The materials for condenser tubing

Condensation is one of the pivotal parts of a turbine generator set. A condenser converts a gas or vapor into a liquid and quickly transfers heat out of the tube. Its performance directly affects the operation of the unit. The condenser operates in a high-temperature environment which is essentially an exothermic process. As the main heat transfer component of the condenser, the cooling tube is the most important part of the condenser, making the selection of the cooling pipe crucial to the condenser's design. Common materials for condenser tubing include carbon steel, brass, cupronickel, titanium, and stainless steel. Today, we will delve into the details of these materials while integrating some recent findings relevant to our field.

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Carbon steel tubing

The ASTM A179 Seamless steel tube remains a primary material for tubular heat exchangers, condensers, and other heat transfer services, particularly for the shell of tubular and box condensers. However, the welding seam between carbon steel tube plates and tubes frequently suffers from corrosion and leaks, leading to system failures and environmental issues. Recent investigations have highlighted emerging corrosion-resistant coatings that could significantly prolong the lifespan of carbon steel tubing used in condenser systems.

Brass tube

Cu-Zn alloy brass tubes, recognized for their excellent heat transfer performance and good corrosion resistance, are still a popular choice. Though they resist scaling compared to stainless steel tubes, they are vulnerable to corrosion in high-salt environments. Recent studies focus on alternative materials that can replace brass in applications susceptible to aggressive liquids, aiming for cost-effective solutions that ensure longevity and performance.

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Cupronickel tubing

Cu-Ni cupronickel offers enhanced chemical stability over brass and demonstrates no tendency for selective corrosion. Its effective corrosion resistance stems from a nanoscale surface film that is compact and stable. In recent months, advancements in manufacturing techniques have improved the availability of cupronickel tubing, making it more accessible for applications requiring stable water quality.

Titanium tube

Titanium has emerged as a leading material for cooling pipes due to its remarkable corrosion resistance in various water types. Titanium condenser pipes exhibit significant resilience against general pitting and crevice corrosion. However, recent industry reports reveal that the majority of titanium failures stem from mechanical damage rather than environmental factors, emphasizing the need for careful installation and maintenance practices in facilities using titanium materials.

Stainless steel pipe

Stainless steel tubes have gained traction due to their commendable mechanical properties, corrosion resistance, and cost-effectiveness, positioning them as a favorable option for condenser tubes. Austenitic stainless steel types like AISI 304, 304L, 316, and 316L are frequently employed. New data suggests that the overall heat transfer coefficient of stainless steel wave-welded pipes can outperform traditional copper pipes significantly. Moreover, evolving metallurgical processes enhance the durability against corrosion even in challenging environments.

• Thin-walled stainless steel welded pipes are much cheaper than copper and titanium pipes.
• High strength and hardness. Stainless steel tubes surpass copper and titanium in terms of strength, which significantly mitigates the erosive effects encountered in high-speed steam applications.
• The elastic modulus is higher than that of copper and titanium, which contributes to enhanced structural stability.
• Stainless steel exhibits superior corrosion resistance compared to copper in environments susceptible to ammonia, further solidifying its position as an excellent choice for condenser applications.
• Innovative compositions, such as adding Mo to stainless steel, improve crevice corrosion and pitting resistance, demonstrating the ongoing evolution of materials used in condenser tubing.

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