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MEMBER OF
WATER OPTIMIZATION CONFERENCE & AWARDS
DROUGHT PROOFING INDIA’S THERMAL POWER PLANTS
BY COOLING SYSTEM CONVERSIONS
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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:
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Mr. Andras BaloghVice President of SPG Dry Cooling, Engineered Retrofits
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SPG DRY COOLINGYOUR WATER CONSERVATION SOLUTIONS PROVIDER
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SPG DRY COOLINGWORLDWIDE DRY COOLING INSTALLATIONS
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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®
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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
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GLOBAL WATER STRESSRESOURCES PLUMMETING
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Number of months in which water is scarce
Global water availability – resources are plummeting
India is among the regions with highest water scarcities
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GLOBAL WATER STRESSDEMAND GROWS
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Developing countries will require more water to sustain their growing power generation
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GLOBAL WATER STRESS RECENT LOSSES IN INDIA
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India lost 30TWh output (equivalent with 1,7 bn USD revenue) between 2013-16
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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.)
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Evaporative/wet cooling systems are the biggest water consumers in a thermal power plant:
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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 !!!
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SUSTAINABLE STRESS RELIEF BY COOLING SYSTEM
CONVERSION
GLOBAL WATER STRESSSUSTAINABLE RELIEF
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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
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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
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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)
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COOLING SYSTEM CONVERSIONDRY COOLING ADD-ON OPTIONS
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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
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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
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Verification is through a year-round impact simulation: A, B, C…A. Atmospheric conditions specific to your plant
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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
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Tem
pera
ture
[°C]
Monthes
Year round temperature variation
Dry Bulb Temperature
Wet Bulb Temperature
A
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COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
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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
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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
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Tem
pera
ture
[°C]
Monthes
Year round temperature variation
Dry Bulb Temperature
Wet Bulb Temperature
A B
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COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
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Verification is through a year-round impact simulation: A, B, C…C. Conversion Solutions
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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
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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
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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
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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%
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COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
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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!
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COOLING SYSTEM CONVERSIONVERIFICATION OF ECONOMY
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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
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• 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
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THANK YOU !Q & A