001b Complete IACCC Proceedings

7/26/2019 001b Complete IACCC Proceedings

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Keynote Report


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4368 130021

300MW600MW

1.

300MW600MW

1000MW

2.

60 1966 50kW

1967 1.5 MW

2000

2001 9 6 MW

2003 200MW ,:


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2004 10 2300MW

2005 4 2600MW


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2008 6 2600MW

2008 7 600MW


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2010 12 21000MW

2014

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014

MW

4110 13310 10000 17550 22650 22540 22650 28755 19837 33905 22265 200152

MW

4110 13310 10000 17550 19050 19480 13125 16270 8750 13630 7520 125375

%

100.00 100.00 100.00 100.00 84.11 86.42 57.95 56.58 44.11 40.20 33.77 62.64

MW

0 0 0 0 3600 1860 9525 12485 11087 20275 14745 74777

%

0.00 0.00 0.00 0.00 15.89 8.25 42.05 43.42 55.89 59.80 66.23 37.36


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0

5000

10000

15000

20000

25000

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014

MW

2009

3.

2014 300MW 157


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114 600MW 51 600MW

600MW 2012

g/kWh % kg/kWh

23 324.44 6.48 0.31

42 336.30 7.99 0.31

126 305.27 4.64 1.12

72 316.29 5.35 1.31

60 5

600MW

kg/kWh

1 120 1.96

2 115 0.43

300MW

300MW 2011 g/kWh % kg/kWh

27 340.78 7.65 0.35

209 331.09 6.00 1.73

300MW

kg/kWh

1 201 2.14

2 142 0.79

600MW

600MW 4500

MW

104kWh

104t

104t

660 297000 90.10 92.07

660 297000 86.50 537.57

3.66 -445.50

600 270000 83.50 83.70

600 270000 80.80 569.70

2.72 -486.00

4.

2004

600MW

1.

2.

3.

4

.

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1.

2.


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3.

4.

M


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2

DL/T 244-2012

(DL/T 1290-2013)

5.

5.1

(1)

(2)

(3) 100%

75kPa-85kPa

mm450 600 620 680 940 1100

m24.52 8.33

MW

150MW

200MW

300~600MW

600MW 600~1000MW 1000MW

mm435 540 665 720 910 1050

m2 2.42 4.43 6.0 7.60 9.2

135MW 300~600MW 600MW 600~1000MW 1000MW

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MW

mm410 658 661 770 863 1030

m22.25 4.17 4.85 6.47 7.5 9.5

MW

135MW

200MW

300~600MW

600MW 600~1000MW 1000MW

5.2


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6.

6.1

6.2

6.3 6.4

6.5

6.6

4368

(P.C.):130021

(E-mail): [email protected]

(Tel): 0431-85798434

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Development of direct ACC in China

HuiChao ChenChengXian MengLingGuo ZhaiYingJun

ACC Technology Center of China Power Engineering Consulting Group Co., Ltd.

No.4368 130021,Renmin Street,ChangChun City

Abstract: The ACC technology, which has solved the contradiction between power development

and limited water resources by means of the excellent performance of water saving, has become

the best option of a large power plant in the areas rich in coal and scanty in water. In the past ten

years, China has built a number of 300MW, 600MW level of air cooling units. This paper

focuses on the summary of the development process of direct ACC in China.

Key words: Direct ACC Development

1. Summary

The ACC technology, which becomes the best option of a large capacity plant in the coalrichness and water shortage area, resolves the contradiction effectively between power

development and scarce water resources at its superior water saving performance. In the past ten

years, our country has built a number of 300MW, 600MW air cooling units in the north of water

shortage areas , and the capacity is more and more. Especially the operation of 1000MW direct

air cooling unit becomes a landmark in China's air cooling technology development. It has

accumulated a lot of valuable experience for the development of large air cooling units in China.

2. Development and capacity of direct ACC units in China

The direct air cooling technology of our country's power plant was started in the 60's,and the test

of the direct air cooling system was carried out in the 50 kW unit of Harbin Institute of

Technology in 1966. The industrial direct air cooling system was carried out directly in the 1.5MW unit of Houma Shanxi power plant in 1967. The actual operation in the industrial was in

2000, and its expansion of the application has been rapid since that time.

Our own design, manufacturing and installation of the first 6 MW direct air cooling unit, which

was in power plant owned by Shanxi Jiaocheng Yiwang factory ,was built and put into operation

in September 2001.

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s


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The first 200MW direct air cooling unit was successfully put into operation in 2003 in Shanxi,

Datang Yungang Thermal Power Co. Ltd.

2x300MW subcritical direct air cooling unit of Huaneng Yushe was put into operation in October

2004.

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2x600MW subcritical direct air cooling unit of Shanxi Datong No.two power plant was put into

operation in April 2005.

2x600MW supercritical direct air cooling unit of Huaneng Shangan Power Plant was put into

operation in June 2008.

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The first 600MW sub.critical direct air cooling unit of China's own design, manufacturing and

installation in Tongliao power plant was put into operation in July 2008.

2x1000MW ultrasupercritical direct air cooling unit of Huadian Lingwu power plant was put into

operation in December 2010.

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At of the end of 2014, the capacity of direct and indirect air cooling units in china as follows :

year 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 Total

construction

unitscapacity

MW

4110 13310 10000 17550 22650 22540 22650 28755 19837 33905 22265 200152

Direct air

coolingunits

capacity(MW)

4110 1 3310 10000 17550 19050 19480 13125 16270 8750 13630 7520 125375

Proportion

of direct aircooling

units (%)

100.00 100.00 100.00 100.00 84.11 86.42 57.95 56.58 44.11 40.20 33.77 62.64

Indirect aircooling

units

capacity(MW)

0 0 0 0 3600 1860 9525 12485 11087 20275 14745 74777

proportionof indirect

air coolingunits (%)

0.00 0.00 0.00 0.00 15.89 8.25 42.05 43.42 55.89 59.80 66.23 37.36

The chart based on the above form as follows:

0

5000

10000

15000

20000

25000

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014

MW

It could be seen from the above chart that China's direct air cooling units of power plant

construction reached a peak in 2009. The direct air cooling units which had been put into

operation gradually exposed some problems at that time: such as high operating backpressure in

summer, weakness of anti wind capability. And at the same time, the domestic steam coal price

was at a high point, see the figures as below:

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Therefore, the indirect air cooling unit whose operating cost is relatively low, and the units with

stronger wind-resistance capability have gradually developed in China.

3. Operating conditions of direct air cooling units in China

The more than 300 MW of the direct air cooling power plants in production and construction

were 157 units until the end of 2014. There were 114 power plants in total which were put intooperation, and more than 600 MW were 51 power plants. According to the electrical assembly

unit benchmarking report, above 600 MW capacity air cooling units coal consumption, power

supply and water consumption are as follows:

Form of operating parameters of the 600MW unitw ( annual average in 2012)

Item Statistical units(set)

Coal consumptionof power supply

g/kWh)

Plant powerconsumption rate

%

Waterconsumption rate

kg/kWh

Supercritical aircooling unit

23 324.44 6.48 0.31

Subcritical aircooling unit 42 336.30 7.99 0.31

Supercritical water

cooled unit

126 305.27 4.64 1.12

Subcritical water

cooling unit

72 316.29 5.35 1.31

Note: The direct air cooling unit are 60 sets, and indirect air cooling unit are 5 sets.

600MW wet cooling units average water consumption rate

No. Classification condition Statistical units (set) Water consumption rate

kg/kWh

1 Closed cycle 120 1.96

2 Open cycle 115 0.43Air cooling units above 300MW electricity consumption and water consumption rate of the

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average values as follows:

Form of operating parameters of the 300MW unit (2011 Annual Average)

Item Statistical units

(set)

Coal consumption

of power supply

g/kWh

Plant power

consumption rate

%

Waterconsumption rate

kg/kWh

Air cooling unit 27 340.78 7.65 0.35

Water cooling unit 209 331.09 6.00 1.73

300MW wet cooling units average water consumption rate

No. Classification condition Statistical units (set) Water consumption rate

kg/kWh

1 Closed cycle 201 2.14

2 Open cycle 142 0.79

According to the above statistics of data , one 600MW unit are as follows:

600MW unit annual consumption of coal consumption and water consumption

Unit type capcityMWannual power supply

104kWh

coal consumption

104t

water consumption

104t

Supercritical air

cooling unit660 297000 90.10 92.07

Supercritical watercooling unit

660 297000 86.50 537.57

Increased value of air cooling unit 3.66 -445.50

Subcritical air

cooling unit600 270000 83.50 83.70

Subcritical water

cooling unit600 270000 80.80 569.70

Increased value of air cooling unit 2.72 -486.00

Note: (4500 h per year).

4. The development of direct air cooling technology research in China

Relying on the 600MW subcritical direct air cooling unit in Tongliao power plant , China began

to design the direct air cooling system. It mainly carried out the following research projects:

1.direct air cooling system optimization design and technology research

Including:Determination of air cooling system design temperature;Determination of

thermodynamic calculation of direct air cooling system, air resistance calculation and

optimization calculation method; environmental wind effects on the cooling condenser system

performance.

2.Research on design and technology of direct air cooling exhausted steam pipe

Design of large diameter and thin wall negative pressure exhausted steam pipe.

3.Research on design and technology of supporting structure for air cooling condenser

Including: the diagonal section of reinforced concrete circular column, the influence of the wind

disturbance force on the vibration of the platform structure, the overall seismic performance of

the platform structure, the mechanical performance of the truss joints.

4.Design of condensate system for super critical air cooling unit

Selection of ion exchange resin for the treatment of condensate water.

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And a large number of experiments have been carried out, including:

1. Simulator test regarding the effect of ambient air on the direct air cooling system and the

layout of air cooling condenser

2. Wind tunnel simulation experiment of air cooling system

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3. Mathematical and physical model tests of the characteristics of the fluid in steam

exhausted pipes

4.Finite element analysis of structural strength of air cooling units pipe system

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5.Large model test of air condenser bracket structure

Design of direct air cooling system with independent intellectual property rights:

Air cooling island in 3D views 1

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Air cooling island in 3D views 2

Formulate a series of standards and codes by summing up the experience and lessons in all

aspects:

Technical specification for design of direct air cooling system of thermal power plant

Direct air cooling system performance test codeDL/T 244-2012

Direct air cooling system acceptance guideelectric power industry standard

Direct air cooling unit vacuum tightness test method(DL/T 1290-2013)

Guide for operation of direct air cooling system of thermal power plantSingle row tube bundle of power plant direct air cooled condenser

Standard for construction and acceptance of exhausted steam pipe for power plant air

cooling island

Standard for construction and acceptance of steel structure for power plant air cooling

island

Power station air cooling fan

Specification for all aspects of the direct air cooling system.

5.Main Equipments of ACC

5.1 Direct air cooling steam turbineThe direct air cooling steam turbine is developed on the basis of wet steam turbine. Air cooling

steam turbine focus economy under the low pressure (high load capacity) and safety and

reliability under high pressure and minimum volume flow rate. The former allows but not

economic; the latter is not allowed to appear. Main reasons as follows:

(1)The operating conditions changes frequently with the ambient air temperature.

(2)The high pressure can easily happen under different loads in the actual operation.

(3)Abnormal situation such as load shedding under the highest summer temperature, and

some damaged air cooling fans. At this time, maximum backpressure can reach up to

75kPa-85kPa under the condition of the highest temperature plus 100% shedding load bypass

and damaged fans. The breakers will definitely stop because of blower overheat.

The domestic main steam turbine manufacturers have specialized in developing the respectivecharacteristics of the air cooling steam turbines:

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HTC

terminal

blade length

mm450 600 620 680 940 1100

circular area

m2

4.52 8.33

applicationmodels

MW

150MW

class

200MWclass

300~600MW class

600MW600~1000M

W1000MW

STC

terminalblade length

mm435 540 665 720 910 1050

circular area

m2

2.42 4.43 6.0 7.60 9.2

application

models

MW

135MW

class

300~600MW class

600MW600~1000M

W1000MW

DEC

terminalblade length

mm

410 658 661 770 863 1030

circular area

m2

2.25 4.17 4.85 6.47 7.5 9.5

application

models

MW

135M

Wclass

200MW

class

300~600M

W class600MW

600~1000M

W1000MW

5.2 Direct air cooling condenser

Air cooling condenser is one of key equipments in power plant, single row tube condensers most

widely used in the direct air cooling unit. It has been researched and developed successfully andsupplied a lot by domestic manufactures.

Single row brazed welding pipe device:

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Automatic welding tube:

Deposited fouling from air infulence on air cooling equipment heat transfering test:

6. Development tendency of direct air cooling system

6.1 We know the direct air cooling and indirect air cooling with all aspects after nearly10 years

of exploration and summary. We will be more rational on construction of power plants.

6.2 Air cooling system is good at water saving, but it causes high coal consumption. Air cooling

steam turbine parameters will be further improved, so the coal consumption is further reduced.6.3 Direct air cooling condenser cooling efficiency is devoloped towards a higher direction;


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6.4 The direct air cooling system with the ability of anti wind is more competitive;

6.5 It has been applied at some points that water supply pump turbine, the main engine

isometric drive technology, and the exhausted steam of water supply pump goes into the host air

cooling system directly.

6.6 Direct air cooling system with natural ventilation is applied with small scale.

About the author:

Hui Chao ,director of air cooling technology center ,China Power Engineering Consulting Coopertation Group.Post Address: No,4368,Renmin street,Changchun city.

(P.C.):130021(E-mail): [email protected]

(Tel): 0431-85798434

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ACC Industry

Status and Developments

ACC Industry

Status and Developments

Dr. Andrew G. Howell

International Air-Cooled Condenser Meeting

October 13-15, 2015 Xian, China

Air-Cooled Condenser Users Group

ACCUG established 2009

Website: http://acc-usersgroup.org/

Look under Presentations tab for presentations

from the first 7 years of meetings.

Evaporative (Wet) Cooling TowerDry (Air) Cooling

Parallel CoolingAir Cooled Condenser Under Construction


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Main Turbine Exhaust Duct: 35 11 m)

diameter


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Typical Large

Air-Cooled Condenser

45 fans, drawing ~8 MW combined

9 streets or bays, 20,358 tubes total

tubes:

single-row

35.3 feet (10.8 m) length

8.2 by 0.75 inch (21 by 2 cm) cross-section

carbon steel with aluminum exterior fins

0.059 inch (1.5 mm) wall thickness

1,158,902 ft2 internal (107,000 m2)

16,514,080 ft2 external (1,500,000 m2)

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From Craig Ripley 2011 ACCUG meeting

Coating process options

Note: only high-pressure cladding and molten aluminumdipping are believed to have been used for Al coatingof ACC tubes at this point.

High pressure cladding

costly process although costs havelowered

strong steel-to-aluminum bond

E le me nt W t%

Al

99

Si 1

F e


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Coating process options

Dipping tubes in molten aluminum

lower cost

lower thickness

uniformity and durability of coatinguncertain

Coating processes

Influence of manufacturing process oninternal tube Al contamination is uncertain

dipped tubes risk internal Al if not enclosedadequately (parallel with known problem forZn-coated tubes)

brazing temperature is too low for Alvolatilization

Concerns regarding Al coating

Possible ingress of Al to tube interior duringmanufacture

deposition on HP section of steam turbine

and loss of turbine performancelimited options for removal of Al deposits

from HP turbine other than turbine outage(7 to 10-year cycle)

E l em en t W ei g ht % A to m ic %

Na 17 25

Al 18 23

Si 20 25

S 2 2

K 3 3

Fe 21 13

Cu 18 10

Totals 100

Improper Galvanic Tube Coating

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Air Cooled Condenser Design

Last major design change in direct-cooledACCs was in 1991: single-row finned tubes

Changes since that time have been relative minor:

tube coating / fin spacing

investigating electric vs geared fan power

wind considerations shields, siting etc.

fan blade material / variable speed motors

fast starting capability

control & freeze protection strategies

construction efficiency to lower labor cost

enhanced controls

performance improvement with available water

Air Cooled Condenser Design

Indirect-cooled ACCs have not seen widespread useworldwide, but have some favorable characteristics

lower energy requirements

easier to design limited water cooling support

uncertainties about materials (aluminum heatexchange tubing)

can be retrofitted to an existing wet-cooled plantmuch easier than with a direct-cooled ACC

Air Cooling Alternatives

Research is ongoing into various alternative dry coolingtechnologies, but none has reached full-scaleimplementation at this point

Electric Power Research Institute, U.S. National Science

Foundation, U.S. Department of Energy, EuropeanUnion projects

Air Cooled Condenser Applications

Initially applied in water-deficient regions of the world:

South Africa

Australia

Western United States

China

Recent installations in areas with plenty of water, due toenvironmental regulations limiting water use.

Air Cooled Condenser Applications

Initially applied in water-deficient regions of the world:

South Africa

Australia

Western United States

China

Recent installations in areas with plenty of water, due toenvironmental regulations limiting water use.

Concentrated solar plants often use dry cooling

Hybrid (wet-dry) cooling is an important option whereadequate water is available.

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Distribution of Air-Cooled Condensersfor Power Generation: North America

USA more than 100, most direct-cooledcombined cycle plants, some coal and solar, afew parallel wet-dry cooled units

Mexico growing number of direct-cooledcombined cycle plants

Canada a few combined cycle plants

Distribution of Air-Cooled Condensersfor Power Generation: North America

Estimated that 20-40% of new plants in NorthAmerica will be dry-cooled, a steady toincreasing trend

Lack of access to water is promoting ACCseven where plenty of water is present,including difficulty getting water use permits

Increasing interest in hybrid cooling,including retrofit, although few have beeninstalled at this point

Distribution of Air-Cooled Condensersfor Power Generation:

Central / South America

ACC units in Peru, Venezuela, Argentina,Brazil, Trinidad & Tobago direct-cooled,combined cycle plants

Distribution of Air-Cooled Condensersfor Power Generation: Europe

ACC units in Ireland, United Kingdom, Spain,Belgium, Luxemburg, Italy, Greece

most direct-cooled, limited indirect-cooled

Distribution of Air-Cooled Condensersfor Power Generation: Middle-East

ACC units in Turkey, Israel, Jordan, SaudiArabia, Qatar, Bahrain

most direct-cooled, combined cycle plants

Distribution of Air-Cooled Condensersfor Power Generation: Africa

ACC units in Algeria, Morocco, South Africa,Ivory Coast

direct-cooled, limited indirect-cooled; coaland combined cycle units, several solarinstallations

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Distribution of Air-Cooled Condensersfor Power Generation: Asia

Increasing installation of direct-cooled ACCs,including India, Bangladesh, Indonesia,Vietnam, Pakistan, Taiwan, Japan, China,Russia

China: more than 100 ACCs and increasingrapidly. Many are direct-cooled, more recentemphasis on indirect-cooled due to powersavings; virtually all are on coal-fired units.

Distribution of Air-Cooled Condensersfor Power Generation: China

~ 1,430 GW of total power generation: ~10%use ACCs, approaching half of thermal powergeneration in rapidly-growing sector

Distribution of Air-Cooled Condensersfor Power Generation: Australia

Several ACCs, coal-fired and combined cycleapplications

Conclusions

Dry Cooling is an important technology forthermal power generation that is increasing inits application. It is anticipated that bothdirect and indirect dry cooling will continue to

be major options for new plant construction inthe next few decades, with hybrid coolinginstallations, including retrofits, also likely toincrease.

Input appreciated regardingstatus / trends with ACCs

SPX

Evapco-BLCT

GEA

SPIG

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ACC Corrosion/FAC

and

Cycle Chemistry

International ACC Conference

Xian, China

13th 16th October 2015

Barry Dooley

ACC Come in Many Sizes

Courtesy of Eskom.But the FAC / Corrosion damage is the same worldw ide with all chemistr ies

Corrosion/FAC in ACC and The Consequences

High concentrations of iron around the cycle

- Boiler/HRSG deposits (expensive ch emical cleaning)

- Boiler/HRSG Tube Failures (overheating and TF)

- Steam Turbine Deposits (including aluminum)

Need for Iron Removal Processes

- Condensate Polishing and/or Filters Limitations around the cycle

- Condensate polishing (may have to change mode)

Overall an ACC controls the unit cycle chemistry

- International Guidelines now available for ACC

and two-phase flow (IAPWS Volatile Guid ance 2015)

There is an ACC Corrosion

Index to Categorize Corros ion

and Track Improvments

DHACI

(Dooley, Howell, Air-cooled Condenser,

Corrosion Index)

DHACI

(Dooley, Howell, Air-cooled Condenser,

Corrosion Index)

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DHACI for Tube Inlets

1. Tube entries in relatively good sh ape (maybe some

dark deposited areas)

2. Various black/grey deposits on tube entries as well as

flash rust areas, but no whi te bare metal areas

3. Few white bare metal areas on a number of tube

entries. Some black areas of deposit

4. Serious white bare metal areas on/at numerous tube

entries. Lots of bl ack areas of deposition adjacent to

whi te areas

5. Most serious. Holes in the tubing or welding. Obviouscorrosion o n many tube entries

Dooley & How ell et al, PPChem 2009

Examples included on later slides

DHACI for Low er Ducts

A. Duc ting shows no general signs of tw o-phase damage

B. Minor white areas on generally grey ducting. Maybe

some tiger striping with darker grey/black areas of

two-phase damage

C. Serious whi te bare metal areas in the hot box and at

numerous changes of direction (eg. at intersections o f

exhaust duct ing to vertical riser). White areas are

obvious regions of lost metal.

Dooley & How ell et al, PPChem 2009

We know what the Corrosion Looks Like

DHACI 3DHACI 4

DHACI 3

The FAC / Corrosion damage is the same worldw ide with all cyc le chemistries

and what Holes at Tube Entries Look Like

DHACI 5

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Inspections Worldwide show the same FeaturesCombined Cycle with ACC after ~ 15,000 hrs.

Concentration of Two-phase

FAC beneath Supports

DHACI 3

Inspections Worldwide show the same Features750 MW Supercri tic al on OT at pH 9, ~4,000 hrs.



Source: Richardson and Joy, ACCUG 2011

DHACI 4

Inspections in China650 MW Supercritical with Shuang Liang ACC. 15 Months.



ACC Duct Work not Passi vatedDHACI 3

So is the ACC Corros ion Mechanism

Low Temperature Two-Phase FAC?

which is

Dependent on Removing the

Saturation of Fe3O4 at the Surface and

Precipitating/Depositing it Adjacently

(Two ACC Tubes with damage (white areas) have been

analyzed)

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Normal Two-phase FAC in Flowing Turbulent Flow(Removes the Saturation of Fe3O4)

Dooley, PPChem 2008

Inside diameter surface of an ACC Tube

Shiny white metal

The black areas are where the

Fe3O4 is Precipitated/Deposited

Locally

6 inch section of ACC tube and detail of the surface showing black deposits and white bare metal areas

Second Tube Showed the Same Features Typical Microscopic Appearance of FAC and ACC

Corrosion

Normal FAC in Fossil Feedwater

and in Combined Cycle/HRSG

Circuits

FAC Damage in ACCs

(white areas)

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So do we Fully Understand the

Environment and the Corrosion

Mechanism?

Solutions are already being appliedIncrease bulk pH up to 9.8

Increase local pH (amines including filming)

Filters (average and absolute) and condensate polishers

Coatings (epoxy), Sleeves, Inserts

Alternate Materi als t o CSDesigns

To Understand the Corrosion Here we need to

Understand the Environment in the PTZ

The PTZ Environment in the LP Steam Turbine is

Completely Understood

Generation of the ACC Environment

Heterogeneous droplet

Nucleation and

Liquid Films on ST Blades

(Droplets and Liquid Films in

the ACC vary from0.1 50 microns and d ont

contain any oxygen until during

shutdown)

2000

2200

2400

2600

2800

3000

3200

3400

3600

3800

5.5 6.5 7.5 8.5

Entropy (kJ/kg/K)

Enthalpy

(kJ/kg)

500

400

300

200

100

600

C

200

100 50 20

10 5

2

1 0.5 0.2 0 .1 0 .05

0.95

0.90

0.85

0.80bar

bar

x

A B

C

Source: IAPWS Technical Guidance Document 2013

Mollier Diagram

A.Fos sil Reheat Turbine

B. Backpressure Turbine

C. Reheat Turbine in a

nuclear LWR plant

Droplets


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The Liquid in ACC Upper Ducts(Lower pH and higher chlorides)

0

5

10

15

20

25

30

35 Chlorideduct cpp

Courtesy Setsweke Phala, Eskom

0

2

4

6

8

10

12 pH

duct cpp

Damage takes time to repair (ex. 2 Years w ith p H 9.8)

DHACI 2


Cross member

LDI not quickly

repaired by pH

DHACI 4DHACI 2

Damage takes time to repair (15 Months with pH 9.8)

Source: Barnett & Olszewski, 2013 FAC Conf. Washington

DHACI 4 DHACI 2

0

10

20

30

40

50

60

70

80

90

100

6/Aug/2007 14/Nov/2007 22/Feb/2008 1/Jun/2008 9/Sep/2008 18/Dec/2008 28/Mar/2009 6/Jul/2009 14/Oct/2009 22/Jan/2010 2/May/2010

IroninCondensate(ug/L)

Operation

atpH9.0

Operation

atpH9.5

Operationat

pH9.8

Dooley/AspdenpH/Fe Relationship.

PPChem 2009


Plant Improvements in ACCs (reduction of t otal iron) are Directly in Agreement

with the Dooley/Aspden relationship

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Thoughts on corrosion in air-cooled condensersBased on work conducted in Australia, Chile, China, Dubai, India, Ireland, Mexico,

Qatar, South Africa, UK and US

Increasing condensate pH to 9.8 will graduallyeliminate the FAC damage at the tubeentries and iron levels will reduce to IAPWSsuggested levels (5 - 10 ppb). Documentedby reducing the DHACI

Damage on cross members is not repaired

as quickly by increasing pH. Is this LDIcaused by the larger droplets leaving thePTZ of the LP Steam Turbine?

Copyright Struct ural Integrity Associates, Inc. 2015

Summary

Some aspects r elate to (LT Two-phase) FAC Adjacent black and white areas in severe turbulent areas

Increasing local pH reduces damage

But some aspects dont (normal FAC scalloped appearance andwhite areas on cross members is probably LDI)

Environment is known and has been measured Two-phase mixture formed in PTZ of the steam turbine

Concentrating liquids (Higher in chloride/sulphate, organics )

Lower in pH (0.5) and very low in dissolved oxygen (close to zero)

Repaired two-phase FAC areas turn red slowly Mechanism in ACC is thus not totally understood & what are amines doing?

Results from a number of pl ants indicate increased Al

levels in turbine and drum deposits- This may result from initial operation

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Session 1 Condensate Polishing in

Air-Cooled Units


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1 2 1 2 1 1

1. 710054

2. 021025

:

(Thermal Power Research InstituteTPRI)

2015 2600MW

10.0 m3

17.7 m3 240

1.8 m3 2.7 m3 120

1

[1]

[2]

0.1%

80%

1.0%

5.0%

TPRI 2011

2012 8 IRIC

I n s t r u m e n t o f i m a g e r e c o g n i t i o n

a n d i n t e l l i g e n t c o n t r o l o f r e s i n s t r a n s p o r t a t i o n IRIC TPRI

IRIC

IRIC IRIC

2 IRIC

2.1

IRIC

2.2 IRIC

IRIC 3

2


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IRIC

95%IRIC 1

1 IRIC

4 100 1280*720

0.5s 3

2 IRIC

2

2

3


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3

PLC4 I/O

2400h W i n d o w s C ELinux

Android 4

4

2.3 IRIC

IRIC

1

0.7%~5% 0.1%

1:1 4m3 10min

5~30s 0.03m3~0.2m3


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4m3 0.7%~5% 0.1%

IRIC PLC 0.5s

0.003m3 4 m3 0.07%

2

mg/L

2:1 3:2 1:1

2:3

IRIC

IRIC

2.4 IRIC

IRIC 13 28 28 60%

IRIC

3

3.1

2600MW 2010 3

3

1 7.64g/L 7.21g/L 4

2 10.0 m3 15.0 m3 67%

3.2

1

1.7% 5.4%

2

3.3

3.3.1 IRIC

2015 3 IRIC

1%

3.3.2 PLC 1

R


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2 PLC

PLC

3.4

2015 6 3

17

4.8m3 3.2m3 3:2

1%

2 1.7% 0.07%

5.4% 0.08%

3 0.2g/L 0.6g/L 3g/L 3g/L D L / T 9 1 2 - 2 0 0 5

4 10.0 m3 17.7 m3 77%

5 111 70 240

1.8 m3 2.7 m3 35 120 /

4

1IRIC

95%

2 IRIC

0.07% 0.08%

77% 300

[1] [M].2010.

[2] J.200740(12)9 0 - 9 3 .

H A N L i c h u a n , L I Z h i g a n g . R e s e a r c h o n M e c h a n i s m a n d A p p l i c a t i o n o f M i x e d B e d P o l i s h e r [ J ] . E l e c t r i c P o w e r ,

2007,40(12):90- 93.

[3] 2 0 1 2 1

0 3 9 8 5 9 8 . 5 [ P ] : 2 0 1 4 - 0 5 - 0 7 .

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1968

029-82002108

Email: [email protected]


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In t e l l i g e n t M o n i t o r i n g o f R e s i n s S e p a r a t i o n a n d T r a n s p o r t a t i o n f o r M i x e d B e d

P o l i s h e r a n d T h e A p p l i c a t i o n i n A i r - c o o l e d U n i t s

Wenhua Tian[1], J i a n L i [2], P e n g L i [1], C h u n r e n L u o [2], X i a o l i a n g Z h u[1], Y i n Q i a n[1]

X i a n T h e r m a l P o w e r R e s e a r c h I n s t i t u t e C o . L t d . , X i a n , S h a a n x i , P . R . C h i n a , 7 1 0 0 5 4

G u o h u a I n n e r M o n g o l i a H u l u n B u i r P o w e r G e n e r a t i o n C o . , L t d , H u l u n B u i r , I n n e r M o n g o l i a , P . R . C h i n a , 0 2 1 0 2 5

Abstract: T h e e f fe c t s o f r e si n s s e pa r at i on a n d t r an s po r ta t io n f o r m i xe d b e d ( M B) p o li s he r a r e p o o r

a nd u n st ab le a s l ac ki ng o f e ff ec t iv e m on it or in g , n e ga ti v el y i mp a ct in g o p er at io n al e ff ec t s o f M B

polisher. Concerning about this issue, Thermal Power Research Institute (TPRI) developed ani n te l li g en t m o n it o ri n g e q ui p me n t , w h i c h i s a b le t o n o t o n l y a c c u r at e ly i n sp e c t t h e t e rm i na l p o i nt o f

r es i ns s epar ati on and t r anspor t ati on, det er m i ni ng r es i ns vol um e and i ncr eas i ng s epar at i on per cent age

o f e x ha u st ed r es in s, b ut a ls o a d ju st t he r at io o f c at io n t o a n io n r es in s, i nc re as in g p er io d ic w at er

production of MB polisher, determining resins transportation rate, avoiding incomplete resinst r an s po r ta t io n , m o ni t or i ng r e si n s t o ta l v o l um e a n d e s ti m at i ng r e si n s l e ak a g e w i th o u t c h an g i ng t h e

i nt er na l s tr uc t ur e o f s ep ar at io n v e ss el . I t h a s b e en s uc c es sf ul ly a p pl ie d i n o v er t en p o we r p la n ts i n

C h i n a . I n 2 0 1 5 , a f t e r t h e 2 6 0 0 M W d i r e c t s u p e r c r i t i c a l c o a l - f i r e d u n i t s i n a n I n n e r M o n g o l i a p o w e r plant applied this equipment, MB operation is much more reliable. Periodic water production is

i nc re as ed f ro m 1 0, 0 00 m 3 to 17, 700 m3. R e si ns r eg e ne ra ti o n t im es a re s ha rp d e cr ea se d , s av i ng

h ig h- qu al it y a ci d a nd a lk al in e b y 2 40 t on /y ea r a nd a ls o r ed uc in g t he c or re sp on di ng r is k o f d a n ge r ou s g o o ds t r an s p or t at i on a n d s t or a ge . A d d it i on a ll y , 1 8 , 0 0 0 m3 d e mi n e ra l iz e d w a te r a n d 2 7 ,

0 0 0 m3 f re sh w at er y e ar c an b e s av ed a n nu a ll y, w h ic h h as s ig n if ic an t e ff ec t a t w at er s av in g . T h ed i r e c t b e n e f i t i s a b o u t 1 . 2 M R M B / y e a r .

Keywords: d ir ec t a ir -c oo le d; c on de ns at e p ol is hi ng ; m ix ed b ed p ol is he r; r es in s s ep ar at io n

percentage; intelligent monitoring; water saving and emission reducing

1. Introduction

M ix ed b ed ( MB ) p ol is he r i n c on de ns at e p ol is hi ng i s o f t he g re at i mp or ta nc e t o g ua ra nt ee t he

f e ed w at e r p u ri t y. R e si n s s e pa r at i on a r ra n ge m en t s s h ou l d b e o p e ra t ed a u to m at i ca l ly a s d e si g n ed .

H o we v e r, F u ll s ep a n d C o n es e p, t h e m o st p o p ul a r a n d e f fe c ti v e r e si n s s e pa r at i on a r ra n g em e nt s , a r e

n o t a b l e t o b e p r og r am - co n tr o ll e d. T h e r e si n s s e pa r at i on p e rc e n ta g e d o n o t r e ac h t h e d e si g ne d v a l uet o m e et t he r eq u ir em en t o f b ot h a ni on r es in i n c at io n a n d ca ti on r es in i n a n io n l es s t ha n 0 . 1% .

T P R I f o un d t h at r e si n s s e pa r at i on p e rc e n ta g e o f 8 0 % s e pa r at i on a r ra n g em e nt s a r e g r ea t er t h an 1 % ,

e ve n t ha n 5 %, w hi ch h as a g re at i mp ac t t o e ff lu en t q ua li ty o f M B p ol is he r a nd p er io di c w at er

production.

A ft er r es ea rc h a nd i nv es ti ga ti on i n m an y p o we r p l an ts , i t i s f ou n d t ha t r es in s a re c h an g ed i n s iz e ,

s pe ci fi c g ra v it y a nd b i g d i ff er en ce i n c o lo r c o mp a re d w it h t he i ni ti al s ta te , r es ul ti ng i n t h at i t i s n o t

a bl e t o d et ec t t he c a ti on a n d a ni on r es in s i nt er fa ce b y p h ot oe le ct ri c d et ec ti o n a nd c o nd u ct iv i tyd et ec ti on . T h er ef or e, r es in s s ep ar at io n e q ui pm en t i s u n ab le t o b e p ro g ra m- co n tr ol le d a nd r es in s

s ep ar at io n a n d t ra n sp or ta ti on h a ve t o b e m an u al ly o p er at ed . C on c er ni ng a b ou t t hi s i ss ue , T P RI

s ta rt ed t o r es ea rc h o n i n te ll ig e nt m on i to ri ng r es in s i nt er fa c e s in ce 2 0 11 . I n A u gu st 2 0 12 , T P RId e v el o pe d t h e i n te l li g en t m o ni t or i ng e q u ip m en t , n a me d a s I ns t ru m en t o f i m ag e r e co g n it i on a n d

i nt el li ge nt c on tr ol o f r es in t ra ns po rt at io n ( IR IC , C hi ne se i nv en ti on p at en t, N o. ZL 2 01 2 1

0 39 85 98 .5 ). ) , a nd s ta rt ed t o a pp ly I RI C i n s om e p ow er p la nt s. L at er o n, T PR I d ev el op ed t he

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s e co n d g e ne r a ti o n o f I R IC b y i n te g ra t in g t h e r e se a rc h r e su l t o f c o n de n sa t e p o l is h in g o p ti m iz a t io n

w i t h t h e t e c h n o l o g y o f r e s i n s i n t e r f a c e m o n i t o r i n g . I R I C 2 . 0 h a s b e e n a l r e a d y s u c c e s s f u l l y a p p l i e d i n

m any pow er pl ant s .

2 . T e c h n i c a l I n t r o d u c t i o n o f I R I C

2.1 Principle

I n t h e p r o c e s s o f r e s i n s s e p a r a t i o n a n d t r a n s p o r t a t i o n , d y n a m i c r e s i n s i m a g e s a r e a c h i e v e d t h r o u g h

s i g h t g l a s s e s o f s e p a r a t i o n v e s s e l . T h e c a t i o n a n d a n i o n r e s i n s i n t e r f a c e a n d r e s i n s s u p e r f a c e a r e

e s t i m a t e d b y t h e i n t e l l i g e n t i m a g e r e c o g n i t i o n t e c h n o l o g y . T h e v o l u m e o f c a t i o n r e s i n s , a n i o n r e s i n s

a n d t h e t o t a l r e s i n s w i l l b e c a l c u l a t e d . T h e n , r e s i n s s e p a r a t i o n s t e p s a n d c o n t r o l p o i n t s w i l l b e g i v e n

a c c o r d i n g t o t h e m o n i t o r e d r e s u l t s . I n t h i s w a y , r e s i n s s e p a r a t i o n a n d t r a n s p o r t a t i o n c a n b e p r o g r a m -

controlled.

.2 Composition

I RI C i s c o ns is t o f t hr ee s ec ti on s, i n cl ud in g r es in s i nt er fa ce i ma g e a cq u is it io n , i nt er fa ce i ma g es

i n te l li g en t r e c og n i ti o n, c o nt r ol p r o gr a m o f r e si n s t r an s po r ta t io n . R e si n s i n te r fa c e i m ag e a c q ui s it i ons ec ti on i s f un ct io n o f a ch ie vi ng t he r ea l t im e i ma ge s o f r es in s s ep ar at io n a nd t ra ns po rt at io n;

i nt er fa ce i ma g es i nt el li ge n t r ec o gn it io n s ec ti on i s f un ct io n o f a n al yz in g t h e a ch i ev ed i ma g es a n d

s e nd i ng c o n tr o l s i gn a l s a s r e sp o n se ; c o n tr o l p r og r am o f r e si n s t r an s po r ta t io n a c ts a s " S i gn a l B r id g e"

between the two sections above, and is responsible for implementing control instructions. The coreo f I R IC i s i n te r fa c e i m ag e s i n te l li g en t r e co g n it i on s e ct i on , w h ic h i s d e v el o pe d o n t h e b a si s o f S e lf -

a d a pt i on a l go r it h m o f r e si n s s e pa r at i on a n d t ra n s po r ta t io n i m ag e s , w i th t h e a c c ur a cy o f i n sp e c ti n g

t he r es in s t ra ns po rt at io n t er mi na l p oi nt h ig h er t h an 9 5% . F ig u re 1 i s t h e s ys te m d ia g ra m o f I RI C

appl i ed i n F ul l s ep.

F i g u r e 1 . I R I C s y s t e m d i a g r a m i n F u l l s e p

a ) R e si n s i n t er f ac e i m ag e a c q ui s it i on s e c ti o n

2

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R e s i n s i n t e r f a c e i m a g e a c q u i s i t i o n s e c t i o n i s c o n s i s t o f h i g h d e f i n i t i o n i n d u s t r i a l d i g i t a l c a m e r a , h i g h

d e fi n it i on c a me r a , f l oo d li g h t a n d s p e ci a l s u pp o rt . H i gh d e fi n it i on i n d us t ri a l d i g it a l c a me r a i s t h e

c ore o f t hi s se cti on , w it h p ix el o f 1 M, r eso lu ti on r at io o f 7 20 P a nd d ela y t im e o f i ma ge d ata

t ra ns mi ss io n i s j us t 0 .5 s . I t c a n w o rk u n in te rr up te dl y. S ep a ra ti on v e ss el w a s i ns ta ll ed w it h t hr eer es in s i nt e rf ac e i ma g e a cq u is it io n s ec ti on s, a t u pp e r, m id dl e a nd l o we r s ig h t g la ss , r es pe c ti v el y.

U p pe r s ig h t g l as s s ec ti on i s u se d t o o b se rv e t he s up e rf ac e o f r es in s; m id dl e s ig h t g l as s s ec ti on i s

u s e d t o o b s e r v e t h e r e s i n s i n t e r f a c e a f t e r b a c k w a s h i n g a n d l a y e r i n g ; l o w e r s i g h t g l a s s s e c t i o n i s u s e dt o o b s e r v e t h e l o c a t i o n o f r e s i n s i n t e r f a c e a t t h e e n d o f c a t i o n r e s i n s t r a n s p o r t a t i o n . F i g u r e 2 i s r e s i n s

i n t e r f a c e i m a g e a c q u i s i t i o n s e c t i o n i n s t a l l e d a t l o w e r s i g h t g l a s s a n d u p p e r s i g h t g l a s s .

(At lower sight glas s) (At upper sight glas s)

F i g u r e 2 . R e s i n s i n t e r f a c e i m a g e a c q u i s i t i o n s e c t i o n

b) Interface images intelligent recognition section

I nt er fa c e i ma g es i nt e ll ig en t r ec og n it io n s ec ti on i s c o ns is t o f h o st c o mp u te r a n d r es in s i nt er fa c e

i m a g e i n t e l l i g e n t r e c o g n i t i o n s o f t w a r e , o f w h i c h i n t e l l i g e n t r e c o g n i t i o n s o f t w a r e i s t h e c o r e . F i g u r e 3

i s t h e d i s p l a y i n t e r f a c e o f t h i s s o f t w a r e .

F i g u r e 3 . D i s p l a y i n t e r f a c e o f i n t e r f a c e i m a g e s i n t e l l i g e n t r e c o g n i t i o n s o f t w a r e

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c ) C o nt r ol p r og r am o f r e s i n s t r a ns p or t at i on s e c ti o n

C o n t r o l p r o g r a m o f r e s i n s t r a n s p o r t a t i o n s e c t i o n i s c o n s i s t o f f o u r p a r t s , w h i c h a r e i n t e l l i g e n t c o n t r o l

h o st , c o nt r ol s i gn a l c i rc u i t, t r an s mi s si o n n e tw o rk o f r e si n s m o n it o ri n g i m ag e a n d P L C . I n te l li g e nt

c on tro l h ost i s th e c ore o f t his s ec ti on , c omp os ed o f i nd us tri al g ra de a cc ess ori es , s uc h a ss wi tc hb o ar d, r em ot e I /O a nd L CD d e ve lo pm en t b oa rd . T h e a v er ag e f ai lu re -f re e o pe ra ti o n t im e i s

o v e r 2 4 0 0 h . L C D d e v el o pm e nt b o ar d s u pp o rt s e m be d d ed o p e ra t in g s y st e ms , i n cl u d in g W i nd o w s

C E, L in u x a n d A nd ro i d. T h e i n te ll ig e nt c o nt ro l h os t i s i ns ta ll ed b y h a ng i ng o n t he w al l, e as y a ndc o n v e n i e n t . F i g u r e 4 i s a n i n t e l l i g e n t c o n t r o l h o s t i n s t a l l e d a t t h e f i e l d .

F i g u r e 4 . I n t e l l i g e n t c o n t r o l h o s t

2.3 Function

I RI C i s c o mp a ti bl e t o t he r es in s s ep a ra ti o n a n d t ra n sp o rt at io n w ay a ft er a dj us ti ng t he r es in s r at io ,

w it ho u t c h an gi ng t he s tr uc tu re o f s ep ar at io n v e ss el ; t he w ho le p ro c es s o f r es in s s ep ar at io n a nd

t ra ns po rt at io n c a n b e p ro gr am -c on t ro ll ed , r el ea si ng m an p ow er a n d r ed uc in g t he d i ff ic u lt y o f m an ag em en t; I t i s a bl e t o d ia gn os e a nd e ar ly w ar n t he r es in s v ol um e a nd r at io , a vo id in g r es in sleakage.

( 1 ) B a si c F u n ct i onA c c ur a te l y i n sp e c t t h e t e rm i na l p o in t o f r e si n s s e pa r at i on a n d t r an s p or t at i on , p r ec i se l y m e as u re t h e

v o l u m e o f c a t i o n r e s i n s a n d a n i o n r e s i n s i n M B p o l i s h e r , i n c r e a s i n g r e s i n s s e p a r a t i o n p e r c e n t a g e .

A s s ta te d b e fo re , i t i s n o t r el ia b le t o a pp ly p ho t oe le ct ri c d et ec ti on , c o nd u ct iv it y d et ec ti on a n d

u l tr a so n i c d e t ec t i on f o r d e t ec t in g r e si n s i n te r fa c e. A f te r m a n ua l ly o p er a te d r e si n s s e pa r at i on , t h e

an i on r es in i n c a ti on a nd c at io n r es in i n a ni o n i s a b ou t 0 . 7% ~5 %, o b vi o us ly e x ce e di ng t h e

s t a n d a r d o f 0 . 1 % . F o r e x a m p l e , a s s u m i n g r e s i n r a t i o i s 1 : 1 a n d r e s i n s v o l u m e i s 4 m 3, i t t a k e s 1 0 m i n

t o t r an s po r t c a t io n r e si n s o u t o f s e pa r at i on v e s se l . T h e t r ad i ti o na l m a nu a l o p er a ti o n i s a s f o ll o wi n g:

o b se rv e t he t er mi na l p o in t o f r es in s t ra ns po rt at io n , c al l t he c o nt ro l r oo m, c o nf ir m b y t h e c o nt ro l

r oo m a nd s to p t ra n sp or ta ti on . T h is w ho l e p ro c es s u su a ll y t ak e s 5 s t o 3 0 s, w hi ch m ea n s 0 . 03 m 3 to0.2m3 m o re r es in s t ra ns po rt ed o u t. A s r es in s v ol um e i s 4 m 3, t he e x ce ss t ra ns po rt ed r es in s i s a bo u t

0 .7 %~ 5% o f t he t ot al v o lu me ( la rg e v a ri ab le r an ge ), o b vi ou sl y e x ce e di ng t he s ta n da rd o f 0 .1 %.

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H o we v e r, i t o n ly t a ke s 0 . 5 s w i t h I R IC b y i n sp e c ti n g t h e t e rm i na l p o i nt o f r e si n s t r a n sp o rt a ti o n a n d

s e nd i ng s i gn a l t o P L C, w i th 0 . 0 03 m3 e x c es s t r an s po r te d r e si n s ( l es s t h a n 0 . 0 7 % o f t h e t o ta l v o lu m e,

l ow v ar ia b le r an ge ). T h er ef or e, m an u al o p er at io n i s n o t c ap a bl e t o m ee t t he r eq ui re me n t o f r es in s

r epar at i on per centage.

( 2) E xpanding F unct i on

A d j u s t c a t i o n / a n i o n r e s i n s r a t i o a n d i n c r e a s e p e r i o d i c w a t e r p r o d u c t i o n w i t h o u t c h a n g i n g t h e i n t e r n a ls t ru c tu r e o f s e p ar a ti o n v e s se l , e s ti ma t e r e si n s t r an s po r ta t io n p e rc e nt a ge t o p r ev e n t i n co m p le t e r e si n s

t r a n s p o r t a t i o n , m o n i t o r r e s i n s t o t a l v o l u m e t o e s t i m a t e i f l e a k a g e o r n o t .

M B i s m o s t l y i n H y d r o g e n - t y p e o p e r a t i o n . A s a m m o n i a c o n t e n t i s i n t h e l e v e l o f m g / L , c a t i o n r e s i n s

w i l l b e e x h a u s t e d f i r s t l y , s o r e s i n r a t i o i s b e t t e r t o b e 2 : 1 o r 3 : 2 . H o w e v e r , r e s i n r a t i o i s u s u a l l y s e t a s

1 : 1 o r e v en 2 : 3 a t p r es e nt , r e su l ti n g i n c a ti o n r e s i ns q u i ck l y e x h a u st e d a n d s h or t o p e ra t io n c y c le . I no r d er t o i n c re a se o p e ra t io n c y c le , r e si n r a ti o i s s u pp o se d t o b e a d j us t ed . I n t h i s w a y , r e si n s i n t e r fa c e

w il l n ot b e o bs er ve d t hr ou gh s ig ht g la ss , w hi ch m ea ns t he v es se l s tr uc tu re h as t o b e c ha ng ed o r r ep la ce d . I f a p pl ie d w it h I RI C, i t i s a b le t o a d ju st r es in r at io a n d e xt en d o p er at io n c y cl e w it ho u t

changi ng ves s el s t r uct ur e.

O n t h e o t he r h a n d, I R IC a d d t h e f u n ct i on o f d e te r mi n in g c a ti o n r e si n s v o l u m e, a n i on r e si n s v o l u m e

a n d t o ta l v o lu m e, a n d f u rt h e r t o e x p an d t h e f u nc t io n o f d e t er m in i ng t h e r e si n t r an s po r ta t io n r a te a n dd e te ct in g r es in s l ea ka g e. T he se u p gr ad e w il l g u ar an t ee t h e a c cu ra cy o f r es in t ra n sp o rt at io n a n d

avoi di ng r es i ns l eakage.

2.4 Application

2 0 12 .I RI C h as b e en s uc ce ss fu l ly a p pl ie d t o 2 8 u n it s i n 1 3 p o we r p la nt s s o f ar , o f w h ic h o v er 6 0%

a re ( ul tr a) s up er cr it ic al u n it s. A mo n g t he se 2 2 u n it s, t he re a re b o th a ir -c o ol ed a nd w a te r- co ol ed ;both Fullsep and Conesep for separation. Specifically, the application effects are as following.

3 . C a s e i n d i r e c t a i r - c o o l e d u n i t s

3.1 Introduction

T h e 2 6 00 M W d i re c t s u pe r c ri t ic a l c o a l - fi r ed u n it s i n a n I n ne r M o ng o l ia p o we r p l a nt w e re p u t i n t oo p e ra t io n i n 2 0 1 0. T h e re a r e t h r e e p o wd e x f i te r s a n d t h re e M B s e t f o r c o n de n sa t e p o l i sh i ng s y st e m.

M B r es in s i s r eg e ne ra te d b y e x te rn a l r eg en e ra ti on w it h F u ll se p. A ft er e st im at io n, T P RI f ou n d o u t

t he pr obl em s as f ol l ow i ng:

(1 ) A t t he e nd o f M B o pe ra ti on , t he p ea k v al ue o f c hl or id e i on a nd s od iu m i on i s 7 .6 4g /L a nd

7.21g / L i n e ff lu e nt w a te r, w hi c h i s o ve r f ou r t im es h ig h er t h an i n i nf lu e nt w at er . C hl or id el e a k a g e a n d s o d i u m l e a k a g e a r e s e r i o u s .

( 2 ) T h e p e r i o di c w a te r p r od u c ti o n i s 1 0 0 ,0 0 0 m3, o n l y 6 7 % o f t h e d e s i g n e d 1 5 0 , 0 0 0 m 3, n e g at i ve l y

i m p a c t i n g t h e s a f e , s t a b l e a n d e c o n o m i c o p e r a t i o n .

3 . 2 A n a l y s i s

W i t h f u r t h e r a n a l y s i s , i t w a s f o u n d r e a s o n s t o t h e p r o b l e m s a b o v e :( 1) R e si ns s ep a ra ti on a nd t ra n sp or ta ti on a re m an ua ll y o pe ra te d , r es ul ti ng i n c h ao s r es in r at io a nd

l ow a c cu ra c y o f r es in s s ep a ra ti o n a nd t ra ns po rt at io n . T h e a ni on r es in i n c a ti on a n d ca ti on

r es in i n a n io n i s u p t o 1 . 7% a n d 5 . 4% . C ro ss c on ta mi na t io n o f r es in i s s er io u s, l ea di ng t o

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ch lo ri de l ea ka g e a n d so di u m l ea ka g e a t t he e nd o f M B o pe ra ti on . M or eo v er , t he w or ki n g

e x c h a n g e c a p a c i t y o f r e s i n s i s i m p a c t e d , l e a d i n g t o a s h o r t e r o p e r a t i o n c y c l e .

( 2) S o me s te ps a nd p ar am et er s a re i mp ro pe rl y s et i n M B o pe ra ti on a nd r eg en er at io n p ro ce ss ,

r e s u l t i n g i n l o w e r w o r k i n g e x c h a n g e c a p a c i t y o f c a t i o n r e s i n s a n d l e s s p e r i o d i c w a t e r p r o d u c t i o n .

3 . 3 S o l u t i o n

3 . 3 . 1 A p p l y I R I C

A ft er i ns ta ll at io n a nd c om mi ss io ni ng o f I RI C, r es in s s ep ar at io n a nd t ra ns po rt at io n a re a ll

aut om at i cal l y oper at ed, w i t h devi at i on of t r ans por t ed r es i ns l es s t han 1% .

3. 3. 2 P r oces s opt i m i zat i on and P L C m odi f i cat i on

( 1) P r oces s opt i m i zat i on

D ia gn o se t h e M B o p er at io n a n d e ac h s te p o f r eg en e ra ti on ( ex te rn al s ep a ra ti on , t ra n sp o rt at io n ,r eg en e ra ti o n, m ix tu re ), t he n p er fo rm o p ti mi za t io n t o t he i mp ro pe r s te p s a nd p a ra me te rs . T he

o pt im iz ed s te p s a re a s f ol lo w in g : a dj us t t he b o os t s te p o f M B, e ns ur e M B i s i n e mp t y c o nd it io n

before regenerated resins transported in, decrease the flowrate into MB, add the step of second

r es in s m ix tu re , e tc . I n a d di ti on , o pt im iz e f lo wr at e a n d t h e p ro ce ss o f w at er f lo wi ng i nt o M B o f

r es i ns t r ans por t at i on, backw as h f l ow r at e of s epar at i on ves s el .

( 2) P L C m odi f i cat i on and com m i s s i oni ng

I n o r d e r t o m a k e t h e p r o c e s s o f r e s i n s s e p a r a t i o n a n d t r a n s p o r t a t i o n a n d t h e o p t i m i z e d s t e p s t o b e

program-controlled, the corresponding programmed logic is also modified, including: add early

w a r n i n g s i g n a l o f r e s i n s v o l u m e d e v i a t i o n ; a d d c o n t r o l s i g n a l o f c a t i o n r e s i n s t r a n s p o r t a t i o n t e r m i n a lpoint; modify PLC as the corresponding modification to process steps.

3.4 Implementation Effect

W i t h t h r e e m o n t h s o p e r a t i o n a f t e r t h e i m p l e m e n t a t i o n o f I R I C , t h e r e a r e s o m e e f f e c t s :

( 1 ) I t i s m u c h m o re r e li a bl e t o c o n tr o l t h e t e rm i n al p o in t o f r e si n s s e p a ra t io n a n d t r an s p or t at i on . T h e

v o l u m e o f s e v e n s e t s o f r e s i n s a n d r e s i n r a t i o i s t h e s a m e a s d e s i g n a l l t h e t i m e ( c a t i o n r e s i n s

v o l u m e i s 4 . 8 m3, a n i o n r e s i n s v o l u m e i s 3 . 2 m 3, r e s i n r a t i o i s 3 : 2 ) .

( 2) R es i ns s epar at i on per cent age i s obvi ous l y i ncr eas ed. A f t er r es i ns s epar at i on, ani on r es i n i n

c a t i o n i s d e c r e a s e d f r o m 1 . 7 % t o 0 . 0 7 % , a n d c a t i o n r e s i n i n a n i o n i s d e c r e a s e d f r o m 5 . 4 % t o

0.08%.( 3 ) D u ri n g a n o p er a ti o n c y c le , t h e a v e ra g e c o n ce n tr a ti o n o f s o d iu m i o n, c h lo r id e i o n , s i l i co n d i ox i d e

a n d t o t a l i r o n i n e f f l u e n t w a t e r i s l e s s t h a n 0 . 2g / L , 0 . 6g / L , 3g / L a n d 3g / L . E a c h i n d e x i s

s u p e r i o r t o t h e r e q u i r e m e n t o f D L / T 9 1 2 - 2 0 0 5 Quality Standard for Water and Steam in

Supercritical Thermal Power Units.

( 4 ) T h e r e ge n e ra t io n M B -t i me i s r e du c e d f r o m 1 1 1 t i me s t o 7 0 t i me s , s a v i n g h i g h -q u a li t y a c i d a n d

a l k a l i n e b y 2 4 0 t o n / y e a r , d e m i n e r a l i z e d w a t e r b y 1 8 , 0 0 0 m 3/ y e a r , f r e s h w a t e r b y 2 7 , 0 0 0

m3/ y e a r a n d t h e c o s t o f s u p p l e m e n t a l r e s i n s b y 3 5 , 0 0 0 R M B / y e a r . T h e d i r e c t b e n e f i t i s a b o u t

1. 2M R M B / year .

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4. Conclusion

( 1 ) I n s t r u m e n t o f i m a g e r e c o g n i t i o n a n d i n t e l l i g e n t c o n t r o l o f r e s i n t r a n s p o r t a t i o n i s a

breakthrough technology in monitoring MB operation. The accuracy of inspecting terminal point ofr e s i n s s e p a r a t i o n a n d t r a n s p o r t a t i o n i s o v e r 9 5 % . I R I C i s c a p a b l e o f a c c u r a t e l y i n s p e c t i n g t e r m i n a l

point of resins separation and transportation, determining resins volume and increasing resins

s e p a r a t i o n p e r c e n t a g e . I R I C i s a b l e t o a d j u s t r e s i n r a t i o , i n c r e a s e p e r i o d i c w a t e r p r o d u c t i o n o f M B

polisher, determine resins transportation rate, avoid incomplete transportation, monitor resins total

vol um e and es t i m at e r es i ns l eakage w i t hout changi ng t he i nt er nal s t r uct ur e of s epar at i on ves s el .

( 2 ) A f t e r a p p l i e d I R C i n t h i s I n n e r M o n g o l i a p o w e r p l a n t , a n i o n r e s i n i n c a t i o n a n d c a t i o n r e s i n

i n a n i o n i s 0 . 0 7 % a n d 0 . 0 8 % . T h e e f f l u e n t w a t e r q u a l i t y i s s i g n i f i c a n t l y i m p r o v e d , c o m p l e t e l y

s o l v i n g t h e p r o b l e m o f s o d i u m l e a k a g e a n d c h l o r i d e l e a k a g e . P e r i o d i c w a t e r p r o d u c t i o n i sh i g h l y i n c r e a s e d b y 7 7 % . T h e p r o j e c t c o s t o f w a s t e w a t e r Z e r o E m i s s i o n i s s a v e d b y o v e r 3 M

R M B . I t h a s t h e s i g n i f i c a n t e f f e c t o f w a t e r s a v i n g a n d e m i s s i o n r e d u c i n g a n d q u a l i t y i m p r o v i n gand ef f ect i ncr eas i ng.

Reference:

[ 1 ] H A N L i c h u a n , W a n g D e l i a n g . C o n d e n s a t e P o l i s h i n g i n T h e r m a l P o w e r P l a n t [ M ] . B e i j i n g : C h i n a E l e c t r i c

P o w e r P r e s s , 2 0 1 0 .

[ 2 ] H A N L i c h u a n , L I Z h i g a n g . R e s e a r c h o n M e c h a n i s m a n d A p p l i c a t i o n o f M i x e d B e d P o l i s h e r [ J ] . E l e c t r i c P o w e r ,2007,40(12):90- 93.

[ 3 ] T I A N W e n h u a , Z H U X i a o l i a n g , Q I A N Y i n . I n s t r u m e n t o f I m a g e R e c o g n i t i o n a n d I n t e l l i g e n t C o n t r o l o f R e s i n

T r a n s p o r t a t i o n a n d t h e M o n i t o r i n g C o n t r o l T e c h n i q u e . C h i n a , 2 0 1 2 1 0 3 9 8 5 9 8 . 5 [ P ] : 2 0 1 4 - 0 5 - 0 7 .

Biography:W e n h u a T i a n , P h . D i n T s i n g h u a U n i v e r s i t y , r e s e a r c h i n t h e a r e a o f c o n d e n s a t e p o l i s h i n g .

Tel 86-29-82102108, Mobile Phone: 13991302260

E-mail: [email protected]

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Ion Exchange Resins for Condensate Polishing in Air-cooled Ultra Super

Critical Thermal Power Plants

Izuru Tokumaru (Mitsubishi Chemical Corporation), Japan

Li Huanfang (Huadian Ningxia Lingwu Power Generation Co.,Ltd.), China

Abstract: Huadian Ningxia Lingwu Power Generation Co., Ltd. No.3 and No.4 Units

(21,060MW) are the first 1,000MW class air-cooled ultra super critical power plants in

the world. In air-cooled power plants, because the temperature of condensate is very

high, mixed bed resin for condensate polishing (CP) requires high durability. For this

requirement, high-crosslinked gel type cation exchange resin (CSK40) and porous type

anion exchange resin (CPA12) were applied to CP in Huadian Ningxia Lingwu Power

Generation Co., Ltd. No.3 and No.4 Units. The resins used in these power plants had

still maintained high quality and performance after 3 years operation. Additionally, in

the lab scale evaluation, CSK40 showed high oxidation resistant ability (durability),

and CPA12 indicated superior PSS (Polystyrene sulfonate) adsorption capability which

relates to the property of anti-organic-fouling. These results show the combination of

CSK40 and CPA12 has high durability as mixed bed resins for CP. Therefore it is

considered that this type of resin combination has high conformity to CP of air-cooled

power plants in which the condensate temperature is very high and operating

conditions are very sever for resins.

Key wards: air-cooled thermal power plant; condensate polishing; ion exchange resin;

mixed bed; oxidation resistance

1. Introduction

In some areas of inland China, the water resource is insufficient. Air-cooled typecoal-fired power plants with high water saving effect are suitable for such areas, and

the introduction of air-cooled type plants is actually progressing. In air-cooled type

power generation units, air is used as a coolant of condensers. Therefore air-cooled type

units can save the consumption of water by about 70% as compared with water-cooled

type units. However, in air-cooled type units, because the cooling effect of condensers is

lower than that of water-cooled type, the temperature of condensate is relatively high

and exceeds 60 in summer, and sometimes may reach about 80. [1.] Therefore, it can

be said that conditions are very severe for ion exchange resins used in the condensate

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polishing (CP) system of air-cooled type power units.

In regards to the CP system of air-cooled type units, precoat filter of mixed powder

resins have mainly been adopted to cope with such severe conditions in the past.[1.],[2.],[3.]

With increases in the scale of power generation units, the required level of water quality

will enhance and the importance of ion exchange resins for CP will also be higher and

higher. Application of precoat filter of powder resins + mixed bed or precoat filter of

powder resins + cation bed + anion bed as a CP system is recommended to the

large-scale supercritical air-cooled power units.[3.]

Huadian Ningxia Lingwu Power Station No.3 and No.4 units (21,060MW) are the

first 1,000MW class air-cooled ultra-supercritical power units in the world, which have

precoat filter of powder resins + mixed bed as their CP system. With regard to mixed

bed resins for CP of air-cooled power units, because the temperature of condensate is

very high, good durability is required as well as high water-treatment ability. In these

No.3 and No.4 units, high-crosslinked gel type cation exchange resin with good

durability and porous type anion exchange resin, which has a property of anti-organic

contamination (fouling), were applied and showed good quality and performance after

15, 25 and 34 months of operation.[4.],[5.],[6.]This report will introduce the time course of

the quality and performance of these CP resins during 34 months of operation again and

also present the consideration about their applicability to CP of air-cooled power units.

2. Operation situation of Linwu Power Station No.3 and No.4 units

The startup time of Linwu Power Station No.3 and No.4 units is in January and April

of 2011, respectively. Concerning the CP system, there are four mixed bed vessels per

one unit, and the two units share one set of resin regeneration equipment. The mixed

bed of CP is basically operated as H-OH form. The temperature of condensate is:

55-60 in winter (from November to April), 65-75 in summer (from May to October).

3. Ion exchange resin to be applied

In air-cooled power units, since condensate temperature is very high and the

operation condition of CP is severe to ion exchange resin, the combination of CSK40 and

CPA12 was applied, which has good durability and high water-treatment ability. CSK40

is high-crosslinked (14%) gel type cation exchange resin with high oxidation-resistance

and less leachables. CPA12 is porous type anion exchange resin with property of

anti-organic contamination (fouling). This kind of resin combination has been applied

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in CP of PWR type nuclear power plants in Japan and high water quality has been

achieved.

4. Resin samples for evaluation

The new resins and the resins taken from the plant were used as samples for

evaluation. The sampling was carried out 4 times at the timing after 10, 15, 25 and 34

months of operation.

5. Evaluation items

The evaluation items are as follows:

- Ion exchange capacity

- Water content

- Particle size

- Uniformity coefficient

- Whole bead count

- Appearance

- Sphericity after osmotic-attrition (Mechanical strength)

- Eluting rate of PSS with high-M.W. (Cation resin)

(PSS: polystyrene sulfonic acid)

- Oxidation elution test (Cation resin)

- Mass transfer coefficient (MTC) (Anion resin)

- PSS adsorption capacity (Anion resin)

Eluting rate of PSS with high molecular weight (M.W.) (= PSS eluting rate) is an

index for checking and comparing the degree of the oxidative degradation of cation resin,

and its value increases with an increase in oxidation degree. The measurement method

is as follows: put a certain amount of pre-treated cation resin into a certain amount ofpure water, and incubate it at 80 with shaking for 20 hours. Then, measure the

amount of PSS elution in the water phase by measuring absorbance (A225nm) and the

ratio of high-M.W. PSS (M.W. 3,000) by gel permeation chromatography (GPC). Using

these values, calculate the value of eluting rate of PSS with high-M.W. (mg/L-Rh).

Oxidation elution test is done to check the oxidation resistant ability (durability) of

cation resins. Cation resins with high oxidation resistance show less leachables (= low

TOC) and low high-M.W. PSS ratio. The measurement method of oxidation eluting

test is: put a certain amount of cation resin with iron-loaded (2g-Fe/L-R) into a certain

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amount of hydrogen peroxide solution, and incubate it at 40 with shaking for 24

hours (= oxidation treatment). Then, put the oxidized resin into a certain amount of

pure water, and incubate it at 40

with shaking for 24 hours. After that, measure theTOC conc. and high-M.W. PSS ratio (M.W. 3,000, by GPC) in the water phase.

Mass transfer coefficient (MTC) and PSS adsorption capacity are the indexes for

checking and compering the degree of surface contamination (organic fouling) of anion

resin. PSS adsorption capacity can also show the anti-organic fouling property.

The measurement method of mass transfer coefficient is: put a certain amount of

pre-treated anion resin into a column. Then, pass the raw water containing a certain

conc. of Na2SO4through resin layer at constant flow rate, and measure the conc. of SO 4-

in inlet and outlet water. After that, calculate the MTC value (m/s). MTC value becomes

lower with surface contamination of anion resin becoming more severe. [7.]

PSS adsorption capacity was measured by dynamic adsorption method: put a certain

amount of pre-treated anion resin into a column. Then, pass the raw water containing a

certain conc. of PSS (e.g. M.W: 10,000) through resin layer at constant flow rate, and

measure the conc. of PSS in outlet water. The total amount of PSS adsorption by resin

at the timing when PSS conc. in outlet water reaches 50% of raw waters (at 50% leak) is

defined as PSS adsorption capacity (mmol/L-R). The lower the PSS adsorption capacity

value of used resin, the more severe the surface fouling. On the other hand, regarding

new anion resin, high PSS adsorption capacity means high anti-organic fouling

property.

6. Results and discussion

6.1 Change of quality and performance of cation resin CSK40

The analysis results of the cation resin samples (new resin and resin after 34 months

operation) are shown in table 1. As for each analysis item, no significant change was

seen after 34 months operation. Although ion exchange capacity decreased a little, thefalling rate of ion exchange capacity after 34 months operation was only 3.4%. (fig.1)

Concerning the values of sphericity after osmotic-attrition (mechanical strength),

there was no decrease after 34 months of operation the mechanical strength was

well maintained. (fig.2)

The value of PSS eluting rate gradually increased for an initial 15 months, but it

decreased to very low level after 25 months of operation. (fig.3) We think the reason

why the value of PSS eluting rate increased in the early period and then decreased, is

that there was small amount of residual PSS in new resin particles and the residual

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PSS was gradually eluted in early period, but the remaining PSS was almost completely

released by the 15th month, then, the value of PSS eluting rate went down. Since the

value was kept at a very low level after 34 months of operation, it is thought that thecation resin practically had not be oxidized, consequently, no deterioration of the quality

and performance was not observed after 34 months operation.

From the above results, the cation exchange resin CSK40 maintained good quality

and performance after about 3 years of operation in CP of air-cooled power units,

therefore, results proved that CSK40 had high oxidation-resistant ability and good

durability.

Table 1

Analysis results of quality and performance of cation resin CSK40 and anion

resin CPA12 before and after use

Fig. 1 Time course of ion exchange capacity of cation resin CSK40 and anion resin

CPA12

Spec New Resin 34 Months Spec New Resin 34 Months

Ion Exchange Capacity mmol/mL 2.4 2.64 2.55 1.2 1.33 1.16

Weakly Basic Capacity mmol/mL - - - - - 0.04

Water Content % 29-39 34.6 33.9 45-55 51.9 52.6

Effective Size mm 0.55-0.70 0.593 0.604 0.50-0.71 0.517 0.520

Uniformity Coefficient - 1.2 1.03 1.05 1.4 1.30 1.31

Whole Bead count % 95 99 97 95 99 98

Mechanical Strength % 90 99.56 98.92 90 95.31 81.20

PSS eluting rate mg/L-R/h - 0.0012 0.0001 - - -

Mass Transfer Coefficent 10 -5(m/s) - - - - 6.5 6.4

PSS Adsorption Capacity mmol/L-R - - - - 0.16 0.18

Anion Resin CPA12Item Unit

Cation Resin CSK40

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Fig.2 Time course of mechanical strength of cation resin CSK40 and anion resin

CPA12

Fig.3 Time course of PSS eluting rate of cation resin CSK40

6.2 Change of quality and performance of anion resin CPA12

The analysis results of the anion resin samples (new resin and resin after 34 months

operation) are shown in table 1. The gradual decline of ion exchange capacity wasobserved, and the falling rate after 34 months operation was 12.8%, as compared with

new resin. (fig.1) It is thought that because condensate temperature of air-cooled

power units is very high, the strongly basic anion exchange groups were decomposed by

heating and turned into weakly basic anion exchange groups or completely lost their

anion exchange capability.

The mechanical strength value slightly decreased in the early period of operation, but

after that, it had been stably maintained around 80%. Moreover, regarding the resin

strength, there was no practical problem after about 3 years of use. (fig.2)

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The MTC value had been very stable and no big change was observed during 34

months operation. (fig.4) The PSS adsorption capacity value gradually decreased and

reached about 44% of new resins level after 15 months of operation. But after that, thevalue was stable for a certain period, and after 34 months of operation, it recovered to

the same level as that of new resin (fig.4). It is thought that PSS adsorption capacity of

anion resin gradually decreases during long time of use because of surface fouling by

leachables eluted from cation resin. In this investigation, the decrease behavior of PSS

adsorption capacity of anion resin (fig.4) accords with the increase behavior of PSS

eluting rate of cation resin (fig.3). We think that, after that, the amount of PSS eluted

from cation resin significantly decreased, as a result, PSS adsorption capacity recovered

by repeated use and regeneration.

With regard to anion resin, since the heat-resistance of the strongly basic anion

exchange group is low, in general, the reduction rate of anion exchange capacity

relatively high. But the capacity of CPA12 still remained about 87%, even if it had been

used under the high temperature condition of air-cooled power unit for about 3 years.

Concerning the situation of organic fouling, although a certain reduction in PSS

adsorption capacity was observed in the early period, MTC had been kept at high level

all the time during operation. So it is considered no severe surface fouling had occurred

during 34 months of operation.

On the whole, it can be said that anion resin CPA12 still maintained good quality and

performance after about 3 years of use.

Fig.4 Surface contamination situation of anion resin CPA12 during 34 months

operation. (Time course of MTC and PSS adsorption capacity.)

6.3 Observation of appearance

The appearance pictures of cation and anion resins before use and after 34 months

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use are shown in Fig.5. Both resins maintained good appearance after 34 months of use,

and a noticeable deterioration in appearance such as cracks or breaking of resin

particles was not observed.

Fig.5 Appearance of cation and anion resins before use and after 34 months use

6.4 Quality of CP outlet water

The quality of CP outlet water of both No.3 and No.4 units had met water quality

control standard (table 2) during 34 months operation, and there had been no problem

about demineralization performance of CP.

Table 2 Quality standard of CP outlet water (DL/T912-2005 Quality criterion of

water and steam for supercritical pressure units in fossil-fired power plant)

6.5 Lab evaluation of oxidation resistant ability (durability) of cation resin CSK40

and PSS adsorption capacity (anti-organic fouling property) of anion resin CPA12

The oxidation elution test was conducted using new sample of CSK40 (gel type, 14%

cross-linkage) and other gel type resin samples (cross-linkage degree: 8%, 10%, 16%) at

the lab in order to verify the superiority of oxidation resistant ability (durability) of

CSK40. The result is shown in Fig.6. The

TOC value and high-M.W. PSS ratio of

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CSK40 after oxidation treatment was controlled at very low level. It means CSK40 has

high oxidation resistant ability (durability).

Fig.6 Oxidation resistant ability of cation resin CSK40 with 14% cross-linkage

(Cross-linkage degree vs. leachables after oxidation treatment)

Regarding the anti-organic fouling property of anion resin CPA12 (porous type,

meddle cross-linkage), its PSS adsorption capacity value was compared with the values

of gel type anion resin (middle cross-linkage) and highly porous type anion resin (high

cross-linkage). The result is shown in Fig.7. Porous type anion resin CPA12 showed

much higher PSS adsorption capacity than gel type and highly porous type anion resins.

Therefore, it is proved that CPA12 has superior anti-organic fouling property.

Fig.7 comparison of PSS adsorption capacity among CPA12 (porous type), gel type and

highly porous type anion resins

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7. Conclusion

In Huadian Ningxia Lingwu Power Station No.3 and No.4 units (21,060MW,air-cooled type), high-crosslinked gel type cation exchange resin CSK40 and porous type

anion exchange resin CPA12 were applied for their CP systems. Resin samples were

taken out after 10, 15, 25 and 34 months of operation, and the analysis of each sample

was carried out. And lab evaluation was also conducted with new resins in order to

verify the superiority of CSK40 in oxidation resistant ability (durability) and CPA12 in

anti-organic fouling property.

Cation resin maintained good quality and performance after 34 months of operation,

and the decreasing rate of ion exchange capacity after 34 months operation was 3.4%

Regarding anion resin, the ion exchange capacity decreased 12.8% after 34 months of

operation. Although PSS adsorption capacity decreased in the early period, it recovered

to the original level in the latter period, and a decrease of MTC values was not observed

all the time during 34 months operation. Therefore it is considered that the surface

contamination (organic fouling) did not occur during 34 months of operation. Since the

porous type anion resin has a property of anti-organic fouling, and cation resin used

together has high oxidation resistant ability and less leachables, the quality and

performance of anion resin had not been affected by organic fouling even after 34

months of operation.

From the consideration about resin analysis results and CP outlet water quality, the

resins applied in CP of No.3 and No.4 units still maintained good quality and

performance after 34 months of operation.

The results of lab evaluation also show that cation resin CSK40 has high oxidation

resistant ability (durability), and anion resin CPA12 has superior PSS adsorption

capacity (anti-organic fouling property).

As a result of analysis of used resins taken from the actual air-cooled power plant and

lab evaluation of new resins, it is considered that combination of high cross-linked geltype cation resin CSK40 and porous type anion resin CPA12 has high durability as

mixed bed resins, and also has a high conformity to CP of air-cooled power plants in

which the condensate temperature is very high and operating conditions are very sever

for resins.

REFERENCES

[1.] Tian Wenhua, He Huiyong, Problems and Measures of Condensate Polishing of

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Direct Air-cooled Power Plants, China Power Plants Chemistry Annual Symposium

2007, 2007: pp.348-352

[2.] Guo Baosheng, Luo Jianghe, Li Jingquan et al., Application of CondensatePolishing with Separated Bed for Steam and Water Quality of 600MW Direct Air-cooled

Power Plants, China Power Plants Chemistry Annual Symposium 2007, 2007:

pp.344-347

[3.] Wei Huan, Characteristics of Water Treatment Processes of Large Scale Air-cooled

Power Plants and Selection of Condensate Polishing system design, China Power

Generation Demineralizer Technology (Xihu) Power Plants Chemistry Technological

Symposium, 2009pp.27-31

[4.] Li Huanfang, Izuru Tokumaru, Application of High-crosslinked Gel Type Cation

Exchange Resin and Porous Type Anion Exchange Resin for Condensate Polishing in

Air-cooled Thermal Power Plants, Thermal Power Generation, 2013: Vol.42, No.11,

pp.127-129

[5.] Izuru Tokumaru, Li Huanfang, Study of Ion Exchange Resins for Condensate

Polishing in Air-cooled Power Plants, China Power Plants Chemistry Annual

Symposium 2013, 2013: pp.306-311

[6.] Fu Jieqi, Wang Luochun, Ding Huanru, Study of Index of Kinetics Anion Resins

Used in Condensate Polishing and Construction of Test Platform, China Power Plants

Chemistry Annual Symposium 2011, 2011: pp.304-310

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1 2 2 3 2 2

1.100025

2. 710054

3. 073004

pH 9.6~9.8FAC

3~4

TPRI 1:1 3:2

0.77m3 20% IRIC

1396mol/m3R 1967mol/m3R 41%

2013 4 69% 7

3g/L 1g/L

pH

1

2660MW 3 4 124.5g/m2.a

7 1.44MPa 2.09MPaFAC

2010 7

AVT(O) pH pH 9.6~9.8 30g/L

10g/L pH

pH

TPRI

DL/T 912-2005

TPRI IRIC

2

1~2

1 g/L

Na+ NH 4+ K + Mg 2+ Ca 2+`

1 4 0.36 79.9 0.2L 0.1L 0.2L

2 3 0.42 98.3 0.2L 0.1L 0.2L

3 2 0.57 117.3 0.2L 0.1L 0.2L

4 1 0.59 134.0 0.2L 0.1L 0.2L

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5 0.75 162.7 0.2L 0.1L 0.2L

2 g/L

F- CH 3COO- HCOO - Cl - NO 2

- SO 42- NO 3

- PO 43-

1 4 0.1L 0.1L 0.42 0.1L 0.1L 0.2L 0.1L 0.39

2 3 0.1L 0.11 0.35 0.1L 0.1L 0.2L 0.1L 0.41

3 2 0.1L 0.19 0.50 0.1 0.1L 0.2L 0.1L 0.37

4 1 0.1L 0.44 1.04 0.1L 0.1L 0.2L 0.1L 0.3L

5 0.1L 0.20 0.97 0.1 0.1L 0.2L 0.1L 0.3L

4 0.080~0.086S/cm

1g/L DL/T 912-2005

3

1

3/ ( )

NHH Vc Ec Qc C

1

H h

Vc m3

Ec mol/m

3

RQc m

3/h

3NHC NH3mmol/L

1

pH

pH 9.4 1.0mg/LpH 9.6 2.2mg/L

2.2 pH 9.4

pH 9.6 2.2

4

pH 45%

3 3 6 4

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3

m3 %

3-1 3.77 3.32 -1.8 -13.5

3-2 3.58 3.37 -6.8 -12.2

3-3 3.87 3.76 +0.8 -2.1

4-1 3.90 3.86 +1.6 +0.5

4-2 3.90 3.62 +1.6 -5.7

4-3 3.54 3.93 -7.8 +2.3

4

.

m3

h

m3

mg/L

mol/m3R

4-3 3.54 1

Documents

001b Complete IACCC Proceedings