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NSFEPRI Joint Solicitation
Informational Webcast
Jessica Shi PhD EPRI Sr Project Manager
Technical Lead for
Tech Innovation Water Program
Sean Bushart PhD EPRI Sr Program Manager
Cross-Sector Lead for EPRI Water Programs
July 24 2013
Sumanta Acharya PhD NSF Program Director
2 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
3 copy 2013 Electric Power Research Institute Inc All rights reserved
Three Key Aspects of EPRI
Independent Objective scientifically based results address reliability efficiency affordability health safety and the environment
Nonprofit Chartered to serve the public benefit
Collaborative Bring together scientists engineers academic researchers industry experts
Independent
Collaborative
Nonprofit
4 copy 2013 Electric Power Research Institute Inc All rights reserved
Water Use and Availability Technology Innovation Program Overview and Objective
bull Initiated in early 2011
bull Globally distributed 3 solicitations
Feb 2011
June 2012
May 2013 (jointly with NSF)
Objective
Seek and develop ldquoout of the boxrdquo game changing early
stage and high risk cooling and water treatment ideas and
technologies with high potential for water consumption
reduction
5 copy 2013 Electric Power Research Institute Inc All rights reserved
Industry Specific Needs Strategic Water Management
Source United States Geological Survey
bull Thermal-electric power plants
withdraw 40 and consume 3 of
US fresh water
bull 90 of power plant water demand is
due to cooling systems
bull Water demand will continue in a
ldquoLow Carbon Worldrdquo
US Freshwater Consumption (1995)
US Freshwater Withdrawal (2005)
0
100
200
300
400
500
600
700
800
900
Nuclear Coal Oil Gas Simple CT
Comb Cycle
IGCC Solar thermal
Solar PV Wind Biofuel
Wate
r u
se
gal
MW
h
Hotel
Fuel processing
CT injection
Inlet air cooling
Ash handling
Scrubbing
Boiler make-up
Cooling
Source EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
6 copy 2013 Electric Power Research Institute Inc All rights reserved
Opportunities for Power Plant Water Use
Reduction
Innovation Priorities Advancing cooling technologies and applying novel water
treatment and waste heat concepts to improve efficiency and reduce water use
7 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF overview slides
bull National Science Foundation (NSF)- Mission is to support fundamental research in support of scientific discovery andor translational technology
bull Major directorates at NSF (annual budget of ~$8Billion) are Engineering (~$800 million) Math amp Physical Sciences Computer amp Information Sciences Biological Sciences Geological Atmospheric and Polar Sciences Social Behavorial amp Economic Sciences Education amp Human Resources
bull In Engineering (ENG) there are 5 divisions CMMI (Civil Mechanical amp Manufacturing) CBET (Chemical Bio Env amp Transport) ECCS (Electrical amp Computer) IIP(Industry Innovation) EERC (Education and Research Centers)
bull In NSFENGCBET- there are 17 programs one of which is Thermal Transport (~$7-$10 million annually)
8 copy 2013 Electric Power Research Institute Inc All rights reserved
Thermal Transport Program at NSF
bull Science Promote the fundamental understanding and application
of thermal transport (heat and mass transfer and the associated
fluids materials and manufacturing processes) at different scales
bull Innovation New amp improved technologies for heatingcooling
devices systems and infrastructure including the relevant
materials processing and manufacturing technologies
Technologies for enhanced energypower efficiency and
generation and greater sustainability
bull ToolsMethods Spatially amp temporally resolved simulation and
diagnostics exploiting high-performance computing using highly-
resolved data for upscalingreduced order models control and
optimization for improved processes amp products
bull Outcomes Sustainable energy-efficient heatingcooling systems
and the science and tools for their design
9 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF vs EPRI Research Interests
bull NSF
Gaining fundamental understandings of thermal sciences
ndash Modeling
ndash Lab scale testing
ndash Fundamental technology development
bull EPRI
Applied research
ndash Feasibility study
ndash Engineering solution development
ndash Prototype testing
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
2 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
3 copy 2013 Electric Power Research Institute Inc All rights reserved
Three Key Aspects of EPRI
Independent Objective scientifically based results address reliability efficiency affordability health safety and the environment
Nonprofit Chartered to serve the public benefit
Collaborative Bring together scientists engineers academic researchers industry experts
Independent
Collaborative
Nonprofit
4 copy 2013 Electric Power Research Institute Inc All rights reserved
Water Use and Availability Technology Innovation Program Overview and Objective
bull Initiated in early 2011
bull Globally distributed 3 solicitations
Feb 2011
June 2012
May 2013 (jointly with NSF)
Objective
Seek and develop ldquoout of the boxrdquo game changing early
stage and high risk cooling and water treatment ideas and
technologies with high potential for water consumption
reduction
5 copy 2013 Electric Power Research Institute Inc All rights reserved
Industry Specific Needs Strategic Water Management
Source United States Geological Survey
bull Thermal-electric power plants
withdraw 40 and consume 3 of
US fresh water
bull 90 of power plant water demand is
due to cooling systems
bull Water demand will continue in a
ldquoLow Carbon Worldrdquo
US Freshwater Consumption (1995)
US Freshwater Withdrawal (2005)
0
100
200
300
400
500
600
700
800
900
Nuclear Coal Oil Gas Simple CT
Comb Cycle
IGCC Solar thermal
Solar PV Wind Biofuel
Wate
r u
se
gal
MW
h
Hotel
Fuel processing
CT injection
Inlet air cooling
Ash handling
Scrubbing
Boiler make-up
Cooling
Source EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
6 copy 2013 Electric Power Research Institute Inc All rights reserved
Opportunities for Power Plant Water Use
Reduction
Innovation Priorities Advancing cooling technologies and applying novel water
treatment and waste heat concepts to improve efficiency and reduce water use
7 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF overview slides
bull National Science Foundation (NSF)- Mission is to support fundamental research in support of scientific discovery andor translational technology
bull Major directorates at NSF (annual budget of ~$8Billion) are Engineering (~$800 million) Math amp Physical Sciences Computer amp Information Sciences Biological Sciences Geological Atmospheric and Polar Sciences Social Behavorial amp Economic Sciences Education amp Human Resources
bull In Engineering (ENG) there are 5 divisions CMMI (Civil Mechanical amp Manufacturing) CBET (Chemical Bio Env amp Transport) ECCS (Electrical amp Computer) IIP(Industry Innovation) EERC (Education and Research Centers)
bull In NSFENGCBET- there are 17 programs one of which is Thermal Transport (~$7-$10 million annually)
8 copy 2013 Electric Power Research Institute Inc All rights reserved
Thermal Transport Program at NSF
bull Science Promote the fundamental understanding and application
of thermal transport (heat and mass transfer and the associated
fluids materials and manufacturing processes) at different scales
bull Innovation New amp improved technologies for heatingcooling
devices systems and infrastructure including the relevant
materials processing and manufacturing technologies
Technologies for enhanced energypower efficiency and
generation and greater sustainability
bull ToolsMethods Spatially amp temporally resolved simulation and
diagnostics exploiting high-performance computing using highly-
resolved data for upscalingreduced order models control and
optimization for improved processes amp products
bull Outcomes Sustainable energy-efficient heatingcooling systems
and the science and tools for their design
9 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF vs EPRI Research Interests
bull NSF
Gaining fundamental understandings of thermal sciences
ndash Modeling
ndash Lab scale testing
ndash Fundamental technology development
bull EPRI
Applied research
ndash Feasibility study
ndash Engineering solution development
ndash Prototype testing
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
3 copy 2013 Electric Power Research Institute Inc All rights reserved
Three Key Aspects of EPRI
Independent Objective scientifically based results address reliability efficiency affordability health safety and the environment
Nonprofit Chartered to serve the public benefit
Collaborative Bring together scientists engineers academic researchers industry experts
Independent
Collaborative
Nonprofit
4 copy 2013 Electric Power Research Institute Inc All rights reserved
Water Use and Availability Technology Innovation Program Overview and Objective
bull Initiated in early 2011
bull Globally distributed 3 solicitations
Feb 2011
June 2012
May 2013 (jointly with NSF)
Objective
Seek and develop ldquoout of the boxrdquo game changing early
stage and high risk cooling and water treatment ideas and
technologies with high potential for water consumption
reduction
5 copy 2013 Electric Power Research Institute Inc All rights reserved
Industry Specific Needs Strategic Water Management
Source United States Geological Survey
bull Thermal-electric power plants
withdraw 40 and consume 3 of
US fresh water
bull 90 of power plant water demand is
due to cooling systems
bull Water demand will continue in a
ldquoLow Carbon Worldrdquo
US Freshwater Consumption (1995)
US Freshwater Withdrawal (2005)
0
100
200
300
400
500
600
700
800
900
Nuclear Coal Oil Gas Simple CT
Comb Cycle
IGCC Solar thermal
Solar PV Wind Biofuel
Wate
r u
se
gal
MW
h
Hotel
Fuel processing
CT injection
Inlet air cooling
Ash handling
Scrubbing
Boiler make-up
Cooling
Source EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
6 copy 2013 Electric Power Research Institute Inc All rights reserved
Opportunities for Power Plant Water Use
Reduction
Innovation Priorities Advancing cooling technologies and applying novel water
treatment and waste heat concepts to improve efficiency and reduce water use
7 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF overview slides
bull National Science Foundation (NSF)- Mission is to support fundamental research in support of scientific discovery andor translational technology
bull Major directorates at NSF (annual budget of ~$8Billion) are Engineering (~$800 million) Math amp Physical Sciences Computer amp Information Sciences Biological Sciences Geological Atmospheric and Polar Sciences Social Behavorial amp Economic Sciences Education amp Human Resources
bull In Engineering (ENG) there are 5 divisions CMMI (Civil Mechanical amp Manufacturing) CBET (Chemical Bio Env amp Transport) ECCS (Electrical amp Computer) IIP(Industry Innovation) EERC (Education and Research Centers)
bull In NSFENGCBET- there are 17 programs one of which is Thermal Transport (~$7-$10 million annually)
8 copy 2013 Electric Power Research Institute Inc All rights reserved
Thermal Transport Program at NSF
bull Science Promote the fundamental understanding and application
of thermal transport (heat and mass transfer and the associated
fluids materials and manufacturing processes) at different scales
bull Innovation New amp improved technologies for heatingcooling
devices systems and infrastructure including the relevant
materials processing and manufacturing technologies
Technologies for enhanced energypower efficiency and
generation and greater sustainability
bull ToolsMethods Spatially amp temporally resolved simulation and
diagnostics exploiting high-performance computing using highly-
resolved data for upscalingreduced order models control and
optimization for improved processes amp products
bull Outcomes Sustainable energy-efficient heatingcooling systems
and the science and tools for their design
9 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF vs EPRI Research Interests
bull NSF
Gaining fundamental understandings of thermal sciences
ndash Modeling
ndash Lab scale testing
ndash Fundamental technology development
bull EPRI
Applied research
ndash Feasibility study
ndash Engineering solution development
ndash Prototype testing
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
4 copy 2013 Electric Power Research Institute Inc All rights reserved
Water Use and Availability Technology Innovation Program Overview and Objective
bull Initiated in early 2011
bull Globally distributed 3 solicitations
Feb 2011
June 2012
May 2013 (jointly with NSF)
Objective
Seek and develop ldquoout of the boxrdquo game changing early
stage and high risk cooling and water treatment ideas and
technologies with high potential for water consumption
reduction
5 copy 2013 Electric Power Research Institute Inc All rights reserved
Industry Specific Needs Strategic Water Management
Source United States Geological Survey
bull Thermal-electric power plants
withdraw 40 and consume 3 of
US fresh water
bull 90 of power plant water demand is
due to cooling systems
bull Water demand will continue in a
ldquoLow Carbon Worldrdquo
US Freshwater Consumption (1995)
US Freshwater Withdrawal (2005)
0
100
200
300
400
500
600
700
800
900
Nuclear Coal Oil Gas Simple CT
Comb Cycle
IGCC Solar thermal
Solar PV Wind Biofuel
Wate
r u
se
gal
MW
h
Hotel
Fuel processing
CT injection
Inlet air cooling
Ash handling
Scrubbing
Boiler make-up
Cooling
Source EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
6 copy 2013 Electric Power Research Institute Inc All rights reserved
Opportunities for Power Plant Water Use
Reduction
Innovation Priorities Advancing cooling technologies and applying novel water
treatment and waste heat concepts to improve efficiency and reduce water use
7 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF overview slides
bull National Science Foundation (NSF)- Mission is to support fundamental research in support of scientific discovery andor translational technology
bull Major directorates at NSF (annual budget of ~$8Billion) are Engineering (~$800 million) Math amp Physical Sciences Computer amp Information Sciences Biological Sciences Geological Atmospheric and Polar Sciences Social Behavorial amp Economic Sciences Education amp Human Resources
bull In Engineering (ENG) there are 5 divisions CMMI (Civil Mechanical amp Manufacturing) CBET (Chemical Bio Env amp Transport) ECCS (Electrical amp Computer) IIP(Industry Innovation) EERC (Education and Research Centers)
bull In NSFENGCBET- there are 17 programs one of which is Thermal Transport (~$7-$10 million annually)
8 copy 2013 Electric Power Research Institute Inc All rights reserved
Thermal Transport Program at NSF
bull Science Promote the fundamental understanding and application
of thermal transport (heat and mass transfer and the associated
fluids materials and manufacturing processes) at different scales
bull Innovation New amp improved technologies for heatingcooling
devices systems and infrastructure including the relevant
materials processing and manufacturing technologies
Technologies for enhanced energypower efficiency and
generation and greater sustainability
bull ToolsMethods Spatially amp temporally resolved simulation and
diagnostics exploiting high-performance computing using highly-
resolved data for upscalingreduced order models control and
optimization for improved processes amp products
bull Outcomes Sustainable energy-efficient heatingcooling systems
and the science and tools for their design
9 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF vs EPRI Research Interests
bull NSF
Gaining fundamental understandings of thermal sciences
ndash Modeling
ndash Lab scale testing
ndash Fundamental technology development
bull EPRI
Applied research
ndash Feasibility study
ndash Engineering solution development
ndash Prototype testing
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
5 copy 2013 Electric Power Research Institute Inc All rights reserved
Industry Specific Needs Strategic Water Management
Source United States Geological Survey
bull Thermal-electric power plants
withdraw 40 and consume 3 of
US fresh water
bull 90 of power plant water demand is
due to cooling systems
bull Water demand will continue in a
ldquoLow Carbon Worldrdquo
US Freshwater Consumption (1995)
US Freshwater Withdrawal (2005)
0
100
200
300
400
500
600
700
800
900
Nuclear Coal Oil Gas Simple CT
Comb Cycle
IGCC Solar thermal
Solar PV Wind Biofuel
Wate
r u
se
gal
MW
h
Hotel
Fuel processing
CT injection
Inlet air cooling
Ash handling
Scrubbing
Boiler make-up
Cooling
Source EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
6 copy 2013 Electric Power Research Institute Inc All rights reserved
Opportunities for Power Plant Water Use
Reduction
Innovation Priorities Advancing cooling technologies and applying novel water
treatment and waste heat concepts to improve efficiency and reduce water use
7 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF overview slides
bull National Science Foundation (NSF)- Mission is to support fundamental research in support of scientific discovery andor translational technology
bull Major directorates at NSF (annual budget of ~$8Billion) are Engineering (~$800 million) Math amp Physical Sciences Computer amp Information Sciences Biological Sciences Geological Atmospheric and Polar Sciences Social Behavorial amp Economic Sciences Education amp Human Resources
bull In Engineering (ENG) there are 5 divisions CMMI (Civil Mechanical amp Manufacturing) CBET (Chemical Bio Env amp Transport) ECCS (Electrical amp Computer) IIP(Industry Innovation) EERC (Education and Research Centers)
bull In NSFENGCBET- there are 17 programs one of which is Thermal Transport (~$7-$10 million annually)
8 copy 2013 Electric Power Research Institute Inc All rights reserved
Thermal Transport Program at NSF
bull Science Promote the fundamental understanding and application
of thermal transport (heat and mass transfer and the associated
fluids materials and manufacturing processes) at different scales
bull Innovation New amp improved technologies for heatingcooling
devices systems and infrastructure including the relevant
materials processing and manufacturing technologies
Technologies for enhanced energypower efficiency and
generation and greater sustainability
bull ToolsMethods Spatially amp temporally resolved simulation and
diagnostics exploiting high-performance computing using highly-
resolved data for upscalingreduced order models control and
optimization for improved processes amp products
bull Outcomes Sustainable energy-efficient heatingcooling systems
and the science and tools for their design
9 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF vs EPRI Research Interests
bull NSF
Gaining fundamental understandings of thermal sciences
ndash Modeling
ndash Lab scale testing
ndash Fundamental technology development
bull EPRI
Applied research
ndash Feasibility study
ndash Engineering solution development
ndash Prototype testing
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
6 copy 2013 Electric Power Research Institute Inc All rights reserved
Opportunities for Power Plant Water Use
Reduction
Innovation Priorities Advancing cooling technologies and applying novel water
treatment and waste heat concepts to improve efficiency and reduce water use
7 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF overview slides
bull National Science Foundation (NSF)- Mission is to support fundamental research in support of scientific discovery andor translational technology
bull Major directorates at NSF (annual budget of ~$8Billion) are Engineering (~$800 million) Math amp Physical Sciences Computer amp Information Sciences Biological Sciences Geological Atmospheric and Polar Sciences Social Behavorial amp Economic Sciences Education amp Human Resources
bull In Engineering (ENG) there are 5 divisions CMMI (Civil Mechanical amp Manufacturing) CBET (Chemical Bio Env amp Transport) ECCS (Electrical amp Computer) IIP(Industry Innovation) EERC (Education and Research Centers)
bull In NSFENGCBET- there are 17 programs one of which is Thermal Transport (~$7-$10 million annually)
8 copy 2013 Electric Power Research Institute Inc All rights reserved
Thermal Transport Program at NSF
bull Science Promote the fundamental understanding and application
of thermal transport (heat and mass transfer and the associated
fluids materials and manufacturing processes) at different scales
bull Innovation New amp improved technologies for heatingcooling
devices systems and infrastructure including the relevant
materials processing and manufacturing technologies
Technologies for enhanced energypower efficiency and
generation and greater sustainability
bull ToolsMethods Spatially amp temporally resolved simulation and
diagnostics exploiting high-performance computing using highly-
resolved data for upscalingreduced order models control and
optimization for improved processes amp products
bull Outcomes Sustainable energy-efficient heatingcooling systems
and the science and tools for their design
9 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF vs EPRI Research Interests
bull NSF
Gaining fundamental understandings of thermal sciences
ndash Modeling
ndash Lab scale testing
ndash Fundamental technology development
bull EPRI
Applied research
ndash Feasibility study
ndash Engineering solution development
ndash Prototype testing
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
7 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF overview slides
bull National Science Foundation (NSF)- Mission is to support fundamental research in support of scientific discovery andor translational technology
bull Major directorates at NSF (annual budget of ~$8Billion) are Engineering (~$800 million) Math amp Physical Sciences Computer amp Information Sciences Biological Sciences Geological Atmospheric and Polar Sciences Social Behavorial amp Economic Sciences Education amp Human Resources
bull In Engineering (ENG) there are 5 divisions CMMI (Civil Mechanical amp Manufacturing) CBET (Chemical Bio Env amp Transport) ECCS (Electrical amp Computer) IIP(Industry Innovation) EERC (Education and Research Centers)
bull In NSFENGCBET- there are 17 programs one of which is Thermal Transport (~$7-$10 million annually)
8 copy 2013 Electric Power Research Institute Inc All rights reserved
Thermal Transport Program at NSF
bull Science Promote the fundamental understanding and application
of thermal transport (heat and mass transfer and the associated
fluids materials and manufacturing processes) at different scales
bull Innovation New amp improved technologies for heatingcooling
devices systems and infrastructure including the relevant
materials processing and manufacturing technologies
Technologies for enhanced energypower efficiency and
generation and greater sustainability
bull ToolsMethods Spatially amp temporally resolved simulation and
diagnostics exploiting high-performance computing using highly-
resolved data for upscalingreduced order models control and
optimization for improved processes amp products
bull Outcomes Sustainable energy-efficient heatingcooling systems
and the science and tools for their design
9 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF vs EPRI Research Interests
bull NSF
Gaining fundamental understandings of thermal sciences
ndash Modeling
ndash Lab scale testing
ndash Fundamental technology development
bull EPRI
Applied research
ndash Feasibility study
ndash Engineering solution development
ndash Prototype testing
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
8 copy 2013 Electric Power Research Institute Inc All rights reserved
Thermal Transport Program at NSF
bull Science Promote the fundamental understanding and application
of thermal transport (heat and mass transfer and the associated
fluids materials and manufacturing processes) at different scales
bull Innovation New amp improved technologies for heatingcooling
devices systems and infrastructure including the relevant
materials processing and manufacturing technologies
Technologies for enhanced energypower efficiency and
generation and greater sustainability
bull ToolsMethods Spatially amp temporally resolved simulation and
diagnostics exploiting high-performance computing using highly-
resolved data for upscalingreduced order models control and
optimization for improved processes amp products
bull Outcomes Sustainable energy-efficient heatingcooling systems
and the science and tools for their design
9 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF vs EPRI Research Interests
bull NSF
Gaining fundamental understandings of thermal sciences
ndash Modeling
ndash Lab scale testing
ndash Fundamental technology development
bull EPRI
Applied research
ndash Feasibility study
ndash Engineering solution development
ndash Prototype testing
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
9 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF vs EPRI Research Interests
bull NSF
Gaining fundamental understandings of thermal sciences
ndash Modeling
ndash Lab scale testing
ndash Fundamental technology development
bull EPRI
Applied research
ndash Feasibility study
ndash Engineering solution development
ndash Prototype testing
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
10 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF-EPRI Partnership
bull With the goal of reducing water usage a key approach is to replace water-cooled wet condensers with air-cooled condensers (ACC)
bull ACCrsquos are primarily comprised of finned tube HX with steam on the tube side and air on the fin side (more later)
bull Seek innovative ideas that need fundamental research (NSF-often done by universities) relevant for power plant cooling with the potential for translational technology that can be commercialized (EPRI-often done by companies)
Source httpwwwgea-energytechnologycomopencmsopencmsgasenproductsDirect_Air-Cooled_Condensershtml
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
11 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFEPRI Joint Solicitation Objective
Seek innovative dry cooling ideas and concepts to dramatically
reduce or eliminate the water use in steam condensation
through the use of air cooled condensers with the following
optional approaches
ndash Significantly increase the air side heat transfer coefficient
ndash Reduce steam side pressure drop size and steam
condensation temperatures
ndash Develop more efficient cost effective and compact
alternative dry and dry-wet hybrid cooling solutions for
power plant steam condensation cooling systems
Note the importance of steam condensation temperature as a key
performance metric (lowering it increases power generation
efficiency) and itrsquos relationship to ambient temperatures
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
12 copy 2013 Electric Power Research Institute Inc All rights reserved
NSFrsquos Merit Review Criteria
bullWhat is the intellectual merit of proposed activity
ndash How important is proposed activity to advancing knowledge amp understanding within its own field or across fields
ndash To what extent does proposal suggest amp explore creative original or potentially transformative concepts
ndash What will be significant contribution of project to research amp knowledge base of field
ndash How well conceived amp organized is proposed activity
ndash Is there sufficient access to resources (equipment facilities etc)
ndash How well qualified is PI to conduct proposed activity (Co-PIs not allowed for CAREER proposals)
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
13 copy 2013 Electric Power Research Institute Inc All rights reserved
NSF Review Criteria
bullWhat are the broader impacts of proposed activity
ndash How well does the activity advance discovery and understanding while promoting teaching training and learning
ndash How well does the proposed activity broaden the participation of underrepresented groups (eg gender ethnicity disability geographic etc)
ndash To what extent will it enhance the infrastructure for research and education such as facilities instrumentation networks and partnerships
ndash Will the results be disseminated broadly to enhance scientific and technological understanding (including outreach)
ndash What may be the benefits of the proposed activity to society
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
14 copy 2013 Electric Power Research Institute Inc All rights reserved
Selection Criteria in Addition to NSFrsquos Merit
Review Criteria
bull Innovation (ldquoout of the boxrdquo game changer cutting edge)
bull Early Stage (not extensively researched before)
bull Potential Impacts
ndash Significant reduction of water (especially fresh water) consumption andor withdrawals
ndash Improved thermal efficiency
Reduced steam condensation temperature
Increased net power production gain
ndash Economic potential in terms of water and energy consumption cost and space in 10 to 20 years
ndash Other such as
Reduced size footprint fan size and power
Potential ease and broadness of adoption
Applicability of all types of steam power plants
bull Respondentrsquos capabilities and related experience
bull Realism of the proposed plan and cost estimates
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
15 copy 2013 Electric Power Research Institute Inc All rights reserved
Funding
bull Funding Size
ndash $6 M Collaboration ($3M commitment from EPRI and
NSF)
ndash $200 K to $700 Kyear for each project
ndash Average about $300 Kyear
ndash 5 to 10 projects
bull Funding Approach
ndash Coordinated but independent funding
NSF awards grants
EPRI contracts
ndash Joint funding for most proposals
ndash Independent funding for a few proposals if needed
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
16 copy 2013 Electric Power Research Institute Inc All rights reserved
Project Size Recommendations
bull Average $3000000year
bull $700000year is for extremely exciting game changing
ideas
Specify project plan and budget request
for each project with NSF and EPRI separately
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
17 copy 2013 Electric Power Research Institute Inc All rights reserved
Eligibility Requirements
bull Proposals must be submitted by universities or colleges
with a campus in US
bull The PI(s) must be full time faculty
bull Primary funds must be directed to the academic institution
to be in compliance with NSF policy
bull EPRI may redesign the selected projects and renegotiate
funding splits among team leads and members for EPRI
funded parts of work
bull PI and co-PI may participate in only one proposal
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
18 copy 2013 Electric Power Research Institute Inc All rights reserved
Additional Eligibility Info
bull Proposals may be submitted by a single organization or a group of organizations consisting of a lead organization in collaboration with one or more partner organizations
bull Only US academic institutions with significant research and degree-granting education programs in disciplines normally supported by NSF are eligible to be the lead organization
bull Principal investigators are encouraged to form synergistic collaborations with industry For interaction with industry the GOALI mechanism (Grant Opportunities for Academic Liaison with Industry) may be used
bull Alternatively subcontracts to industrial collaborators may be employed
bull Collaborations between researchers that are doing fundamental research in ACC or hybrid cooling with those that focus on applied research and have appropriate facilities for testing successful ideas are encouraged In these cases if the PIs are at different institutions submission of separately submitted collaborative proposals is required
bull See GPG Chapter IID4b for information about submission of a collaborative proposal from multiple organizations
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
19 copy 2013 Electric Power Research Institute Inc All rights reserved
Collaboration with industry or national labs is
strongly recommended
bullPrincipal investigators are encouraged to
form synergistic collaborations with industry
bullThere is no requirement to force
collaboration with power plants or power
plant cooling vendors if it is not needed
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
20 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Review Panel
bull Experts from both academia industry national labs and
other federal agencies with expertise in cooling and power
plant cooling technologies
bull Sign off of Confidential and No-Conflict of Interest
Agreement Form
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
21 copy 2013 Electric Power Research Institute Inc All rights reserved
Proposal Due Time
bull Proposals are due by 5 pm proposers local time on
Monday August 19 2013
bull Early submission is encouraged to avoid last minute
traffic jam
bull NSF has zero tolerance in late proposals
bull EPRI may consider late proposals and white papers for other
potential funding
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
22 copy 2013 Electric Power Research Institute Inc All rights reserved
How to improve your chance of winning
Preliminary feasibility assessment data are encouraged including the following
bull Assumptions
bull System integration (if the concept includes system integration such as a waste heat utilization concept) and component level diagrams with energy balance temperature flow rate pressure drop thermal resistance dimensions and other key performance data
bull Data about effects on steam condensation temperature pressure drop power production gain (You may assume 3 degC reduction asymp 1 power production gain rather than power plant efficiency gain)
bull Data about potential benefits and cons
Do Your Homework
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
23 copy 2013 Electric Power Research Institute Inc All rights reserved
Agenda
bull Welcome
bull EPRI and NSF Objectives
bull NSFEPRI Joint Solicitation Overview
bull Power Plant Cooling System Overview
bull FAQ
bull Open Question Session
bull Adjourn at 10 am PST
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
24 copy 2013 Electric Power Research Institute Inc All rights reserved
Effect of Reducing Condensing Temperature on
Steam Turbine Rankine Cycle Efficiency
a
Potential for 5 (1st Order Estimate) more power production or $11M more annual
income ($005kWh) for a 500 MW power plant due to reduced steam condensation
temperature from 50 degC to 35 degC
0
100
200
300
400
500
600
0 2 4 6 8 10
Te
mp
era
ture
(degC
)
Entropy (kJkgK)
T-S Rankine Cycle Diagram for Steam
Nuclear Power
Plant
Coal-Fired Power Plant
2
3
4 1
T-S Diagram for
Pure Water
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
25 copy 2013 Electric Power Research Institute Inc All rights reserved
What Cooling System Options are Currently Deployed in the Industry
Water Cooling Air Cooling1 Hybrid Cooling1
Once Through Cooling1
(43 in US) 2
Air Cooled Condenser
(1Usage in US)2
Increasing demand for dry cooling
in water scarcity regions
1 EPRI Report ldquoWater Use for Electric Power generationrdquo No 1014026 2008
2 Report of Department of Energy National Energy Technology Laboratory ldquoEstimating Freshwater Needs to
Meet Future Thermoelectric Generation Requirementsrdquo DOENETL-40020081339 2008
Cooling Pond
(14 in US)2
Cooling Tower 1(42 in US)2
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
26 copy 2013 Electric Power Research Institute Inc All rights reserved
bull Pros
bull Most cost effective
bull Lowest steam condensate temp
bull Cons
bull Facing tightened EPA rules to minimize once through cooling (OTC) system entrance and discharge disturbance to water eco systems
bull Forced to or increasing pressure to retrofit OTC systems to cooling tower or dry cooling systems (19 power plans already affected by CA retrofitting regulations)
Once Through Cooling ProsCons
43 Usage in US
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
27 copy 2013 Electric Power Research Institute Inc All rights reserved
Cooling Tower Cooling System ProsCons
bull Pros
bull Most effective cooling system due to evaporative cooling-95 less water withdrawal than once through cooling systems
bull Cons
bull Significant vapor loss and makeup water needs
bull Shut down in drought seasons
bull Twice as expensive as once through cooling systems
bull Less power production on hot days due to higher steam condensation temperatures compared to once through systems
bull Water treatment cost
42 Usage in US
Challenges Vapor Capture and Cooler Steam
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
28 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser ProsCons
1 Usage in US Pros
bull Dry system
Zero water consumption and
water supply needed
Cons
bull Up to 10 less power production
on hot days due to higher steam
condensation temperature
compared to CT and OTC
systems
bull Up to five times more expensive
than cooling tower systems
bull Noise wind effect and freezing in
cold days
Challenge Reduce ITD from 30 degC to 10 degC gtgt 6 more Power Production
Source EVAPCO BLCT Dry Cooling
Click Here for Animation
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
29 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Dimensions and Air Flow Rate
Air Flow
1 ndash 15 M
ACFM
per Fan
Fins
Vtotal[ms] 2 ndash 3
Vfin [ms] 35 ndash 5
Heat Flux [Wm2] 350-400 Heat Flux
Vfin Vfin Vfin
Vtotal
Vfin Vfin Vfin
AIR
Evapcorsquos Steam
Condenser
Tube with Fins
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
30 copy 2013 Electric Power Research Institute Inc All rights reserved
Sample Data123 for Air Cooled Condensers
Ambient Air at 40degC and RH50
Parameter Air Side Steam Side
Hydraulic Diameter [mm] 19 ndash 20 44 ndash 65
Flow Rate [kgs] 540 ndash 750 5 ndash 9
Reynoldrsquos Number 4000 ndash 6000 NA
Temperature [degC] 40 60 ndash 85
Area [m2] 40000 930
HTC [Wm2K] 45 ndash 50 15000 - 18000
Pressure Drop [Pa] 75 ndash 100 125 ndash 250
Sources
1 Heyns J A ldquoPerformance Characteristics Of An Air
Cooled Steam Condenser Incorporating A Hybrid
(DryWet) Dephlegmatorrdquo Thesis 2008
2 MaulbetschJS ldquoWater Conserving Cooling Systems
‐ Air‐Cooled Condensersrdquo DOE ARPA-E Workshop
Presentation 2012
3 Evapco BLCT Dry Cooling
ACC Design Parameters
Cooling Capacity [MW] 10 ndash 22
Tube Bundles per cell 8 ndash 10
Tubes per bundle 40 ndash 57
Spacing between Tubes [mm] 57
Overall Heat Transfer Coefficient [Wm2K] 35 ndash 50
Fan Static Pressure [Pa] 120 ndash 190
Fan Power per cell [kW] 125 ndash 190
Fan Diameter [m] 9 ndash 10
Cost $15 Million ACC cell
(Footprint size 12x12 m2ACC cell)
Dependent on flow rate steam condensation temperature and quality etc
A Street of ACC
with 6 FansCells
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
31 copy 2013 Electric Power Research Institute Inc All rights reserved
0 100 200 300 400 500 600 700 800 900 1000 1100
240
220
200
180
160
140
120
100
80
60
40
20
0
Fan
Sta
tic P
ressu
re [P
a]
Volumetric Flow Rate [m3s]
Fan Static Pressure
vs Flow Rate
Sample ACC Fan Performance Curves1
Source 1 Howden Netherlands BV ndash 36DLF8 Fan Model
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000 1100
Fan
Sh
aft
Po
we
r [k
W]
Volumetric Flow Rate [m3s]
Fan Shaft Power
vs Flow Rate
System Resistance
of a Single Row
Tube ACC Blade Tip Angles
Fan Model 36 DLF 8 (8 blades)
Type Axial Vertical Shaft
Forced Draught
Fan Diameter 1097 m [36ft]
Air Inlet Temperature 20degC
Relative Humidity 60
Design Conditions
Air Side Tube-Fin
Resistance
= 50 - 60 of
System Resistance
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
32 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Eskomrsquos Matimba
Power Station (6 x 665 MWe) in South Africa bull Direct dry-cooled 6x 685 MW ndash The largest operating one in the world
bull Contract awarded 1982
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
33 copy 2013 Electric Power Research Institute Inc All rights reserved
Top View of Air Cooled Condensers
at Matimba Power Station
Steam
Pipes
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
34 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condensers at Matimba Power Station
Inside View
Steam Tubes
with Fins
Catwalk Between
Streets
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
35 copy 2013 Electric Power Research Institute Inc All rights reserved
Air Cooled Condenser Fans at Matimba Power
Station
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
36 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe) in South
Africa bull Indirect system (surface condenser 6 x natural draft dry-cooling towers (165 meter tall)
bull Contract awarded 1983
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
37 copy 2013 Electric Power Research Institute Inc All rights reserved
Kendal Power Station (6 x 686 MWe)
bull Currently largest dry-cooled power station worldwide
Cooling Tower
Top View
Hot water from condenser is
cooled by A ndash frame air
coolers
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
38 copy 2013 Electric Power Research Institute Inc All rights reserved
More Air Cooler Views at Kendal Power Station
Bottom Views
Cooler Tubes with Fins
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
39 copy 2013 Electric Power Research Institute Inc All rights reserved
Eskom Dry-Cooling Initial Temperature Difference
(ITD) Variation with Ambient Temperature
25
30
35
40
45
50
55
0 5 10 15 20 25 30 35 40 45
Ambient Temperature [degC]
ITD
[degC
]
Grootvlei 5amp6 design
Matimba - Direct Dry Cooled
Majuba - Direct Dry Cooled
Kendal - Indirect Dry Cooled
Medupi - Direct Dry Cooled
Source JP Pretorius and AF Du Preez ldquoEskom Cooling Technologiesrdquo 14th IAHR Conference 2009
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
40 copy 2013 Electric Power Research Institute Inc All rights reserved
What do you do when it is hot
Inlet air cooling with sprays
Testing at Crockett Co‐Gen plant
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
41 copy 2013 Electric Power Research Institute Inc All rights reserved
Hybrid Cooling ProsCons
bull Pros
bull Full power output even on hot days due to full operation of cooling tower systems
bull Potential for more than 50 less vapor loss compared to cooling tower systems
Cons
bull Cooling tower shut down in drought
seasons
bull As expensive as air cooled condensers
bull Dual cooling components
Challenge
Develop alternative more
cost effective hybrid sys
8 Installations in US
1 Installation in Argentina
8 in Parallel
1 in Series in US
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
42 copy 2013 Electric Power Research Institute Inc All rights reserved
Current Cooling System Data Comparison
Steam Condensation Temperatures Based on TDB of 100deg F and TWB of 78deg F
500 MW Coal Fired Steam Power Plant with Heat Load of 2500 Mbtuhr and
Steam Flow Rate of 25 Mlbhr
Cooling
System
Heat Transfer
Area (ft2)
Tube Dia
(in)
of
Tubes
Tube
Length (ft)
Cost
(MM$)
No of
Cells
Cell Dimensions
(ft x ft)
TowerACC
Footprint (ft2)
Cost
(MM$)
Wet Cooling
Tower and
Condenser
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 15 - 20 48 x 48 to 60 x 60 50000 - 80000 7 - 10
Dry Direct na na na na na 40 - 72 40 x 40 64000 - 120000 60 - 100
Once Through
Cooling
175000 -
350000 1125 - 125
17000 -
3500030 - 40 1 - 25 na na na na
Hybrid 50000 - 350000 1125 - 12510000 -
35000030 - 40 04 - 25
4 - 10
15- 30
48 x 48 to 60 x 60
40 x 40
10000 - 36000
24000 - 4800030 - 80
Steam Condenser TowerACC
Cooling SystemSystem Cost
($MM)Cost Ratio Relative to Wet
Evaporative Loss
(kgalMWh)
Steam
Condensation
Temperature (degF)
Coolant Flow Rate
(gpm)
Wet Cooling Tower and
Condenser20 - 25 100 05 - 07 116 100000 - 250000
Dry Direct 60 - 100 25 - 5 000 155 0
Once Through Cooling 10 - 15 04 - 75 02 - 03 100 150000 - 350000
Hybrid 40 -75 2 - 4 01 - 05 116 50000 - 150000
Steam Condensation Temperatures Based on T of 100deg F and T of 78deg F
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
43 copy 2013 Electric Power Research Institute Inc All rights reserved
Examples of On-Going Advanced Cooling
Technology Projects for Water Use Reduction
1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
2 Thermosyphon Cooler Technology
(Collaboration with Johnson Controls)
3 Advanced M-Cycle Dew Point Cooling Tower Fill
(Collaboration with Gas Technology Institute)
4 Heat Absorption Nanoparticles in Coolant
(Collaboration with Argonne National Laboratory)
5 Hybrid drywet cooling to enhance air cooled
condensers (Collaboration with University of Stellenbosch in S Africa)
More information about our current projects can be found here and from report list
on page 2 of our Program Home Page Posting
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
44 copy 2013 Electric Power Research Institute Inc All rights reserved
Key Potential Benefits
bull Dry cooling system
Near Zero water use and consumption
bull Reduced condensation temperature
As low as 35 degC
Potential for annual power production increase by up to 5
bull Full power production even on the hottest days compared to air cooled condensers
Project 1 Waste HeatSolar Driven Green Adsorption Chillers
for Steam Condensation (Collaboration with Allcomp)
Hot Air
Air-Cooled
Condenser
Desorption
Chamber Adsorption
Chamber
Evaporator
Schematic Illustration of a Typical Adsorption Chiller
Steam
Water
Air
Air
Refrigerant
(EPRI Patent Pending)
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
45 copy 2013 Electric Power Research Institute Inc All rights reserved
Exploratory Cooling Projects
bull Thermoelectric Cooling and Waste Heat
Recovery Technology (Purdue)
bull Near 100 Vapor Capturing Technology (UMD)
bull Emerging Heat Transfer Enhancement
Technology Evaluation (UIUC)
bull Parametric Evaluation of Effects of Nanofluid on
Cooling Tower Evaporation Loss Reduction
(GTI)
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
46 copy 2013 Electric Power Research Institute Inc All rights reserved
More Cooling Information Resources
bull Power Plant Cooling System Information and Data EPRI
2013
bull NSFEPRI Workshop on Advancing Power Plant Cooling
Technologies Nov 2012
bull Cost and Performance Baseline for Fossil Energy Plants -
Volume 1 Bituminous Coal and Natural Gas to Electricity
DOENETL-20101397 Nov 2010 (Case 11 or 12)
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
47 copy 2013 Electric Power Research Institute Inc All rights reserved
Resources
wwwepricomPagesAdvanced-Water-Research-for-Power-Plantsaspx
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
48 copy 2013 Electric Power Research Institute Inc All rights reserved
More Resources
bull FAQAnswers
bull 2013 Joint EPRI-NSF Solicitation
bull 2012 Request for Information Solicitation
bull Power Plant Cooling System Information and Data
bull How to Work with EPRI
bull EPRI-University Contract Agreement
bull Program Home Page Posting ndashRecordings presentation files FAQ and additional information will be posted at
Technology Innovation Water Use and Availability Program Overview
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
49 copy 2013 Electric Power Research Institute Inc All rights reserved
Frequently Asked Questions
bull What are the principle investigator (PI) requirements for EPRI funded work
bull Can bidders submit proposals to EPRI directly
bull What is EPRI cost sharing requirement
bull Will EPRI own IP developed before and during contract
bull How long will it take to negotiate and sign off a contract
bull When will awardrejection decisions be made
bull Will late submissions be accepted
bull FAQAnswers for shaded and more questions
httpmydocsepricomdocsPublicMeetingMaterials06132013Solc_FAQ_2pdf
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
50 copy 2013 Electric Power Research Institute Inc All rights reserved
Questions amp Answers If you have a question during the webcast you canhellip
Type your question to the
presenters using the QampA
Feature
Let us know
you have a
question
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom
51 copy 2013 Electric Power Research Institute Inc All rights reserved
TogetherhellipShaping the Future of Electricity
Thank You
Any Questions or Data Required for Assessment
Please feel free to contact us
Technical Contacts
Dr Sumanta Acharya at sacharyansfgov
Dr Jessica Shi at JShiepricom
General Questions
Vivian Li at VLiepricom