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8/3/2019 Dry Cooling Tower
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Air Cooled Condensor/adp 1
PLEASE REMEMBER
Only 2.5 % of the world’s water is fresh water.
And a tiny fraction (0.007%) of all water on earth
is accessible for direct human uses.
Wet Condenser cooling for 1000 MW plant
requires 3000 M3/ Hr water,which can feed Rural Population of ONE
Million.
WHY WATER CONSERVATION ?
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Air Cooled Condensor/adp 2
Please Ponder
Power generators will benefit by water conservation
as local & regional supplies will last longer.
So future plant operation will be guaranteed.
Accelerated approval of construction permit.
Shortened project schedule.(No large barrage &
Pipelines or canals for raw water )Better economics and Siting options.
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Air Cooled Condensor/adp 3
WATER WILL BE SCARCE & COSTLY
As water will become scares & costlier,TPS may be
compelled to go for RETROFIT dry cooling towers.
This will be an avoidable extra cost.
Dry cooling worldwide has grown 20 times in last 5years.
China already has 30,000 MW Dry cooling installations.
As per National Policy , USA is adopting Dry Cooling
Systems even for Non-Arid Regions.
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Air Cooled Condensor/adp 4
V I D A R B H AJust think about 35000 – 40000 MW upcoming
Thermal Projects in Vidarbha.
H.C.S.D. system for ash disposal and
Dry Cooling can ensure water supply forDRINKING AND IRRIGATION
in this dry area.
The State can have POWER and save preciouswater for Drinking & Irrigation.
Water pollution will greatly reduce.
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Air Cooled Condensor/adp 5
Water needs of a Thermal Power Station
A 210 MW TPS needs water for-
1. Boiler water make-up (D.M. Water-25 M3 / Hr)
2. Drinking Water ( 5.0 M3 / Hr)
3. Water for Wet Ash Handling – (750 M3 / Hr)
4. Cooling Tower water Make-up – ( 650 M3 / Hr)
5. Service Water – ( 10 M3 / Hr)
6. Total = 1440 M / Hr.
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Air Cooled Condensor/adp 6
Air Cooled Condensor
A T.P.S. needs large quantity of Cooling Water.
Recently, during last summer(2010), six units of Chandrapur TPS were shut down due to water shortage.
Also, water is getting costlier and scarce.
An air cooled condenser overcomes these limitations.Site restrictions are also overcome.
No expenditure on chemicals for water treatment.
Life time cost of a dry cooling tower is surely less than
conventional evaporative cooling tower.
Dry cooling tower cost may be 2.5 times that of a
conventional evaporative cooling tower.
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Air Cooled Condensor/adp 7
H.C.S.D. FOR WATER CONSERVATION
Typical lean slurry disposal has slurry
concentration of 15-20 % only.(20% ash in slurry).i.e. 100 M.T. of ash needs 400 M3 of Water.
But High Concentration Slurry Disposal system
need only 65-70 M3 of Water for 100 MT ash.
A reduction of 330 M3 of water consumption for
100 MT of Ash.
MORE THAN 80% SAVING OF WATER.
HCSD system is running successfully at
Khaperkheda TPS for last 11 years.
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Air Cooled Condensor/adp 8
COOLING TOWER MAKE-UP
Conventional Cooling Tower cools the water byEvaporative Cooling.
Hourly evaporation = Hourly steam flow to condenser.
In addition, there are 2-3 % drift loss and
Blow down loss to maintain water quality.
The DRY AIR COOLING eliminates this water
consumption almost totally.
The make up reduces by 95 % or more.
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Air Cooled Condensor/adp 9
Forced Draft Dry C.T.
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Air Cooled Condensor/adp 10
Site selection and water clearances
The pragmatic developer may select dry cooling early in
a project because,
It increases plant siting options and,
Its use can significantly accelerate approval of
construction permits,
Because water use issues are taken off the table.
Shortening a project schedule by even six months can
completely change the economics of a project and,Easily balance the increased capital cost of dry cooling
options
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Air Cooled Condensor/adp 11
Examples of EXTRA COST
1. Parli TPS – Huge barrage on Godavari and two
stage pumping of water. Reservoir at Naikotwadi.2. Paras TPS – Barrage.
3. Koradi & Khaperkheda TPS – 7 day reservoir and
22 Km long pipe line of 1600 mm dia.Bridges onKolar & Kanhan rivers.
4. Also construction of Salt Lagoons at all power
stations and Soften Water plants.
5. Chlorination plants. (Ozonization Plants.)
6. Serious damages to Cooling Towers and repair costs
at Nasik & Koradi TPS.
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Air Cooled Condensor/adp 12
Some Costing
Evaporative Cooling Tower- 270 MW unit – 22.0 Crores
Total Plant cost – 270 x 6.0 =1620.0 Cr.Dry Cooling Tower – 22 x 2.5 = 55.0 Cr.
Extra expenditure = 33.0 Cr.only
Salt consumption 2000 MT/Yr, @ Rs.2000 /MT,Cost Rs.40 lakhs/year.
25 years cost = 10 Cr.
There is saving in cost of salt lagoons, Godowns,
Softening plant etc.
Huge saving in annual cost of water itself.(Next slide)
No blow downs and water pollution.
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Air Cooled Condensor/adp 13
COST OF MAKE-UP WATER
Unit Capacity MW 210 270 300 500 660
C.W. Make-up M3/Hr 500 643 714 1190 1571
ANNUAL-CW Make-up
in Mn. M34.38 5.63 6.26 10.43 13.77
Plant PLF 0.90 0.90 0.90 0.90 0.90
NET ANNUAL-CW
Make-up Mn. M33.94 5.07 5.63 9.39 12.39
RATE-Rs./Cub.Mtr 5 5 5 5 5
ANNUAL COST OFWATER in Rs.Cr
1.97 2.53 2.82 4.69 6.19
Water cost may escalate @ 4-5 % per year.
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Air Cooled Condensor/adp 14
Life Cycle Cost
Considering all the costs,
HELLER cooling system cost can be as low as2/3rd of Conventional Wet Cooling System.
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Air Cooled Condensor/adp 16
Natural Draft Dry Cooling Tower
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Air Cooled Condensor/adp 17
Dry Steam Condenser or Dry C.T.
Steam may be condensed in the cooling tower .
OR,A surface(or Jet) condenser may be used and the
cooling water is cooled in the dry C.T.
In both cases Evaporative Water Loss is eliminated.Because the water circuit is a closed one and there is
no loss.
Just consider a modern car.Earlier the radiator had to
be topped up daily.
Now, one can travel thousands of miles without
topping up the radiator.
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Air Cooled Condensor/adp 18
FREE COOLING
. An indirect dry-cooling system was installed at the 6 x
686-MW power plant in Kendal, South Africa.In this cooling system design, water is circulated from a
standard condenser to the tower, where it enters a series
of heat exchange elements on the base.
Air enters the bottom periphery of the tower, passingover heat exchange elements.
The heated air rises inside the tower, pulling in more cool
air.No fans are required.
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Air Cooled Condensor/adp 19
Waterless condensing
Steam enters the air-cooled condenser at the top
(blue pipe) of the heat exchangers,flows downward through the heat exchanger
tubes,
and it condenses and is captured in pipes at thebase of the heat exchangers.
The condensate is then returned to the boiler
water system.Mechanical fans force air over the heat
exchangers.
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Air Cooled Condensor/adp 20
DRY COOLING MAY BE N.D.C.T. OR I.D.C.T.
Heller system is an indirect dry cooling plant.
The Power Plant Waste Heat is initially transferred in
a Condenser (Preferably Jet Type) to a CLOSED
C.W.Circuit.
Heat pick-up by the C.W. Water is rejected to
Ambient Air in FIN TUBE type heat exchanger.
Air moving can be either Natural or Forced.
i.e. N.D.C.T. OR I.D.C.T.
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Air Cooled Condensor/adp 21
Initial Temperature Difference
I.T.D. is the Temperature difference between CONDENSING
STEAM and Ambient Air.I.T.D. is the driving force for Heat Transfer in Dry Cooling.
Typical ITD value range : 28 – 36 Deg.C.
The difference between ITD values of DC Jet Condenser and
Surface Condenser is : 3.5 – 4.5 Deg.C.
This is about 15 % of the Driving Force.
Therefore, Dry Systems with SURFACE CONDENSER need a
LARGER COOLING TOWER.
[ water flow rate, heat exchanger surface area, mechanical
equipment,and civil construction.]
L t D C l d CCPP 3 770 MW GEBZE &
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Air Cooled Condensor/adp 22
Largest Dry Cooled CCPP – 3 x 770 MW – GEBZE &
ADAPAZARI – 2002 – TURKEY.
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Air Cooled Condensor/adp 23
HELLER SYSTEM (With Supplemental Spray)
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Air Cooled Condensor/adp 24
Heller System (With assisting wet cells)
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Air Cooled Condensor/adp 25
200 MW Trakya CCPP, Turkey (ABB)
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Air Cooled Condensor/adp 26
2 x 600 MW coal fired – Yangcheng P.S. China.
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Air Cooled Condensor/adp 27
Russia : Strogino Co-Gen CCPP , 2 x 200 MW. With
supplemental spray.
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Air Cooled Condensor/adp 28
Modugno CCPP 800 MW, Italy (2008) IDCT.
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Air Cooled Condensor/adp 29
Modugno CCPP 800 MW, Italy (2008) IDCT.
front view
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Air Cooled Condensor/adp 30
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Air Cooled Condensor/adp 31
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Air Cooled Condensor/adp 32
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Air Cooled Condensor/adp 33
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Air Cooled Condensor/adp 34
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Air Cooled Condensor/adp 35
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Air Cooled Condensor/adp 36
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Air Cooled Condensor/adp 37
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Air Cooled Condensor/adp 38
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Air Cooled Condensor/adp 39
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Ai C l d C d / d 40