems that integrate evaporative cooling withair-cooledcondensersformaximumefficiency.
Thisreportprovidesadetailedbreakdownofcoolingsystem performanceacrosspowerplantsandrefrigerationsystems, withinsightsintoenergysavings,efficiencyimprovements, andwaterlossreductionstrategies.
9. Cooling Water Use in Thermoelectric Power Generation
9.1 Study Overview
Thisstudyfocusesonthewater-energynexus,whichrefers to the interdependence between water and energy in thermoelectricpowerplants.Itemphasizesthatwaterisa critical resource for power generation, particularly for cooling systems in thermoelectric power plants, which account for a significant portion of global freshwater withdrawals.Thestudyalsohighlightsthechallengesposed by climate change, water scarcity, and increasing energy demands,leadingtoagrowingneedformorewater-efficient coolingtechnologies.
Theresearchexaminesdifferentcoolingsystemtypes,such asonce-through,wetrecirculating,anddrycoolingsystems, and evaluates their efficiency, water consumption, and environmentalimpact.Italsodiscussesstrategieslikeusing alternative water sources (e.g., treated wastewater, seawater, and brackish water) to reduce freshwater dependency.
9.2 Source
Title: "Cooling Water Use in Thermoelectric Power Generation and Its Associated Challenges for Addressing Water-EnergyNexus"
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
Publishedin:Water-EnergyNexusJournal,2018
Authors:Shu-YuanPan,SethW.Snyder,AaronI.Packman, YupoJ.Lin,andPen-ChiChiang.
AffiliatedInstitutions:
National Taiwan University (Environmental Engineering Department).
Idaho National Laboratory (Energy and Transportation Division).
Northwestern University (Department of Civil & EnvironmentalEngineering).
ArgonneNationalLaboratory(EnergySystemsDivision).
The study was published in a peer-reviewed journal, ensuringthattheresearchisbackedbyrigorousscientific methodologyandempiricaldata.
9.3 Objective
Themaingoalofthisstudyistoassessthechallengesand opportunities for improving water efficiency in thermoelectric power plants, particularly in their cooling systems.
Thestudyaimsto:
Identify key challenges in cooling water use in thermoelectricpowerplants.
Analyzedifferenttypesofcoolingsystems,theirefficiency, andwaterconsumptionlevels.
Evaluate alternative water sources that can be used for coolingtoreducefreshwaterdemand.
Explore technological innovations to enhance water conservationandefficiencyincoolingsystems.
Providepolicyandregulatoryrecommendationstoensurea sustainablebalancebetweenwaterandenergyuse.
With the rising global energy demand and increasing concernsoverwaterscarcity,improvingwateruseefficiency in thermoelectric power plants has become a priority for bothpolicymakersandengineers.
9.4 Key Findings
Thestudypresentsseveralimportantfindingsthatcanhelp optimizewateruseinthermoelectricpowerplants.
1.CoolingSystemsareHighlyWater-Intensive
Cooling systems account for a major share of freshwater withdrawalsinthermoelectricpowerplants.
Themostcommoncoolingmethodsinclude:
Once-through cooling: Withdraws large amounts of freshwater, but returns it to the source at a higher temperature,negativelyimpactingaquaticlife.
Wet recirculating cooling: Uses cooling towers to reuse water, reducing withdrawals but increasing water consumption.
Drycooling:Usesairinsteadofwaterforcooling,butisless effectiveinhotclimates.
2.ChallengesintheWater-EnergyNexus
High water dependency makes thermoelectric plants vulnerabletodroughtsandclimatechange.
Zero Liquid Discharge (ZLD) regulations require plants to reduceliquidwaste,increasingoperationalcomplexityand costs.
Energy demands for water treatment add to the overall powerplantinefficiency.
3.StrategiesforWaterEfficiency
Alternativewatersources:
Treated wastewater and brackish water can replace freshwaterforcoolingpurposes.
Seawater cooling is suitable for coastal power plants, but requirescorrosion-resistantmaterials.
Technologicaladvancements:
Hybrid cooling systems balance water conservation and energyefficiency.
Brackish water desalination can provide an alternative coolingwatersource.
9.5 Conclusion
Thestudyconcludesthatwaterefficiencyinthermoelectric power plants must be prioritized to reduce freshwater dependency and increase energy security. Regulatory policies should support the transition to hybrid cooling technologiesandalternativewatersources.
Furthermore, improving water use efficiency in cooling systems can help achieve the United Nations Sustainable Development Goals (SDGs) related to clean water and sustainableenergy.
9.6 Final Summary and Recommendations
Thermoelectric power plants must transition to hybrid or drycoolingtoreducewaterstress.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
Impairedwatersources(suchastreatedwastewater)should bewidelyadopted.
Real-time monitoring systems should be implemented to optimizewaterusage.
Researchfundingshould be allocatedfordevelopingcosteffectivedesalinationtechnologiesforcooling.
9.7 Key Takeaways from the Study
Thermoelectricplantsareoneofthelargestconsumers of freshwaterworldwide.
The choice of cooling technology greatly impacts water efficiencyandenvironmentalsustainability.
Usingalternativewatersourcescansignificantlyreducethe strainonfreshwaterresources.
9.8 Recommendations for Future Research
Develop AI-based predictive models for water use optimization.
Study new materials for corrosion resistance in seawater coolingsystems.
Investigatelow-energydesalinationmethodsforsustainable powerplantcooling.
10. Analysis on Performance of Condenser in Thermal Power Plants10.1 Study Overview
This study examines the performance of condensers in thermal power plants, highlighting their crucial role in improving overall plant efficiency. Condensers are responsibleforconvertingsteambackintowaterafterithas been used to generate electricity in turbines. Efficient condensation allows the power cycle to operate at low pressure, which increases the amount of work extracted fromthesteamandimprovesplantefficiency.
The study explores various types of condensers, analyzes factors affecting their efficiency, and suggests ways to optimize their performance. Poor condenser performance leadstohigherfuelconsumption,increasedoperatingcosts, andreducedpowergenerationefficiency.
10.2 Source
Title: "Analysis on Performance of Condenser in Thermal PowerPlant"
Publishedin:InternationalJournalofEngineeringResearch &Technology(IJERT),2017
Authors: J. Dixon Jim Joseph, K. Rajan Chakravarthi, M. Sarathkumar,V.SharanRaghul,M.VijayKumar.
Institution:HindusthanInstituteofTechnology,Coimbatore, India.
This research is highly relevant to thermal power plant engineers, policymakers, and researchers focused on improvingenergyefficiencyinpowergeneration.
10.3 Objective
Thestudyaimsto:
Analyze the role of condensers in thermal power plant operations.
Identify factors affecting condenser efficiency, such as coolingwaterflowrate,pressure,andtemperature.
Examinedifferenttypesofcondensers,theiradvantagesand disadvantages.
Suggestimprovementsincondenseroperationtooptimize powerplantperformance.
By understanding how condenser performance impacts plant efficiency, engineers can make better design and operational decisions to maximize energy output while minimizingwasteandcosts.
10.4 Key Findings
Theresearchprovidesvaluableinsightsintohowdifferent parametersaffectcondenserperformance.
1.TheRoleofCondensersinPowerPlants
Condensers increase efficiency by maintaining low exit pressureinturbines.
Theconversionofsteamintowaterallowsittobereusedin theboiler,reducingwaterwaste.
2.FactorsAffectingCondenserPerformance
CoolingWaterFlowRate:
Iftheflowrateistoolow,heatremovalisinefficient,leading tohighercondenserpressureandreducedefficiency.
Anoptimumflowrateensuresmaximumheattransferand maintainsastablevacuuminthecondenser.
CondenserPressure:
Lowerpressureimprovesefficiencybecauseitextractsmore workfromsteambeforecondensation.
However, excessively low pressure can cause air leakage, reducingperformance.
CoolingWaterTemperature:
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
Higher inlet temperatures reduce heat transfer efficiency, leading to higher backpressure in the turbine and lower poweroutput.
Keepingthecoolingwaterascoldaspossiblemaximizesheat rejection.
3.TypesofCondensersUsedinThermalPowerPlants
JetCondenser:
Steamandcoolingwatermixdirectly,leadingtohighheat transferefficiency.
However, the condensate is not reusable, making it less sustainable.
Examples: Low-level counter flow, barometric, ejector condensers.
SurfaceCondenser:
Steamandcoolingwaterdonotmix,sothecondensatecan bereused.
Requiresmorespaceandhigherinitialcosts,butimproves overallplantefficiency.
Examples:Downflow,centralflow,evaporativecondensers.
4.ImpactofPoorCondenserPerformanceonPowerPlants
Inefficient condensers lead to a 2.7% reduction in overall plantefficiency.
Increased fuel consumption to compensate for lost efficiency.
Higheroperatingandmaintenancecostsduetoscalebuildup andfouling.
10.5 Conclusion
The study concludes that regular monitoring and optimization of condenser parameters can significantly improve the performance of a thermal power plant. Controllingfactorslikecoolingwatertemperature,pressure, and flow rate ensures that the plant runs at maximum efficiencywithminimumenergywaste.
Switching to surface condensers and implementing better coolingstrategiescanenhanceenergyefficiencyandreduce operationalcostsoverthelongterm.
10.6 Final Summary and Recommendations
Optimizecoolingwaterflowratetomaintainefficientheat transfer.
Usereal-timemonitoringtodetectfouling,scaleformation, andblockages.
Regular maintenance of condenser tubes to prevent corrosionandbiofouling.
Install advanced surface condensers to allow for reuse of condensedsteam,improvingsustainability.
10.7 Key Takeaways from the Study
Coolingwaterflowrateandpressuredirectlyimpactpower plantefficiency.
Surfacecondensersaremoreefficientthanjetcondensersin large-scalethermalpowerplants.
Scaling, fouling, and corrosion reduce condenser performance,requiringfrequentmaintenance.
10.8 Recommendations for Future Research
DevelopAI-basedmonitoringsystemstopredictcondenser faultsbeforetheyoccur.
Explore new materials for condenser tubes that resist corrosionandfouling.
Investigate alternative cooling methods, such as hybrid coolingorair-basedcoolingsystems.
11. Evaporative Condenser Control in Industrial Refrigeration Systems
11.1 Study Overview
This study focuses on evaporative condensers used in industrialrefrigerationsystems.Itexploreshowautomated control strategies can enhance energy efficiency, reduce operational costs, and improve refrigeration system performance.
Evaporative condensers play a crucial role in large-scale coolingapplications,suchasfoodprocessing,coldstorage, andairconditioninginlargebuildings.Propercontroland monitoring of these condensers can lead to significant energysavingsandlongerequipmentlife.
11.2 Source
Title: "Evaporative Condenser Control in Industrial RefrigerationSystems"
Publishedin:InternationalJournalofRefrigeration,2001
Authors:DouglasT.Reindl,S.A.Klein.
Institution:UniversityofWisconsin–Madison.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
11.3 Objective
Improve evaporative condenser control to enhance efficiency.
Reduce energy consumption through smart control strategies.
Analyzetheimpactoftemperatureandpressurefluctuations oncondenserperformance.
11.4 Key Findings
Evaporative condensers offer high energy efficiency but requireprecisecontroltooptimizeperformance.
Automatedcontrolsystemsadjustfanspeed,waterflow,and refrigerantpressuretominimizeenergyuse.
Real-timemonitoringhelpsdetectissuesbeforetheyaffect systemefficiency.
11.5 Conclusion
Usingautomatedcondensercontrolimprovesefficiencyand reducesoperationalcosts.Implementingsmartmonitoring systems ensures stable performance and minimizes maintenancerequirements.
11.6 Final Summary and Recommendations
Use automation and real-time monitoring to optimize evaporativecondenserperformance.
Adjustfanandpumpspeedstoreduceenergywaste.
Implement AI-driven predictive maintenance to minimize downtime.
11.7 Key Takeaways
Automated control significantly improves condenser efficiency.
Real-timemonitoringpreventsperformanceissues.
11.8 Recommendations for Future Research
Explore AI-based predictive control for industrial refrigerationsystems.
Studyalternativerefrigerantsforbetterenergyefficiency.
3. CONCLUSIONS:
Byoptimizingwatertreatmentandimprovingcoolingtower operations,evaporationlossesandenergyconsumptioncan besignificantlyreduced.TheimplementationofDMplants and PHE installations has demonstrated efficiency improvements, cost savings, and extended equipment
lifespan. Future research should explore advanced automationtechniquesforreal-timemonitoringandcontrol.
ACKNOWLEDGEMENT
TheauthorextendsgratitudetoBritanniaIndustriesLimited fortheirsupportandguidancethroughoutthisresearch.
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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
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https://www.sciencedirect.com/science/article/abs/pii/S0 140700700000840
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