11CEA

YOUR PARTNER FOR COMPLETE POWER PLANT SOLUTIONS

A PRESENTATION ON

INDO-GERMAN ENERGY PROGRAMMEWORKSHOP ON

Renovation & Modernization and Water Optimization

in Thermal Power StationsAT HOTEL TAJMAHAL , MANSINGH ROAD NEW DELHI

30th June, 2009

BY

DINESH B SINGHMD (ENERGO ENGINEERING PROJECTS LIMITED)

DRY CONDENSER COOLING SYSTEMS FOR

THERMAL POWER STATIONS

ENERGO & GEA EGI MoU

includes...

Condenser Cooling System

Condensate Polishing Unit

DM Plant

Desalination / Reverse Osmosis

Zero Effluent Discharge System

High Concentration Ash Slurry Disposal (HCSD) Systems

Contracting of Balance of Power Plant Packages

Visit us at:

www.energoindia.com /www.egi.hu

Cooling System in USA

Once Through From 1930sWet Cooling From 1950sDry From 1970sHybrid From 1980sParallel From 1990s

India not even in 1950s

Let us act before it is too late !

Mitigating Limitations

Evaporative Wet CoolingLimitations

Wet bulb temperature

Dry bulb temperature

Huge Evaporative Water loss

Limits Plant Location Options

Limitation for Natural Draft Tower to be in RCC

High Emission / Effluent Generation

Forced Power Plant Shutdown Possibilities

To many Variables Effecting Design Point Availability

High Auxiliary Power Consumption

High O&M Costs

Water Uncertainty w.r.t Social Reaction / Sabotage / Availability / Allocation / Water Intake Land Acquisition

Direct ACC Limitations

Layout Restrictions

Natural Draft Cooling Tower not feasible

Wind Effects of Flow Separation, Recirculation

& Mal-Distribution in Forced Draft Systems

High Fan Power Consumption

Limitation on Range of Operating Condition

Low Power plant efficiency

Poor Availability w.r.t Design Point

High Noise Emission

Very High O&M Costs

Invented by the founders of EGI (now GEA EGI) 50 years ago

Dr. Heller Lszl Dr. Forg Lszl

Rejected heat Q = k x F x DTln, wherek: heat transfer rate (kcal/h,m2,oC) F: heat transfer surface,DTln: logarithmic mean temperature differenceCondenser TTD =

~0.5CCondenser TTD =

~3C

Tcold

Twarm

Tcold

Twarm

Ther

mo

dyn

amic

lo

ss o

f

surf

ace

con

den

ser

With DC Jet Condenser gives 3.5- 4.5 oC ITD Advantage

The Best use of Ambient Air as Heat Sink

DC Jet Condenser

Heller Indirect Dry Cooling System

HELLER System: The Way It Works

HELLER WET ASSISTED

0% 50% 100%

ALL DRY ALL WET

HELLER SPRAYED

HEAD

PLUME ABATEMENT HYBRID

SERIES SINGLE CIRCUIT HYBRID

Heat Exch.Water-Water

Boiler Feed Water

CondenserDC

CW Pump

Recovery Turbine

Cell

CoolingWet

Heat ExchangerWater to Air

CoolingTower

Dry

Steam Turbine

Steam Turbine

Condenser

Boiler Feed Water

Recovery Turbine

CW Pump Water to AirHeat Exchanger

CoolingTower

Dry

DC

Supplemental Spraying Dry-Deluged Coolers

Heller with Wet Assisted Cells Relative Annual Water Consumption

Dry/wet HELLER System Combinations

The cooling tower can be built either with a conventional reinforcedconcrete shell or with a steel structure covered by corrugated Al- clad.

Cooling Tower Construction Options

Concrete Tower

Steel Tower

Forced Draft Cooling Tower

Natural Draft Cooling Towers

Environmental Aspects

Mtra PS 800 MWe - originally commissioned: 1969-1972

Retrofitted in 1999-2000 incl. 2 FGD plants each put inside one HELLER tower of a 230 MWe unit, however treating flue gas from 440 MWe capacity.

Greener & Cheaper : Flue gas exhaust

How flue gases are routed from the boiler to the stack-in-tower at the 320 MWe Can TPP


Greener & Cheaper : Flue gas exhaust FGD-in-tower

in the 800 MWe Mtra PS, Hungary

Stack-in-tower in the 320 MWe Can PS,

Turkey

FGD-in-tower

BaoJi SC PS

2700 MWe

Contract: 2007

Com: 2011

CPC = 25.5 MWth/K

-8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8

8

6,

4,

3,

1,

0

-1

-3

-4

-6

-805

10152025303540

SO

2 [g

/m3]

Source Distance W - E [km]

So

urc

e d

ista

nce N

- S [k

m]

35-40

30-35

25-30

20-25

15-20

10-15

5-10

0-5

N

Modeling the max. 1-hour SO2concentration at a1616 km area

Average max. 29 g / m3

Max.max. 38 g / m3

BaoJi Supercritical PS 2 700 MWe Owner: Guodian Corp.

Contract date: Oct. 2007

To be commissioned: 2011

CPC = 25.5 MWth/K

FGD-in-tower to reduce ground level concentration of pollutants

OT water treatment (similar to EPRI GL)


Completely closed circuit, nil effluents

Direct ACC (var. D) HELLER System (var. A)

Impact of cooling systems on noise emmission

Sound pressure levels around the 800 MWe CCPP equipped with functionally equivalent dry cooling systems: natural draft HELLER System (var. A) and mechanical draft direct ACC (var. D):

Noise pollution

Higher annual efficiency compared to other dry cooling options means lower emission of atmospheric pollutants

No plume as opposed to wet cooling systems avoids water plume related greenhouse effect

Greenhouse Gases

Typical Performance of 800MW

Super Critical Coal Based Thermal Power Plant

Typical Curve for 800 MW Coal Based

Super Critical Thermal Power Plant

Ambient Temperature Range (-27 deg. C to 38 deg. C), Design Point Ambient Temperature (dry bulb) (12.22 deg. C)Design Point Relative Humidity (30%) Site Elevation (5100 feet)

The indirect cooling circuit by the high thermal inertia of its water fill buffers or mitigates the negativeeffect of wind gusts, resulting in smaller performance reduction and more stabile turbine back-pressure. Incase of an ACC even a 1-2 minutes long wind gusts affects the cooling, with Heller system only wind gustslasting appr.15-minute are sensible.

3

4

5

6

7

8

9

10

11

12

660 720 780 840 900 960 1020

Number of measurements

Win

d s

peed

m/s

15-minute average wind speed

2-minute average wind speed

12:00 hours TIME 14:0013:00 hours

A so called emergency spraying can be applied whenever high wind is combined with hot ambient airtemperatures, even in case of otherwise all-dry HELLER Systems. Then spraying is selectively applied on themost affected air cooler sections automatically controlled from their outlet water temperature.

Response to wind effect and its mitigation

Capital investment cost (Including Cost of rawwater intake /pumping )

Difference in annual net generation Water costs Maintenance costs Cost of cooling system related unit unavailability

Factors Taken Into Consideration

For Life Cycle Cost Comparison

120 MWe coal fired unit of Rugeley A PS, Great Britain

Commissioned: 1962 Decommissioned: 1996

REFERENCES

The 1st larger PS with HELLER

Altitude: 1760 m

In the background: towers of the original plant for 4 x 200 MWe built in the 1970s

In the foreground: cooling tower to serve 620 MWe supercritical extension (mid 1990)

Armenia: High altitude & seismicity

Esfahan PS 1. 4 200 MWe (1980s)

Esfahan PS 2. 4 200 MWe (1990s)

Elevation: 1600 m

Montazer Ghaem CCPP3 360 MWe(1998-2001)+20 units

Shahid Rajai TPP Elevation: 1400 m 4 250 MWe(1995)

Arak PS 4 325 MWe (1998-2002) Elevation: 2000 m

Russia: frosty winter

The only dry cooled nuclear PS in the world

Bilibino NPP 4x12 MWe (1970s)Over the Arctic Belt

Strogino Co-gen CCPP, 2x200 MWe (2008), winter proof up to -42C(-43.6F)

Winter cells

Summer cells

&

Moscow City 2. Co-gen CCPP260 MWe, (2008),winter proof up to -42C

Sochi Co-gen CCPP, 80 MWe (2004) with supplemental spraying; exception: mild climate at the sea shore

Turkey: superior availabilities

Trakia CCPP, 1200 MWe (1987-97)EPC: ABB-Enka, Owner: EAS

1400 MWe Bursa CCPP (1999)EPC: MHI / ENKA ; Owner: EAS

3 x 777 MWe Gebze & Adapazari CCPP

(2002)

Owner: Intergen/Enka

EPC: Bechtel/Enka

CAN PP (CFB); 320 MWe 2003/4EPC: Alstom, Owner: EAS

Turkey

Parallel delugable cells within the dry tower

1400 MWe Bursa CCPP (1999)EPC: MHI / ENKA ; Owner: EAS

Turkey

3 x 777 MWe GEBZE & ADAPAZARI CCPP (2002)

Owner: Intergen/Enka

EPC Contractor: Bechtel/Enka0

Worlds largest dry cooled combined cycle power plant

Syria: sizzling deserts

Teshrin PS 2 x 210 MWe(1991/1992) Owner: PEEGT

Al Zara T.P.P. 3 x 220 MWe, (2001)EPC: MHI Owner: PEEGT

Nasserieh CCPP 540 MWeEPC: Siemens (2007)Owner: PEEGT

sizzling desertZayzoun CCPP 540 MWe

EPC: Siemens (2007) Owner: PEEGT

Deir Ali CCPP 750 MWeEPC: Siemens (2009)

Owner: PEEGT

sizzling desert

China: cool for coal

Datong PS 2 x 200 MWe (1988)

BaoJi SC PS

2 x 700 MWe

Owner: Guodian Corp.

Contract: 2007

Comm: 2011

CPC = 25.5 MW th / K

170 m

84 m

152 m

2 x 600 MWe Yangcheng T.P.P. (2007)Owner: Datang Int.

2 x 600 MWe Yangcheng T.P.P.

Thank You for Your Attention!

GEA EGI with over 24000 MW indirect Dry CoolingInstallations around the world, (from -62 deg.C to+50 deg.C) Beat the myth that Dry CoolingProcesses are not viable in extreme temperatureconditions !

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11CEA