Steam Condenser: Types,

Working, Advantages and

Disadvantages,
Calculations
Dr DRE Ewim

daniele@dut.ac.za
1.0 Steam Condenser

A steam condenser is a closed vessel in which steam is condensed by abstracting the heat
by cooling it with water and where the pressure is maintained below atmospheric pressure.
During the condensation process, steam gives heat energy to the coolant (which is typically
water). There are also air-cooled condensers. The condensed steam is known as
condensate. The efficiency of the steam power plant is increased by the use of a condenser.
The steam condenser is an essential component of all modern steam power plants.

1.1. Objectives of the Steam Condenser

A steam condenser has the following two objectives:

I. The primary objective is to maintain a low pressure (below atmospheric pressure) to

obtain the maximum possible energy from steam and thus to secure a high efficiency.
II. The secondary objective is to supply pure feed water to the hot well, from where it is
pumped back to the boiler.

1.2. Working of Steam Condenser

The steam condenser receives exhaust steam from one end and gets in contact with the
cooling water flowed within it form the cooling tower.

As the low-pressure steam meets the cooling water, it condenses and turns into water. It is
attached to the air extraction pump and condensation extraction pump. After condensation of
steam, the condensate is pumped into the hot well by the help of condensate extraction pump.

The air extraction pump extracts air from the condenser and produces a vacuum inside it.
The vacuum produced helps in the circulation of cooling water and the flow of condensate
downstream.

1.3. Advantages of Steam Condenser

The main advantages of incorporating a steam condenser in a steam power plant

are as follows:

I. Increases the efficiency of the power plant due to increased enthalpy drop.
II. It reduces back pressure of the steam which results in more work output.
III. It reduces temperature of the exhaust steam which also results in more work output.

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IV. The condensed steam can be reused as feed water for boiler which reduces the cost
of power generation.

V. The temperature of the condensate is higher than that of the fresh water which
reduces the heat supplied per kg of steam produced.

1.4. Elements of a Condensing Plant

The essential elements of a steam condensing plant are as shown in the figure. It includes:

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The main elements of a steam condensing plants are:

✓ A condenser in which the exhaust steam is condensed.

✓ Supply of cooling water for condensing exhaust steam
✓ A pump to circulate the cooling water in case of a surface condenser.
✓ A pump called the wet air pump to remove the condensed steam (condensate) the
air, and uncondensed water vapour and gases from the condenser (separate pump
may be used to remove air and condensed steam).
✓ A hot well where the condensed steam can be discharged and from which the boiler
feed water is taken.
✓ An arrangement (cooling pond or cooling tower) for cooling the circulation water
when a surface condenser is used, and the supply of water is limited.

I. Condensate Pump
It is a pump, which removes condensate (i.e., condensed steam) from a condenser
to a hot well.
Hot Well
It is a pump between the condenser and boiler, which receives condensate pumped
by the condensate pump.
II. Boiler Feed Pump
Boiler feed pump pumps the condensate from a hot well to a boiler. This is done by
increasing the condensate pressure above the boiler pressure.
III. Air Extraction Pump
Air extraction pump is a pump which extracts (i.e., removes) air from the condenser.
IV. Cooling Tower
The cooling tower is a tower employed for cooling the water which is discharged
from the condenser.
V. Cooling Water Pump
The cooling water pump is a pump, which circulates the cooling water through the
condenser.

2.0. Types of Steam Condenser

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 Picture of a Steam Condenser

1. Jet condensers (mixing type condensers)

1. Parallel flow jet condenser
2. Counterflow or Low-level jet condenser
3. Barometric or High-level jet condenser
4. Ejector Condenser

2. Surface condensers (non-mixing type condensers)

1. Downflow surface condenser
2. Central flow condenser
3. Regenerative condenser
4. Evaporative condenser

1. Jet Condensers

In jet condensers, there is direct contact between the cooling water and the steam that is to
be condensed. Steam escapes with the cooling water and the recovery of the condensate for
re-use, as boiler feed water is not possible.

Types of Jet Condensers

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 1. Parallel flow jet condenser
2. Counterflow or Low-level jet condenser
3. Barometric or High-level jet condenser
4. Ejector Condenser

(a) Parallel Flow Jet Condensers

In parallel flow jet condensers, both the steam and water enter at the top and the mixture is
removed from the bottom.

The principle of this condenser is shown in the figure. The exhaust steam mixes up with the
water and condensed. Condensate, cooling water and airflow downwards and are removed
by two separate pumps known as an air pump and condensate pump. The condensate pump
carries the condensate to the hot well.

(b) Low-level Jet Condenser or Counter Flow Jet Condenser

A low-level or counter-flow jet condenser is shown in the figure. In these types of steam
condenser, the cooling water enters at the top and sprayed through jets. The steam enters at

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the bottom and mixes with the fine spray of cooling water. A separate pump removes the
condensate.

The air is removed by an air pump separately from the top. In a parallel flow type of this
condenser, the cooling water and steam to be condensed move in the same direction. (i.e.
from top to bottom).

(c) High-level Jet Condenser (or) Barometric Jet Condenser

A high-level jet condenser is shown in the figure. This is similar to the low-level condenser,
except the condenser shell is placed at a height of 10.36 m (barometric height) above the hot
well. In this condenser, the cooling water enters at the top and sprayed through jets.

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The steam enters the bottom and mixes with the fine spray of cooling water. The column of
water in the tailpipe forces the condensate into the hot well by gravity.

(d) Ejector Condenser

An ejector condenser is shown in the figure. In this condenser, cooling water under ahead of
5 to 6 m. enters at the top of the condenser and it is passed through a series of convergent
nozzles. There is a pressure drop at the throat of the nozzle.

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The reduction in pressure draws exhaust steam into the nozzle through a non-return valve.
Steam is mixed with water and condensed. In the converging cones, pressure energy is partly
converted into kinetic energy. In diverging cones, the kinetic energy is partly converted into
pressure energy. The pressure obtained is higher than atmospheric pressure and this forces
the condensate to the hot well.

2. Surface Condensers

In surface condensers, there is no direct contact between the cooling water and the steam
that is to be condensed. The heat transfer between steam and cooling water is by conduction
and convection. The condensate can be recovered for re-use as feed water.

Types of Surface Condenser

1. Downflow surface condenser

2. Central flow condenser
3. Regenerative condenser
4. Evaporative condenser

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(a) Downflow Surface Condenser (Two-pass surface condenser)

The figure shows a two-pass downflow surface condenser. This arrangement is compact, and
the heat exchange is more efficient. The surface condenser has a great advantage over the
jet condensers, as the condensate does not mix up with the cooling water.

As a result of this, the whole condensate can be reused in the boiler. This type of steam
condenser can be used when the supply of cooling water is limited. It consists of a horizontal
cast-iron cylindrical vessel packed with tubes, through which the cooling water flows.

The ends of the condenser are cut off by vertical perforated type plates into which, the water
tubes are attached. The condensate extraction pump, which is located at the bottom, creates
suction. The exhaust steam enters from the top and flows over a nest of tubes.

The cooling water enters at the bottom tubes and leaves through the upper half of the tubes.
A section of tubes is screened by providing a baffle. This reduces the amount of water vapour
escaping with air.

(b) Central Flow Condenser

In the central flow condenser, steam enters the top of the condenser and flows downward.
In this suction pipe of the air extraction pump at the centre of the tube nest.

Due to this placement of the suction pipe at the centre of the tube nest, and the exhaust
steam passes radially inside over the tubes towards the suction pipe. The condensate is
collected at the bottom of the condenser and pumped into the hot well.

(c) Regenerative Condenser

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In the regenerative surface condenser, the condensate is heated using the regenerative
method. In it, the condensation passes through the exhaust steam emitted from the turbine
or engine. It raises its temperature and is utilised as feedwater for boilers.

(d) Evaporative condenser

Evaporative condenser is another type of surface condenser. When the supply of cooling water
is limited, evaporating the circulating water under small partial pressure can reduce its
quantity required for condensing the steam. This principle is employed in evaporative
condensers.

The exhaust steam from the steam engine or steam turbine enters at the top of a series of
pipes outside of which a film of cold water is falling. At the same time, a stream of air rotates
above the water film, causing rapid evaporation of some of the cooled water.

As a result of this, the steam circulating inside the pipe is condensed. The coolant pump draws
water from a cooling pond and forces it to a horizontal header. The header is provided with
several spray nozzles. Hence the cooling water is sprayed over the finned pipes.

A portion of cooling water is evaporated as it flows over the finned tubes by taking its latent
heat from the steam. The remaining water drips back to the cooling pond.

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3.0. Advantages and disadvantages of jet condensers:

Advantages

1. Intimate mixing of steam and cooling water.

2. Quantity of cooling water required is less.
3. Simple equipment and cost are low.
4. Less space is required.
5. The cooling water pump is not needed in the low-level jet condenser. Condensate
extraction pump is not needed for high level and ejector condensers.

Disadvantages

1. Condensate is wasted.
2. The cooling water should be clean and free from harmful impurities,
3. In low-level jet condensers, the engine may remain flooded, if condensate extraction
pump fails.

Advantages and disadvantages of surface condensers

Advantages

1. The maximum vacuum can be attained, and it gives the highest thermal efficiency.
2. Any type of cooling water can be used.
3. Water supply is not affected by a drop in vacuum.
4. The condensate can be reused in the boiler for raising steam.

Disadvantages

1. It is heavier in construction.
2. It requires more space for its erection.
3. Capital running and maintenance costs are considerably higher.

3.1. Comparison of jet and surface condenser

Jet Condenser Surface Condenser

1. Cooling water and steam mixed up Cooling water and steam are not mixed up
2. It is less suitable for high-capacity plants It is more suitable for high-capacity plants
3. Condensation is wasted Condensate is reused
It requires less quantity of circulating It requires a large quantity of circulating
4.
water water
The condensing plant is economical and The condensing plant is costly and
5.
simple complicated
6. Maintenance cost is low Maintenance cost is high
7. More power is required for air pump Less power is required for air pump

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8. High power is required for water pumping Low power is required for water pumping

4.0. Sources of Air in the Condenser:

The sources of air in the condenser are as follows:

1. Leakage through packing glands and microscopic holes in shell joints since the pressure
inside the condenser is less than the atmospheric pressure.

2. Leakage through relief valves and other accessories.

3. Feed water contains dissolved air, which is liberated in the boiler during steam formation
the exhaust steam from the steam engine carries air.

4. In case of jet condenser some air comes in with the injection/cooling water (in which it is
dissolved).

The condenser has a high vacuum. The air always moves from higher pressure to the lower
pressure and the pressure in the condenser is very low (high vacuum) therefore, air leakage
occurs in the condenser. The main sources of air leakage in condensers are stated below:

• Air leakage through Joints.

• Air dissolved in Feed Water.
• Air dissolved with injection water to condenser (in case of Jet condensers)

Air leakage through Joints

Now, let us understand each point in detail. Air leakage can take place through various joints,
packing and glands due to the high vacuum in the condenser. We can prevent this by using
vacuum joints and keeping all the joints tight and sealed.

Air dissolved in Feedwater

When air dissolved feedwater enters the boiler and after the conversion of feedwater into
steam, it enters the condenser along with the exhaust steam which causes air leakage in the
condenser. We can prevent this by treating the feedwater before entering the boiler.

4.1. Effects of air leakage on steam condenser

Following are the effects of air, leakage in condenser on its performance:

1. Back pressure in the steam power plant increases and corresponding work output
decreases and the very purpose of using the condenser is defeated.

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2. Due to poor thermal conductivity of air, rate of heat transfer is low therefore more cooling
water is required to be supplied.

3. For maintaining the required vacuum, the air pump is to be provided.

5.0. Condenser Vacuum:

The vacuum in the condenser is usually expressed in mm of Hg. The absolute pressure in the
condenser is equal to the difference of barometric pressure and the vacuum pressure as shown
in Fig. 21.10.

6.0. Dalton’s Law of Partial Pressure

This law states that “Total pressure exerted by mixture of gases or mixture of gas (air) and
vapour (steam) is equal to the sum of partial pressure of constituents, if they would occupy
the same volume and are at the same temperature”.

∴ Pressure of mixture in condenser = Partial pressure of steam + Partial pressure of air.

P c = Ps + Pa

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If the condenser temperature is known, Ps is found from steam tables and Pc can be read
from the vacuum gauge.

∴ We can write, Pa = Pc – Ps

Knowing the partial pressure of air Pa its mass ma can now be calculated with the help of
ideal gas equation PaVc = maRTa where Vc = volume of condenser; Ta = temperature; R =
characteristic gas constant of air.

Also note that – Each constituent is considered to occupy condenser volume Vc.

7.0. Vacuum Efficiency of Condenser:

It may be defined as the ratio of actual vacuum as recorded by the vacuum gauge to the
ideal vacuum.

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8.0. Condenser Efficiency:

There is no standard method of determining the condenser efficiency, but a method adopted
by the well-known makers of steam turbine M/s Parson & Co. has been widely used in
engineering practice.

9.0. Cooling Water Requirements for Condenser:

In a condenser, cooling water absorbs heat from steam to be condensed and the
temperature of cooling water increases. In jet condensers steam to be condensed directly
mixes with cooling water and hence temperature of condensate and cooling water are same.

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10.0. Capacity of Air Extraction Pumps Used in Condenser:

We know that absolute pressure in the condenser.

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11. Function of Cooling Towers in Condenser:

The function of the cooling tower is to cool the cooling water of the condenser, by the
current of air flowing in the opposite direction.

A large amount of cooling water is required for condensation in large capacity power plants.
If the water is freely available either from the river or lake, then the water can be directly
pumped from the river to the condenser as shown in Fig. 21.13 (a).

If the water is not freely available, then a cooling tower has to be used for cooling the hot
water of condenser. The cooled water can be used again as cooling water for the condenser.

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Figure 21.13 (b) shows the hyperbolic cooling tower. It is usually made of steel Reinforced
cement concrete. The hot water from the condenser is supplied to the ring troughs which
are placed at 8-10 m above the ground level. The nozzles are provided on the bottom side
of troughs to break up water into sprays.

The air rises up from the pond in the opposite direction of water flow and absorbs heat from
the falling water spray. The cooled water is collected into a pond built below the tower. This
type of cooling tower is generally used since it is very efficient, however, it needs about 3-5
% of makeup water for compensating the evaporation losses.

The other types of cooling towers are:

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(i) Natural Draught Towers:

In this type the circulation of air is obtained by virtue of pressure difference of the air inside
and outside the tower. Here no fan is required.

(ii) Forced Draught Tower:

In this case, the circulation of air is obtained by means of fans provided at the bottom of the
tower.

(iii) Induced Draught Tower:

In this case, the circulation of air is obtained by providing a fan at the top of the tower.

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 BASIC CALCULATIONS

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Example 6

A condenser receives 1000 kg/h of wet steam, 0.95 dry and at 38 °C. Air leaks into the
condenser at the rate of 10 kg/h. Calculate the condenser pressure. This air is pumped out
and carries with it a quantity of saturated steam. Calculate the mass flow rate of steam
extracted, taking a condensate temperature of 32 °C. What is the volume flow rate of the air-
steam mixture? Note that the condenser pressure is kept constant by the air pump

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(0.06628 bar, 15.8 kg/h, 467 m3/h)

Example 7

In a condenser test, the following observations were made: vacuum = 715 mm Hg, barometer
reading = 765 mm Hg, mean temperature of condensation = 34 °C, hot well temperature =
29°C, inlet temperature of cooling water = 15 °C, outlet temperature of cooling water = 25
°C Determine: (a) vacuum corrected to standard barometer at 760 mm, (b) undercooling
efficiency, (c) undercooling of condensate, (d) condenser efficiency

1. Vacuum corrected = 710 mm of Hg

2. Vacuum Efficiency = 98.61%
3.Undercooling = 9.0935℃
4. Condenser Efficiency = 50%

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Example 8

The following observations refer to a surface condenser mean temperature of condensation

is 34.6 °C condenser vacuum is 70 cm of Hg barometer pressure is 76cm of Hg mass of cooling
water is 45450 kg/hr inlet temperature is 16.92 °C outlet temperature is 30.9 °C mass of
condensate per hour is 1178.45kg/hr. Determine amount of air present per m3 of condenser
volume and the dryness fraction of steam entering the condenser.

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Example 9

Calculate the vacuum efficiency of a condenser from the following data, vacuum at steam
inlet to condenser=725mm, barometer=760mm, hot well temperature=26.4°c

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Example 10

An industrial condenser uses river water to condense steam at 50 kg/s from saturated vapor
to saturated liquid at 10 kPa. Several hundred meters upstream from the plant, the river has
a flow rate of 50 m3/s and a temperature of 15 °C. Neglecting changes in potential and
kinetic energy, for steady state operation, what is the temperature rise of the river water
downstream of the plant traceable to use of this condenser? condenser river Considering a
different control volume, what is the heat transfer rate between the two condenser fluids?

Simple concept has been used that heat rejected by the condensate is absorbed by
river water. Value of saturated steam enthalpy and saturated liquid enthalpy and
specific volume and specific heat has been taken from steam table which may vary
according to steam table you are going to choose so please tolerate some variation
in answer and focus more on concept.

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Example 11

Exhaust steam from a turbine developing 3 MW enters a surface condenser with a dryness
fraction of 0.9. The condenser vacuum is 90 kN/m2 when the reading of the barometer is 100
kN/m2 . The inlet temperature of the cooling water is 18 C and it leaves the condenser at a
temperature of 39 C. The volume of air entering the condenser with steam is 0.28 m3 /s and
its temperature is 38 C. Given that 3.7 kg of steam/MJ enters the condenser estimate the
quantity of cooling water required and the rate of air leakage into the condenser in kg/h

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QUESTION 12

A surface condenser receives steam at a rate of 100 kg per minute. The vacuum
reading is 670 mmHg and the barometer reading is 760 mmHg. The air pump
temperature is 38 °C and the condensate temperature is 42.7 °C. The cooling water

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enters at 21,1 °C and leaves at 40 °C. The gas constant is 287 J/kg.K and the
specific heat capacity of water is 4,187 kJ/kg °C. Calculate the following:

i. The absolute pressure of the steam in the condenser

ii. The amount of cooling water required in kg per second
iii. The mass of air in kg in the condenser if the capacity is 2 m3
iv. The mass of air in kg if the capacity is increased by 0,5 m3
v. By how many kilograms has the mass of air increased due to the rise in the
capacity of air

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UNSOLVED PROBLEMS

QUESTION 13

The barometer and manometer readings of a surface condenser are 755 mmHg and 650
mmHg respectively. The condenser receives 200 kg of steam per minute and is 10% wet. The
inlet temperature of the cooling water is 15 °C and the outlet temperature is 23 °C. The
condensate leaves the condenser at a temperature of 45.8 °C. Take specific heat capacity of
water as 4.187 kJ/kg.K. Calculate the following:

i. The absolute pressure.

ii. The mass of cooling water.
iii. The logarithmic temperature difference.

Answer:

QUESTION 14

Steam enters the condenser of a steam power plant at 20 kPa and quality of 95 percent with
a mass flow rate of 20 000 kg/h. It is to be cooled by water from a nearby river by circulating
the water through the tubes within the condenser. To prevent thermal pollution, the river
water is not allowed to experience a temperature rise above 10 °C. If the steam is to leave
the condenser as saturated liquid at 20 kPa, determine the mass flow rate of the cooling tower
required. Answer:297.7 kg/s

QUESTION 15

Steam is to be condensed in the condenser of a steam power plant at a temperature of 50°C

with cooling water from a nearby lake, which enters the tubes of the condenser at 18 °C at a
rate of 101 kg/s and leaves at 27 °C. Determine the rate of condensation of the steam in the
condenser. Answer: 1.60 kg/s

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