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MEMBER OF
WATER OPTIMIZATION CONFERENCE & AWARDS
DROUGHT PROOFING INDIA’S THERMAL POWER PLANTS
BY COOLING SYSTEM CONVERSIONS
PRESENTATION TOPICS
1. SPG Dry Cooling – brief intro
2. Global water stress – recent losses in India
3. Water consumption for cooling thermal power plants
4. Stress-relief by Cooling system conversions
5. Q&A
SPEAKER:
2
Mr. Andras BaloghVice President of SPG Dry Cooling, Engineered Retrofits
3
SPG DRY COOLINGYOUR WATER CONSERVATION SOLUTIONS PROVIDER
4
SPG DRY COOLINGWORLDWIDE DRY COOLING INSTALLATIONS
Hexacool®
State of the art ACC with SRC© tubesOther types of finned tubes available
BoxAir ACC®
Induced Draft Forced Draft Induced Draft
SPX DC Unique and patented
<30 MWe <50 MWe All size All size
Induced Draft
Air Cooled Condenser
ModuleAir ® W-Style ACC®
5
SPG DRY COOLINGDRY COOLING SOLUTIONS PORTFOLIO
Indirect Dry Cooling
State of the art plant flexibility with SPX DC MCTtubes; Other types of finned tubes available
GLOBAL WATER STRESSRESOURCES PLUMMETING
6
Number of months in which water is scarce
Global water availability – resources are plummeting
India is among the regions with highest water scarcities
GLOBAL WATER STRESSDEMAND GROWS
7
Developing countries will require more water to sustain their growing power generation
GLOBAL WATER STRESS RECENT LOSSES IN INDIA
8
India lost 30TWh output (equivalent with 1,7 bn USD revenue) between 2013-16
GLOBAL WATER STRESS WATER USE IN VARIOUS POWER GENERATION TECHNOLOGIES
• Example: the daily make-up water consumption by a wet cooling tower of a 500MW steam turbine – catering for 600 000 public
electricity consumers - equates the public water consumption of 150 000 people (EU average≈ 5-700W/pers. & 200 l/d/pers.)
10
Evaporative/wet cooling systems are the biggest water consumers in a thermal power plant:
Open Loop CoolingConsumption1,100 L/MWh
Withdrawal130,000 L/MWh
Wet Cooling TowerConsumption> 1,800 L/MWh
Withdrawal> 2,100 L/MWh
GLOBAL WATER STRESS WATER CONSUMPTION FOR COOLING THERMAL POWER PLANTS
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Cooling systems are the thirstiest water consumers in a thermal power plantThey rob water from 30%-40% of the same people the plant provides electricity for
45% Electricity
47% Cooling/waste heat
8% Flue Gas
100% Fuel
Dry CoolingConsumption0 L/MWh
Withdrawal0 L/MWh
Reservoir CoolingConsumption1,500 L/MWh
Withdrawal1,700 L/MWh
Most common cooling methods in India; all consume water in large quantities
Any existing cooling system combined with an appropriately selected dry cooling will cut water dependence !!!
12
SUSTAINABLE STRESS RELIEF BY COOLING SYSTEM
CONVERSION
GLOBAL WATER STRESSSUSTAINABLE RELIEF
COOLING SYSTEM CONVERSIONPURPOSE , METHOD AND VERIFICATION OF ECONOMY
Purpose :
• Reduce water consumption and find the optimum power generation/water consumption balance in the power plant, aiming at maximized drought resiliency
Method :
• Split cooling duty between the existing wet, and an add-on dry technology
Verification of economic feasibility:
• Simulate and compare the year-round operation of the plant with present all-water cooled versus the converted cooling system, and calculate Present Value of conversion for the remaning life of the plant
13
14
Input data needed:
• Water availability / cost
• Power Plant load schedule
• Existing surface condenser
characteristics
• Dry and wet bulb temperatures:
maximum and distribution
• Turbine characteristic curve
• Available space for conversion
• Economics (interest rate,
commercial life left)
COOLING SYSTEM CONVERSIONINPUT DATA AND COMPONENTS USED
Proven components utilized:
EXISTING CONDENSER(RE-USED)
PLATE HEAT EXCHANGER
WET COOLING TOWER(RE-USED)
DRY COOLING ADD-ON
15
COOLING SYSTEM CONVERSION THE SELECTION & OPTIMIZATION METHOD
=
Existing wet cooling system
Simulation of operation, selection of optimum based on Present Value
Input data collection+ + +
Investigation of all applicable dry cooling add-on solutions
Wet/dry conversion solution (example)
COOLING SYSTEM CONVERSIONDRY COOLING ADD-ON OPTIONS
16
The conversions may fully, or partly rely on the following proven technologies:
• Direct steam condensing: ACC or NDACC• Relpaces existing SC, thus eliminating a heat transfer barrier
• Best positioned right next to turbine hall if site layout permits
• Dry/Wet operation possible
• Indirect steam condensing with closed water loop: M-IDCT or IDCT• Utilizing the existing surface condenser
• Implementation flexibility, anywhere inside or adjacent to site
• Dry/Wet operation possible
M
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Redirect the whole, or tap part of exhaust steam from surface condenser neck redirect steam from turbine outlet for dry-cooling by an add-on Air Cooled Condenser
Ideal, where the layout of the existing facility allows for the placement of an add-on ACC right next to the Turbine Hall, to ensure minimal steam-side pressure drop
COOLING SYSTEM CONVERSIONWITH ADD-ON DIRECT AIR COOLED CONDENSER
Full Dry
Wet / DryPCS
Present all-wet cooling orConverted to
COOLING SYSTEM CONVERSIONWITH ADD-ON INDIRECT AIR COOLED CONDENSER
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Interconnect a dry tower (mechanical, or natural draft) with the surface condenser, and enhance dry cooling in hot summer hours by the wet cooling tower
Fits all small to large conversion sizes; Can be built any distance from the
Turbine Hall, thus with no restriction by existing plant layout
Flexibly adapts to any existing plant layout, plant down-time forconversion is minimal
Converted to
Full Dry
Wet / Dry
Wet / Dry
Present all-wet cooling
or
or
Verification is through a year-round impact simulation: A, B, C…A. Atmospheric conditions specific to your plant
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
1-Jan-2013 1-Feb-2013 1-Mar-2013 1-Apr-2013 1-May-2013 1-Jun-2013 1-Jul-2013 1-Aug-2013 1-Sep-2013 1-Oct-2013 1-Nov-2013 1-Dec-2013
Tem
pera
ture
[°C]
Monthes
Year round temperature variation
Dry Bulb Temperature
Wet Bulb Temperature
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
1-Jan-2013 1-Feb-2013 1-Mar-2013 1-Apr-2013 1-May-2013 1-Jun-2013 1-Jul-2013 1-Aug-2013 1-Sep-2013 1-Oct-2013 1-Nov-2013 1-Dec-2013
Tem
pera
ture
[°C]
Monthes
Year round temperature variation
Dry Bulb Temperature
Wet Bulb Temperature
A
19
COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
460
465
470
475
480
485
490
495
500
505
510
515
520
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26
Gene
rato
r out
put,
MW
e
Backpressure, bara
Steam turbine characteristic curve
Design (0.0951 bara)Pgen = 500.253 MWe
ALARM point (0.2 bara)Pgen = ~475.8 MWe
Allowable backpressure range
Maximum output @ 0.05 bara)Pgen = ~508.6 MWe
Verification is through a year-round impact simulation: A, B, C… B. Backpressure evaluation with steam turbine curves
460
465
470
475
480
485
490
495
500
505
510
515
520
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26
Gene
rato
r ou
tput
, MW
e
Backpressure, bara
Steam turbine characteristic curve
Design (0.0951 bara)Pgen = 500.253 MWe
ALARM point (0.2 bara)Pgen = ~475.8 MWe
Allowable backpressure range
Maximum output @ 0.05 bara)Pgen = ~508.6 MWe
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
1-Jan-2013 1-Feb-2013 1-Mar-2013 1-Apr-2013 1-May-2013 1-Jun-2013 1-Jul-2013 1-Aug-2013 1-Sep-2013 1-Oct-2013 1-Nov-2013 1-Dec-2013
Tem
pera
ture
[°C]
Monthes
Year round temperature variation
Dry Bulb Temperature
Wet Bulb Temperature
A B
20
COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
Verification is through a year-round impact simulation: A, B, C…C. Conversion Solutions
460
465
470
475
480
485
490
495
500
505
510
515
520
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26
Gene
rato
r ou
tput
, MW
e
Backpressure, bara
Steam turbine characteristic curve
Design (0.0951 bara)Pgen = 500.253 MWe
ALARM point (0.2 bara)Pgen = ~475.8 MWe
Allowable backpressure range
Maximum output @ 0.05 bara)Pgen = ~508.6 MWe
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
1-Jan-2013 1-Feb-2013 1-Mar-2013 1-Apr-2013 1-May-2013 1-Jun-2013 1-Jul-2013 1-Aug-2013 1-Sep-2013 1-Oct-2013 1-Nov-2013 1-Dec-2013
Tem
pera
ture
[°C]
Monthes
Year round temperature variation
Dry Bulb Temperature
Wet Bulb Temperature
A B
Ci
Cii
Ciii…n21
COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
Verification is throuigh a year-round impact simulation: A, B, C…Results: Annualized make-up water consumption & plant output
&(Wi…Wn) (Pi…Pn)
Year-round Impact Simulation COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
22
Actual case studies prove, the impact of conversion on power generation can be minimal, while plant cooling water consumption isdramatically reduced...see example
Targeted annual water consumption, 30% of original
Best solution within 0.4% net generation output while saving 70% of the annual waterAll solutions within 2.4% net generation output while saving 70% of the annual water
98.5%
97.6%
99.6%
98.4%
100%
~30%99.6% 100%
23
COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
The year-round simulation of plant operation with conversion cooling returns
• annual GWh/year output, and
• Tons/year water consumption
From which the Present Value of the Conversion, over the remainin g lifetime of the plant is calculated
PV = Revenue / A - I where
• I ($) total „cooling system conversion” related investment cost
• R ($ / year) annual revenue = balance of yearly electricity income and yearly water- and maintenance costs
• A (1 / year) annuity, function of interest rate % and commercial life in years
Sensitivity analisys can also be conducted upon request to see the impact of changing economic factors!
24
COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
Plant owner benefits include:
Optimized power generation/water consumption balance
Increased yearly availability/load factor of the power plant
Maximized drought resilience – less dependence on water
Reduced/eliminated cooling water-related costs
Leasable water rights to 3rd parties (where applicable)
Reduced plant maintenance and repair cost
COOLING SYSTEM CONVERSIONCUSTOMER BENEFIT
25
• Seasonal or persistent water stress today can curtail your plant’s output and availability tomorrow.
• Control your water-dependency, ensure your asset is drought-proof.
• Eliminate vulnerability to rising water costs, growing and unknown future regulations, and speculation of a precious commodity.
• Ask SPG Dry Cooling, your heat-sink specialist, to optimize a hybrid, or all-dry cooling solution to meet your targeted water savings in a Wet-to-Dry conversion.
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COOLING SYSTEM CONVERSIONSUMMARY
27
THANK YOU !Q & A
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