Plate heat exchanger in power generation and energy storage

Weather using fossil fuels, waste or biomass fired heating plants or power plants, the thermal tasks are similar regardless of the fuel used. Heat exchangers are used as condensers, condensate sub-cooling, feed water pre-heating and heat extraction. Some distinctions lie in the operating temperatures or the flow rates. In nuclear power plants heat exchangers are also used for cooling of wet storage. Heat exchangers operate as gas and electrolyte coolers for storing renewable energy with electrolysis plants.

The following examples show the experience of GESMEX in these areas:


Steam turbine condenser

The main task of condensers, after steam turbines, is the complete condensation of the vapor from the turbine exhaust. This prevents back pressure, ensuring the maximum performance of the turbine. The condensate is then recycled back into the process.
XPS - Plate & Shell heat exchangers are high performance condensers, with a close temperature approach and compact footprint minimising the water use and structual steelwork. The cylindrical shell design allows large connection at steam inlet and smaller connection at steam outlet.

condenser
Example:
Post-condenser to a steam turbine
Type:
XPS 150
Variant:
countercurrent flow, fully welded
Installation site:
France


Condensate sub-cooling & heat extraction

Sub-cooling the condensate, ensures complete condensation is achieved, even in periods of low heat demand. Cooling can be done via an open re-cooling circuit or via heat recovery, boosting a district heating network or used in industrial applications as process heat.
XPS - Plate & Shell heat exchangers are well suited for sub-cooling duties due to the very compact design and high heat transfer rates. Multi-pass configurations enable long thermal lengths, achieiving very close temperature approaches.

Example:
Condensate cooler in a steam power plant
Type:
Plate & Shell, XPS 100
Variant:
both sides openable
Features:
crossflow, multi-pass by an external bypass circuit
Installation site:
Russia


Feedwater pre-heating

Boiler feed water can be pre-heated in two stages:

  • The feed water is first heated to just below the bubble point before the feedwater dearator.
  • It is then heated further before entering the boiler to minimize the sensible heat required in the boiler.
  • XPS - Plate & Shell heat exchangers are preferably used with steam: low-pressure steam before feedwater dearation, medium or high pressure steam before it enters the boiler.

Example:
Feedwater heater before dearation
Type:
Plate & Shell, XPS 50
Variant:
counter flow, fully welded
Installation site:
Germany


Cooling of cool-down-basins

In the the nuclear industry, heat exchangers cool down water bath where spent fuel elements are stored. The storage usually lasts for several years, until the the fuel elements can be transported.
XPT - Thermo Plate heat exchangers are used as water-cooled immersion coolers. The cooling elements are designed to fit the tanks, and fixed where suitable.
In addition to the usual pressure vessel codes, extensive manufacturing and testing to satisfy the safety regulations of nuclear power plant are met.


Example:
Immersion coolers for wet storage
Type:
XPT Thermoplate
Features:
material, pressure and temperature resistance according to individual project specification
Installation site:
Germany


Gas and electrolyte cooler in electrolysis plants

Gas coolers in hydrogen electrolysis plants cool hydrogen and oxygen obtained by the electrolytic decomposition of water. In particular the hydrogen is used for energy storaging to stabilize the power generation from renewable energy. The electrolyte must be cooled during operation.
XPS - Plate & Shell heat exchangers are used for hydrogen coolers, oxygen coolers, electrolyte coolers and pre-heaters.

Example:
Hydrogen cooler in an electrolysis plant of a hybrid power plant
Type:
Type: Plate & Shell XPS 50
Variant:
crossflow, openable, multi-pass, with service opening
Installation site:
Germany


Heat exchangers in utility systems and for heat recovery

In addition to process-specific tasks, GESMEX plate heat exchangers are also used in numerous auxiliary and utility systems, such as: heating of cleaning solutions, cooling lubricating oil, drying compressed air, jacket cooling ...

GESMEX plate heat exchangers are used for heat recovery from exhaust vapors or flash steam, in sewage systems, for heat recovery or power generation from waste gases ...

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XPS

XPS – Plate & Shell heat exchangers are highly suitable for heat transfer between liquids and gases or for evaporation and condensation duties. The gasket-free and cylindrical design allows operating pressures from full vacuum to 400bar and temperatures ranging from -200 to 500°C.

XPT

XPT – Thermoplate heat exchangers can handle dirty media and show low pressure drop even with high volume flows. The all welded plate-pairs are used from vacuum to 60 bar and from -200 to 800 °C.